SMC /TSMC 100 Mk4 - Engineering Manual

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

The SMC/TSMC-type piston compressor can be The variants featured on the unit are marked with
fitted with a range of equipment, depending on the an 'x' in the following diagram, with the compres-
function and requirements it is expected to meet. sor number stated below.
Some of these variants are discussed in this in-
struction manual, even if they are not featured on
your particular unit.

Compressor type
SMC ❑ TSMC ❏ ❏
S L❏ E❏
104 ❑ 106 ❏ 108 ❏ 112 ❏ 116 ❏

Designation

Compressor no.

Refrigerant
R717 ❑ Other _________ ❏
Control UNISAB II Control- and regulating system
01 introduction.fm

Electro Mechanical System

Compressor Thermopump
cooling
Water cooled top and side covers

Air cooled top and side covers

Oil cooling (water-cooled side covers)

Oil cooling OSSI/OOKH

Drive type Coupling

V-belts

Explosion-proof electrical design

Equipment for parallel operation

SABROE OVUR-type oil separator

0178-931 - ENG 1/288

Rev. 27.10.03
SMC /TSMC 100 Mk4 - Engineering Manual
1. Introduction
1. Introduction
The purpose of this manual is to provide the oper-
ating personnel with a thorough knowledge of the
compressor as well information about:
• The function and maintenance of each
component.
• Service schedules.
This manual describes the compressor and its
component parts as well as safety instruc-
tions/regulations. Moreover, the manual explains
the different settings that can be of assistance to
those who are responsible for the daily operation
and maintenance of the equipment.
To prevent any accidents, assembly and disas-
sembly of components should only be carried out
by authorized personnel.
It is essential that the operating personnel famil-
iarize themselves with the contents of this manual
in order to ensure a proper and efficient operation.
YORK Refrigeration is not liable for damage oc-
In the space below you may enter the name and address of your local YORK Representative
2/288
curring during the warranty period where this is at-
tributable to incorrect operation.
YORK Refrigeration's manual concept covers six
standard manuals: Engineering, Operating, Serv-
ice, Installation and Commissioning, Transport
and Spare Parts. Therefore, references may be
made to sections which are not part of this manu-
al.
This manual was produced by:
YORK Refrigeration
Chr. X’s Vej 201
DK-8270 Hoejbjerg
Denmark
Copyright © 2003 YORK Refrigeration
This manual must not be copied without the writ-
ten permission of YORK Refrigeration and the
contents must not be imparted to a third party nor
be used for any unauthorised purpose.
Contravention will be prosecuted.
0178-931 - ENG
Rev. 27.10.03
 SMC /TSMC 100 Mk4 - Engineering Manual

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

Signs and Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

Identification of YORK Refrigeration Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Unit Pipe System Name Plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Compressor Name Plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Vessel Name Plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Signs in Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
The Sign: CAUTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
The Sign: High Voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
The Label: The Temperature of Tangible Surfaces . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
The Label: Internal Protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Other Warning Labels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Emergency Stop . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Safety during Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Warnings in Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Texts Marked with Danger! . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Texts Marked with Warning! . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Texts Marked with Caution! . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
0178_931TOC.fm

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

0178-931 - ENG 3/288

Rev. 27.10.03
SMC /TSMC 100 Mk4 - Engineering Manual

Technical Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Areas of Application of the Reciprocating Compressor Unit . . . . . . . . . . . . . . . . . . . . . . . . 29
Description of the Compressors Compressor Types . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Compressor Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
One-stage Compressors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
Two-stage Compressors Type TSMC 100 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
Compressor Block . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
Piston Pin Bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
Suction Filters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
Conversion of TSMC Compressors from Two-stage to One-stage . . . . . . . . . . . . . . . . . . . 46
Oil Separator Type OVUR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
Mode of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
Selecting an Oil Separator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
Oil Return to the Compressor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
Thermodynamic Liquid Trap (TLT) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
Oil Return in Connection with Parallel Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
System A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
System B . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
System C . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
Capacity Regulation of Compressor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
Capacity Regulation and Unloading of Compressor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
Start Unloading . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
Regulating Sequence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
Schematic Drawings, Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
Variable speed drive (VSD) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
Compressor Units . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
Instrumentation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
Manometers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
Cooling of the Intermediate Discharge Gas on TSMC Compressors . . . . . . . . . . . . . . . . . 77
Automatic Regulation of Intermediate Pressure IP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
Determining the Intermediate Pressure IP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
Cooling Systems for Compressors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
Standard Cooling Systems for Compressors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
Mounting of Cooling Water Hoses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83
Pressure Loss in the Cooling System in SMC/TSMC Compressors . . . . . . . . . . . . . . . . . . 88
1c: Cooling with Thermo Pump - R717 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
Description of the Pumping Cycle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92
Ensuring Liquid to the Thermo Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94
Power Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95
Types of Spare Parts Set: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98

Physical and Connection Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99

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

4/288 0178-931 - ENG

Rev. 27.10.03
 SMC /TSMC 100 Mk4 - Engineering Manual

Control of the Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111

1. Pressure Transmitters marked PT1, PT2 and PT3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111
Heating Element for Oil Heating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113

Technical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115

Technical Data for the SMC 100 Series . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116
Weight of Electric Motors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 118
Compressor Capacity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119
Dimension Sketches of Compressor Block . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120
Planning the Machine Room . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 124
Operating Limits Diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 125
Direction of Rotation of the Compressor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 140
Choice of Electric Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 141
Motor Dimension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 141
Starting Torque of the Compressor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 143
Start up torque SMC 100 R717 25% load . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 144
Moment of Intertia . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 146
Direction of Rotation of Electric Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 147
Handling of Compressor and Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 148
Compressor Shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 149
Coupling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 151
V-Belt Drive for SMC/TSMC 100 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 153
0178_931TOC.fm

Transmission Ratio . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 153

Power Transmission . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 155
Construction of V-Belt Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 157
Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 158
Laying the Foundation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 159
Mounting of Vibration Dampers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 161
Marine Installations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 164
Noise from Compressors and Units . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 166
Noise Data for Reciprocating Compressors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 170
Reverberation Time . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 171
Vibration Data for Compressors - All Compressor Types . . . . . . . . . . . . . . . . . . . . . . . . . . 173
Test Pressure Levels for Standard Compressors and Components . . . . . . . . . . . . . . . . . 175
Charging the Compressor with Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 176
Oil Consumption . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 177
Selecting Oil Separator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 177
Data Sheet for Listed Sabroe Oils . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 186
List of Part Numbers for Available Sabroe Oils . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 187
List of Major Oil Companies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 191
Selecting Lubricating Oil for SABROE Reciprocating Compressors . . . . . . . . . . . . . . . . . 192
Oil Changing Intervals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 197
Data Sheet for Listed Sabroe Oils . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 198
List of Part Numbers for Available Sabroe Oils . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 199
List of Major Oil Companies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 211

Installation Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 213

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

0178-931 - ENG 5/288

Rev. 27.10.03
SMC /TSMC 100 Mk4 - Engineering Manual

Installation Drawings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 213

Personnel Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 213
Preparing the Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 214
Tools and Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 214
Ordinary Hand Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 214
Safety Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 214
Local Regulations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 214
Space Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 214
Preparing the Mounting Site . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 214
Lifting Accessories and Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 215
Preparing Lifts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 215
Lifting and Loading Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 215
Unpacking and Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 215
Disposal of Materials which are not Reusable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 215
Moving the Equipment to the Mounting Site after Unloading and Unpacking . . . . . . . . . . . 215
Installation Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 216
1. Alignment of Unit against Foundation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 216
Mounting on Vibration Dampers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 217
Mounting Directly on Foundation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 218
2. Alignment of Compressor on Base Frame . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 218
3. Alignment of Motor on Base Frame . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 218
Fitting and alignment of coupling type AMR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 219
4. Installation and alignment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 219
Preliminary installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 220
Alignment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 221
Achieving correct centre height . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 222
Achieving parallel shafts in vertical plane . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 222
Final installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 222
Preliminary Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 223
Alignment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 223
Achieving Parallel Shafts in Horizontal Plane . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 223
Achieving Correct Centre Height . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 224
Achieving Parallel Shafts in Vertical Plane . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 224
Final Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 224
5. Piping Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 225
6. Connecting Electricity Supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 226
7. Pressure Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 228
8. Oil Charging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 230
Final Check of the Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 231

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

6/288 0178-931 - ENG

Rev. 27.10.03
 SMC /TSMC 100 Mk4 - Engineering Manual

Oil Separators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 234

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

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

Operating Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 243

Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 243
Ventilation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 243
Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 243
Hot and Cold Surfaces . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 244
Qualification Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 244
0178_931TOC.fm

Compressor Control and Alarm Functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 245

Alarms and Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 245
UNISAB II Reading, Safety and Capacity Regulating System . . . . . . . . . . . . . . . . . . . . . . 245
Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 247
Front Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 247
Control Section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 247
Recording Section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 248
Menu Structure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 249
Preparations for Starting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 250
Starting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 251
Operating Mode UNISAB II . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 251
Checks during Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 259

Transport Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 261

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

0178-931 - ENG 7/288

Rev. 27.10.03
SMC /TSMC 100 Mk4 - Engineering Manual

Commissioning Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 265

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

Compliance Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 269

Conformity with EU Regulations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 269

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

Final Disposal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 273

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

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

8/288 0178-931 - ENG

Rev. 27.10.03
 SMC /TSMC 100 Mk4 - Engineering Manual
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 deliv-
ered by YORK Refrigeration.
• How information important to the safety of
personnel and equipment is presented in in-
structions belonging to equipment delivered
by YORK Refrigeration.
This document is intended for all user categories.
This document describes the importance of the in-
dividual signs which are attached to the
YORK Refrigeration products.
Before a compressor/unit is put into operation it
02 signs and warnings.fm
must be provided with the warning signs corre-
sponding to the actual type of compressor/unit in
accordance with the rules and regulations in force.
0178-931 - ENG
Rev. 27.10.03
This document was produced by:
YORK Refrigeration
Chr. X’s 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. Contra-
vention will be prosecuted.
WDanger!
Risk of injury to personnel and damage to equip-
ment! Always read the safety precautions belong-
ing to this equipment before starting the installa-
tion process. Failure to comply with safety precau-
tions may cause death or injury to personnel. It
may also cause damage to or destruction of the
equipment
9/288
SMC /TSMC 100 Mk4 - Engineering Manual
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

1. Compressor name plate

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

10/288 0178-931 - ENG

Rev. 27.10.03
 SMC /TSMC 100 Mk4 - Engineering Manual
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 author-
ity, the design code will be shown here.
• Approval no
Refrigeration If the unit has been approved by an author-
DK 8270 Højbjerg 2516-328
ity, the approval no will be shown here.
Unit Pipe System Year
Type • Pressure system
Identification No Low pressure side of compressor piping is
Design Code referred to as LP.
Approval No High pressure side of compressor piping is
Pressure System LP HP referred to as HP.
Fluid/Group
Allowable Pressure
PS Bar • Fluid/Group
Max
Leak Test Pressure PT Bar Refrigerant designation according to
Design Temperature ISO817 or fluid group according to directive
Min/max TS °C
67/548/EEC.
0062
02 signs and warnings.fm

• Max allowable pressure

Shows max allowable pressure relative to
The unit pipe system name plate is positioned on atmospheric pressure for which the pipe
the frame - (see 3. Unit pipe system name plate). system has been designed.
The name plate contains the following informa- • Leak test pressure, PT
tion: Shows the pressure with which the pipe sys-
• Type tem has been leak tested.
Manufacturer's type designation. • Design temperature, TS
• Year Shows min and max temperatures for which
Year of manufacture. the pipe system including components have
been designed.
• Identification no
Individual no for identification of supplied • CE xxxx
pipe system. The four digits compose the registration no
of the notified body in charge of the assess-
• Design code
ment modules for the vessel.
For PED orders: EN 378-2

0178-931 - ENG 11/288

Rev. 27.10.03
SMC /TSMC 100 Mk4 - Engineering Manual
2. Signs and Warnings

Compressor Name Plate Vessel Name Plate

Fig. 2.3 Compressor Name Plate Fig. 2.4 Vessel Name Plate

Refrigeration Refrigeration
DK 8270 Højbjerg 2516-327 DK 8270 Højbjerg 2516-326
Beholder/Vessel/ År
Behalter No Year
Compressor No Year Jahr
Type
Type
Beregningsnorm/Design
Nominal Speed RPM
code/ Berechnungsnorm
Swept Volume m3/h Godkendelsesnr
/CAT.
Allowable Pressure bar Approval no
Abnahme nr Svøb/Shell/Mantel Rør/Tube/Rohr
Test Pressure bar
Side/Seite Medie/Media
Tilladeligt tryk/Allowa-
ble pressure/Zuläs- bar
PS
siger Druck
Tilladelig temp./Allowable °C
The compressor name plate is positioned on the temp./Zulässiger Temp.
-L.
compressor - (see 1. Compressor name plate). Volumen/ Volume V

The plate contains the following information: 0062

• Compressor no
Compressor manufacturing number. The vessel name plate is positioned on the shell
• Year of the vessel (see 2. Vessel name plate). The
Year of manufacture. name plate contains the following information:

• Type • Vessel no
Manufacturer's type designation. Vessel number stated by
YORK Refrigeration.
• Nominal speed
Shows rotational speed of drive shaft at typ- • Year
ical running condition. Year of manufacture.

• Swept volume • Type

Shows swept volume of compressor in m3/h
at nominal speed.
• Allowable pressure
Shows max working pressure of compres-
sor.
• Test pressure
Shows pressure at which compressor en-
closure has been strength tested.
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 cat-
egory according to PED 97/23/EEC,
Article 9.
• Side
Refers to the columns “Shell” and “Tube”.

12/288 0178-931 - ENG

Rev. 27.10.03
 SMC /TSMC 100 Mk4 - Engineering Manual
2. Signs and Warnings
• Media
Shows the refrigerant designation accord-
ing to ISO817.
• Allowable pressure, PS
Shows min and max pressure relative to at-
mospheric pressure for which the vessel or
vessel part has been designed.
02 signs and warnings.fm
0178-931 - ENG
Rev. 27.10.03
• Allowable temperature, TS
Shows min and max temperatures for which
the vessel 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 assess-
ment modules for the vessel.
13/288
SMC /TSMC 100 Mk4 - Engineering Manual
2. Signs and Warnings

In the following section all signs which may be The Sign: High Voltage

found on the equipment are described. How-
ever, the number of signs may vary from prod-
uct to product.
Signs in Instructions
The Sign: CAUTION
A CAUTION tag like the one illustrated below is
fixed to the compressor. The sign imposes the us-
ers to read the Safety Precautions section in the
manual before handling, operating or servicing
the compressor and unit.
Caution
WDanger
HIGH VOLTAGE!
Before working on any electrical circuits, turn the
machine Main Disconnect Device “OFF” and lock
it. Dismantle the main fuses to the compressor
unit.
Unless expressly stated in applicable
YORK Refrigeration documentation or by a
YORK Refrigeration Field Service Representa-
tive, do NOT work with the electrical power “ON”.
Any work with the electrical power “ON” should be
performed by a YORK Refrigeration Field Service
Representative. The customer and subsequent
transferees must make sure that any other person
performing work with the electrical power “ON” is
trained and technically qualified.

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 mar-

cha o dar servicio al compresor y la uni-
dad, leer la sección Precauciones de
seguridad en el Libro de Instruc-
ciones.
Es respondabilidad del operarío o de su
patrón, que el libro de instrucciones
permanezca siempre al alcance de la
mano.
Esta señal no debe de ninguna manera
suprimirse o dañarse. 2516-297

14/288 0178-931 - ENG

Rev. 27.10.03
 SMC /TSMC 100 Mk4 - Engineering Manual
2. Signs and Warnings

The Label: The Temperature of

Tangible Surfaces Påfyldt beskyttelsesgas N2
Charged with inert gas
When a compressor is working, the surfaces Enthält Schutzgas 0,2 bar
Chargé du gaz protecteur 3 PSI
which are in contact with the warm discharge gas Contiene gas protector 1534-169
will also get warm. However, the temperature de-
pends on the refrigerants used as well as the op-
erating conditions of the compressor. Often the
Other Warning Labels
temperature exceeds 70°C [158 °F], which for
metal surfaces may cause skin burns even at a
light touch.
Consequently, the compressors are equipped Hazardous substance!
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.
02 signs and warnings.fm

Dangerous noise level,

use hearing protectors!

Internal overpressure!

The Label: Internal Protection

Compressor blocks and units are usually deliv-
ered without any refrigerant or oil.
To protect the compressors against internal corro-
sion, they are delivered evacuated of all atmos- Cold surfaces!
pheric air and charged with Nitrogen (N2) to an
overpressure of 0.2 bar [3 psi].
In such cases a yellow label like the one shown
below is affixed to a visible spot on the compres-
sor.

0178-931 - ENG 15/288

Rev. 27.10.03
SMC /TSMC 100 Mk4 - Engineering Manual
2. Signs and Warnings

Emergency Stop • Switch off all electric components on the

Fig. 2.5 Emergency stop on the reciprocating compressor/unit before the disman-
compressor unit tling/servicing.

Electromechanical control system

• Make sure that there is neither overpressure
nor any refrigerant in the part to be disman-
tled. Close all necessary stop valves.
• Use gloves and safety goggles and make
sure to have a gas mask ready for use.
• Use the prescribed tools and check that
they are properly maintained and in good
working condition. In explosion-proof areas,
Emergency stop, mounted when use tools especially suited for this specific
installing the unit
purpose.
UNISAB II control system
• When dismantling the top covers, attention
should be paid to the considerable spring
Emergency stop
force beneath the covers. When the screws
are loosened, the cover must lift itself from
the frame as described in the instruction
manual.
Fig. 2.6

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 in- • Before dismantling the side covers, empty
advertently. It is recommended to remove the crankcase of its oil content.
all main fuses.
• Check that the heating rod in the crankcase
is de-energized.

16/288 0178-931 - ENG

Rev. 27.10.03
 SMC /TSMC 100 Mk4 - Engineering Manual
2. Signs and Warnings
Warnings in Instructions
This section describes warnings used in instruc-
tions pertaining to YORK Refrigeration equip-
ment.
Information of importance to the safety of person-
nel or equipment is given at three levels.
• Danger!
• Warning!
• Caution!
There is an important distinction between these
three levels. However, as shown below, the prin-
ciple is the same at all three levels.
Note: Information is sometimes given in a Note.
A Note is used to emphasise information but it is
never used for information vital to the safety of
02 signs and warnings.fm
personnel and equipment.
Texts Marked with Danger!
The example below shows how information vital to
the safety of involved personnel is presented.
WDanger!
Risk of electrical shock! Always turn off the main
switch before servicing the unit! Contact with high
voltage may cause death or serious injury.
0178-931 - ENG
Rev. 27.10.03
Failure to observe information marked with Dan-
ger! may cause death or serious injury to person-
nel or even to a third party.
Texts Marked with Warning!
The example below shows how information of im-
portance to the safety of involved personnel or of
major importance to the safety of the equipment is
presented.
WWarning!
Risk of damage to compressor! Always consult
your supplier before using a compressor under
operating conditions outside the specified working
range.
Texts Marked with Caution!
The example below shows how information vital to
the safety of involved personnel is presented.
WCaution!
Risk of incorrect viscosity! Always make sure that
all oils used are mixable without causing chemical
reactions. Chemical reactions might have serious
effects on the viscosity.
Failure to observe information marked with Cau-
tion! may cause damage to the equipment.
17/288
SMC /TSMC 100 Mk4 - Engineering Manual
2. Signs and Warnings

18/288 0178-931 - ENG

Rev. 27.10.03
 SMC /TSMC 100 Mk4 - Engineering Manual
3. Safety Precautions
3. Safety Precautions
The purpose of this document is to provide gener-
al safety precautions for this equipment. Additioal
safety precautions relating to a specific task are
given in the corresponding documents.
The safety precautions are intended for all user
categories.
This document was produced by:
YORK Refrigeration
Chr. X’s 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
03 safety precautions.fm
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 equip-
ment! Always read the safety precautions belong-
ing to this equipment before start. Failure to com-
ply with safety precautions may cause death or in-
jury to personnel. It may also cause damage to or
destruction of the equipment.
W Warning!
Read related safety precautions before operating
the compressor/unit. Failure to follow safety in-
structions may result in serious personal injury or
death.
Important!
The safety precautions for this
YORK Refrigeration compressor have been pre-
pared to assist the operator, programmer and
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 be-
fore operating, setting up, running or performing
maintenance on the compressor/unit.
These precautions are to be used as a supple-
ment to the safety precautions and warnings in-
cluded in:
a. All other manuals pertaining to the compres-
sor/unit.
b. Local, plant and shop safety rules and codes.
c. National safety rules and regulations.
General Safety Instructions and
Considerations
Personal 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 pro-
cedures.
Make sure that everyone who works for, with or
near you fully understands and - more importantly
- complies with the following safety precautions
and procedures when operating this compres-
sor/unit.
Observe the safety warnings on the compres-
sor/unit.
Use safety equipment. Wear approved eye or face
protection as well as gloves when working with
19/288
SMC /TSMC 100 Mk4 - Engineering Manual
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.
Never operate or service this equipment if affect-
ed by alcohol, drugs or other substances or if in a
condition which decreases alertness or judgment.
Work Area Safety
Always keep your work area clean. Dirty work ar-
eas with such hazards as oil, debris or water on
the floor may cause someone to fall onto the floor,
into the machine or onto other objects resulting in
serious personal injury.
Make sure your work area is free of hazardous ob-
structions and be aware of protruding machine
members.
Always keep your work area tidy so you are able
to escape should a dangerous situation arise.
Report unsafe working conditions to your supervi-
sor or safety department.
Tool Safety
Always make sure that the hand tools are in prop-
er working condition.
Remove hand tools such as wrenches, measuring
equipment, hammers, etc. from the compres-
sor/unit immediately after use.
Lifting and Carrying 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
Before lifting or carrying a compressor/unit or oth-
er parts, determine the weight and size by means
of e.g. tags, shipping data, labels, marked infor-
mation or manuals.
Use power hoists or other mechanical lifting and
carrying equipment for heavy, bulky or unwieldy
objects. Use hook-up methods recommended by
your safety department and familiarise yourself
with the signals for safely directing a crane opera-
tor.
Never place any part of your body under a sus-
pended load or move a suspended load over any
other persons. Before lifting, be certain that you
have a safe spot for depositing the load. Never
work on a component while it is hanging from a
crane or any other lifting mechanism.
If in doubt as to the size or type of lifting equip-
ment, the method and procedures to be used in
connection with lifting, contact
YORK Refrigeration before proceeding to lift the
compressor, motor, unit or its components.
Always inspect slings, chains, hoists and other lift-
ing devices prior to use. Do not use lifting devices
which are defective or in a questionable condition.
Never exceed the lifting capacity of cranes, slings,
eyebolts and other lifting equipment. Follow
standards and instructions applicable to any lifting
equipment used.
Before inserting an eyebolt, be certain that both
the eyebolt and the hole have the same size and
type of threads. To attain safe working loads, at
least 90% of the threaded portion of a standard
forged eyebolt must be engaged.
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
Before lifting the compressor, unit or other parts of
the plant, consult the instruction manual or
YORK Refrigeration for proper methods and pro-
cedures.
An electrician must read and understand the elec-
trical diagrams prior to connecting the machine to
the power source. After connecting the machine,
test all aspects of the electrical system for proper
functioning. Always make sure that the machine is
grounded properly. Place all selector switches in
03 safety precautions.fm
their O or neutral (disengaged) position. The
doors of the main electrical cabinet must be
closed and the main disconnect switch must be in
the O position after the power source connec-
tion is complete.
Before starting the compressor for the first time,
make sure that all the motors rotate in the indicat-
ed direction.
Set-Up and Operation Safety
Read and understand all the safety instructions
before setting up, operating or servicing this com-
pressor. Assign only qualified personnel instruct-
ed in safety and all machine functions to operate
or service this compressor.
Operators and maintenance personnel must care-
fully read, understand and fully comply with all
warnings and instruction plates mounted on the
machine. Do not paint over, alter or deface these
plates or remove them from the compressor/unit.
Replace all plates which become illegible. Re-
placement plates can be purchased from
YORK Refrigeration.
0178-931 - ENG
Rev. 27.10.03
Safety guards, shields, barriers, covers and pro-
tective devices must not be removed while the
compressor/unit is operating.
All safety features, disengagements and inter-
locks must be in place and function correctly be-
fore this equipment is put in operation. Never by-
pass or wire around any safety device.
Keep all parts of your body off the compres-
sor/motor/unit during operation. Never lean on or
reach over the compressor.
During operation, pay attention to the compressor
unit process. Excessive vibration, unusual
sounds, etc. can indicate problems requiring your
immediate attention.
Maintenance Safety
Do not attempt to perform maintenance on the
compressor unit until you have read and under-
stood all the safety instructions.
Assign only qualified service or maintenance per-
sonnel trained by YORK Refrigeration to perform
maintenance and repair work on the unit. They
should consult the service manual before attempt-
ing any service or repair work and contact
YORK Refrigeration in case of questions. Use
only YORK Refrigeration replacement parts; other
parts may impair the safety of the compres-
sor/unit.
Before removing or opening any electrical enclo-
sure, cover, plate or door, be sure that the Main
Disconnect Switch is in the O position and the
main fuses are dismantled.
If any tool is required to remove a guard, cover,
bracket or any basic part of this compressor, place
the Main Disconnect Switch in the O position
and lock it in the O position. If possible, post a
sign at the disconnect switch indicating that main-
21/288
SMC /TSMC 100 Mk4 - Engineering Manual
3. Safety Precautions
tenance is being performed. Dismantle main fus-
es to the unit.
W Danger
HIGH VOLTAGE!
Before working on any electrical circuits, place
the Main Disconnect Device of the compres-
sor/unit in the "OFF" position and lock it. Dis-
mantle the main fuses to the compressor unit.
Unless expressly stated in applicable
YORK Refrigeration documentation or by ap-
propriate YORK Refrigeration Field Service
Representative, do NOT work with the electri-
cal power "ON". If such express statement or
advice exists, work with the electrical power
"ON" should be performed by a
YORK Refrigeration Field Service Represent-
ative. The customer and subsequent transfer-
ees must make sure that any other person per-
forming work with the electrical power "ON" is
trained and technically qualified.
FAILURE TO FOLLOW THIS INSTRUCTION
MAY RESULT IN DEATH OR SERIOUS
PERSONAL SHOCK INJURY.
When maintenance is to be performed in an area
away from the disconnect, and the switch is not
locked, tag all start button stations with a “DO
NOT START” tag.
Adequate precautions such as warning notices or
other equally effective means must be taken to
prevent electrical equipment from being activated
electrically when maintenance work is being per-
formed.
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 recon-
nected.
An electrician must analyse the electrical system
to determine the possible use of power retaining
devices such as capacitors. Such power retaining
devices must be disconnected, discharged or
made safe before maintenance is performed.
Working space around electrical equipment must
be clear of obstructions.
Provide adequate illumination to allow for proper
operation and maintenance.
Materials Used with this 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
Rev. 27.10.03
 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.
General
Ammonia is not a cumulative poison. It has a di-
stinctive, pungent odour that even at very low,
harmless concentrations is detectable by most
persons.
Since ammonia is self-alarming, it serves as its
own warning agent so that no person remains vol-
03 safety precautions.fm
untarily in hazardous concentrations. Since am-
monia is lighter than air, adequate ventilation is
the best means of preventing an accumulation.
Experience has shown that ammonia is extremely
hard to ignite and under normal conditions a very
stable compound. At extremely high, though limit-
ed concentrations, ammonia can form ignitable
mixtures with air and oxygen and should be treat-
ed with respect.
Basic Rules for First 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
First Aid Measures
Inhalation: Immediately, move affected person-
nel into fresh air and loosen clothing restricting
breathing.
Call a doctor/ambulance with oxygen equipment.
Keep the patient still and warmly wrapped in blan-
kets.
If mouth and throat are burnt (freeze or acid burn)
and the patient is conscious, let him drink water in
small mouthfuls.
If the patient is conscious and mouth and throat
are not burnt, feed him sweetened tea or coffee
(never feed an unconscious person).
Oxygen may be given to the patient, but only
when authorised by a doctor. If the patient stops
breathing, apply artificial respiration.
Eyes: In case of injuries from liquid splashes or
concentrated vapour, immediately rinse with wa-
ter (preferably using an eye rinser) and consult a
doctor. Continue rinsing until otherwise stated by
a doctor.
If the affected person wears contact lenses these
must be removed before the rinsing.
Skin: In case of burns from liquid splashes or con-
centrated vapour, immediately wash with large
quantities of water until the pain stops.
Consult a doctor about actual burns.
After washing, apply wet compresses - wetted
with a sterile isotonic (0.9%) NaCl-solution (salt
water) - to affected areas until medical advice is
available.
23/288
SMC /TSMC 100 Mk4 - Engineering Manual
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. 300°C, they break
down into toxic, acid gas components, which are
strongly irritating and aggressive to nose, eyes
and skin and generally corrosive.
Besides the obvious risk of unnoticeable, heavy
gases displacing the atmospheric oxygen, inhala-
tion of larger concentrations may have an accu-
mulating, anaesthetic effect which may not be im-
mediately apparent. 24 hours medical observation
is therefore recommended.
24/288
Basic Rules for First Aid
When affected persons are moved from low-lying
or poorly ventilated rooms where high gas con-
centrations are suspected, the rescuer must wear
a lifeline and be under constant observation from
an assistant outside the room.
Do not use adrenaline or similar heart stimuli.
Inhalation: Immediately move affected persons
into fresh air. Keep them still and warm and loos-
en clothing restricting breathing.
If the patient is unconscious, call a doctor/ambu-
lance with oxygen equipment immediately.
Apply artificial respiration until a doctor authorizes
other treatment.
Eyes: Immediately rinse with water (preferably
using an eye rinser) and consult a doctor. Contin-
ue rinsing until otherwise stated by a doctor.
If the affected person wears contact lenses these
must be removed before the rinsing.
Skin: In case of frost-bite, immediately rinse with
luke-warm water (max. 37°C) and remove all
clothes impeding blood circulation.
Consult a doctor.
Avoid direct contact with contaminated oil/refriger-
ant mixtures from electrically burnt-out hermetic
compressors.
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! If high concentrations of refrigerant vapours are

inhaled, they will attack the human nervous sys-
tem.
No plant can ever be said to be too safe - safety is
a way of life. When halogenated gasses come into contact with
open flame or hot surfaces (over approx. 300°C),
Increasing industrialisation threatens our environ-
they will decompose to produce poisonous chem-
ment. It is therefore absolutely imperative to pro-
icals. These have a very pungent odour and will
tect nature against pollution.
thus warn personnel of their presence.
To this end, many countries have passed legisla-
At high concentrations R717 causes respiratory
tion in an effort to reduce pollution and preserve
problems. When the amount of ammonia vapour
the environment. This legislation applies to all
in air is between 15 and 28 vol. % the combination
fields of industry, including refrigeration, and must
is explosive and can be ignited by an electric
be complied with.
spark or open flame.
Pay extra attention to the following substances:
Oil vapour in the ammonia vapour increases this
• refrigerants risk significantly as the point of ignition falls below
03 safety precautions.fm

• cooling media (brine, etc.) that of the mixture ratio stated.

• lubricating oils
Refrigerants usually have a natural boiling point
considerably below 0°C. This means that liquid re-
frigerants can be extremely harmful if they come
into contact with skin or eyes.
High concentrations of refrigerant vapours can be
suffocating when they displace air.
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.

Am-
Halogenated refrigerants CO2
monia

HFC HCFC

R134a R404a R407C R410a R507 R22 R717 R744

TWA Unit
Time weighted
average during a 0.1 0.1 0.1 0.1 0.1 0.1 0.005 0.5
week Vol.%

Warning smell Vol.% 0.2 0.002

0178-931 - ENG 25/288

Rev. 27.10.03
SMC /TSMC 100 Mk4 - Engineering Manual
3. Safety Precautions
Furthermore, it can be said about
refrigerants:
HFC/HCFC
• If released into the atmosphere, halogenat-
ed refrigerants of the type HCFC (e.g. R22)
will contribute to the depletion of the ozone
layer in the stratosphere. The ozone layer
protects the earth from the ultraviolet rays of
the sun. Refrigerants of the types HFC and
HCFC are greenhouse gases which contrib-
ute to an intensification of the greenhouse
effect. They must, therefore, never be re-
leased into the atmosphere. Use a separate
compressor to draw the refrigerant into the
plant condenser/receiver or into separate
refrigerant cylinders.
Ammonia
• Ammonia is easily absorbed by water:
At 15°C 1 litre of water can absorb approx.
0.5 kg liquid ammonia (or approx. 700 litres
ammonia vapour).
• Even small amounts of ammonia in water
(2-5 mg per litre) are enough to wreak havoc
with marine life if allowed to pollute water-
ways and lakes.
• As ammonia is alkaline, it will damage plant
life if released into the atmosphere in large
quantities.
Hydro Carbons (HC)
• HC gasses are a group of B1 refrigerants
characterized as very flammable.
26/288
• Hydro carbons are odourless and non-toxic
gasses. Specific mixtures of air and gas cre-
ate danger of explosion. As the gasses are
heavier than air, they will be concentrated at
the lowest possible level in case of leaks.
Carbon Dioxide (CO2)
• Carbon dioxide (CO2) is a greenhouse gas
with a GWP (Global Warming Potential) fac-
tor of 1. It is found in the atmosphere in a
concentration of 0.036 vol. % (360 parts per
million, ppm). As CO2 is extracted from at-
mospheric air, it can safely be released into
the atmosphere and does not contribute to
enhancing the greenhouse effect.
• The boiling point for CO2 is -78.5°C at 1.013
bar.
• CO2 is an odourless, non-toxic non-inflam-
mable gas. At concentrations higher than
5000 ppm the gas can be dangerous for hu-
mans. The gas is heavier than air and will
thus be concentrated on the lowest level of
the room in case of a leak. In closed rooms
the gas can displace oxygen and cause suf-
focation.
Refrigerant evacuated from a refrigeration plant
must be charged into refrigerant cylinders intend-
ed for this specific refrigerant.
If the refrigerant is not to be reused, return it to
the supplier or to an authorized incineration plant.
Halogenated refrigerants must never be mixed.
Nor must R717 ever be mixed with halogenated
refrigerants.
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 ap-
proved air purger. The purged air must pass
through an open container of water for any
remaining R717 to be absorbed. The water
03 safety precautions.fm
mixture must be sent to an authorized incin-
eration plant.
• Halogenated refrigerants cannot be ab-
sorbed by water. An approved air purger
must be fitted to the plant. This must be
checked regularly by use of a leak detector.
Note: The occurrence of air is usually an indica-
tion of poor maintenance or lack of thoroughness
at installation.

0178-931 - ENG 27/288

Rev. 27.10.03
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 refrigera-
tion plant.
Never empty brines down a sewer or into the
environment.
The brine must be collected in suitable containers
clearly marked with the contents and sent to an
approved incineration plant.
Lubricating Oils
WWarning!
When charging oil, follow the safety instructions
given by the oil supplier (MSDS: Material Safety
Data Sheet). Always avoid direcst contact with the
oil as this may cause skin allergies. Always use
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
protective equipment - goggles and gloves - when
charging oil.
Refrigeration compressors are lubricated by one
of the following oil types depending on the refrig-
erant plant type, and operating conditons.
– Mineral oil (M oil)
– Hydro treated mineral oil (H oil)
– Semi-synthetic oil (mix of M oil and syn-
thetic oil)
– Alkyl benzene-based synthetic oil (A oil)
– Polyalphaolefine-based synthetic oil
(PAO oil)
– Polyalkylen Glycol-based synthetic oil
(PAG oil)
– Ester oil (E oil)
See the section Selecting lubricating oil for
YORK Refrigeration compressors in section 6,
Technical Data.
When changing the oil in the compressor or drain-
ing oil from the vessel of the refrigeration plant, al-
ways collect the used oil in containers marked
“waste oil” and send them to an approved inciner-
ation plant. It is not recommended to re-use oil.
0178-931 - ENG
Rev. 27.10.03
 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.
This document was produced by:
YORK Refrigeration
Chr. X's 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
04 technical description.fm
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
frigerants: R717 - R22 - R134a - R407C -
R404A - R507 - R600 - R600A - R290 -
LPG. This manual only deals with the ones
written in bold letters.
• Compressor types SMC 100 and TSMC 100
in an E execution are as standard compres-
sors used with R717 only.
• The compressors can be used with other re-
frigerants, but only following a written agree-
ment with YORK Refrigeration.
• SMC 100 and TSMC 100 compressors in S,
L or E executions may be used at a max dis-
charge design pressure of 25 bar. See Test
Pressure Levels for Standard Compressors
and Components in section 6.
• The compressors are approved for applica-
tion in an explosion-prone environment, pro-
vided they have been fitted with explo-
sion-proof equipment. This can be seen
from the Ex nameplates, , fixed on each
unit.
Fig. 4.1
T2516273_0
Please, note that specially made tools which can-
not 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 test-
ing,
• As an air compressor.
30/288
WDanger!
YORK Refrigeration does not take any responsi-
bility for injuries to personnel or damage to equip-
ment resulting from using this equipment for other
purposes than the ones stated above.
Application of Combustion Engines
If combustion engines are installed in rooms con-
taining refrigeration machinery or rooms where
there are pipes and components containing refrig-
erant, make sure that in case of leakage the com-
bustion air for the engine comes from an area in
which there is no refrigerant gas.
Failure to do so will involve a risk of lubricating oil
from the combustion engine mixing with refriger-
ant; at worst this may lead to corrosion and dam-
age of the engine.
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 compres-
sors with 4 to 16 cylinders in one and the same
block. The cylinders are positioned in a V or W po-
sition and have the same internal diameter of 100
Fig. 4.2
Short Block
04 technical description.fm
SABROE
One-stage compressors are designated SMC
which is an abbreviation of SABROE Multi-cylin-
der Compressor. As for the two-stage compres-
sors the letter T has been added to indicate Two
stages.
Further, the compressors can be delivered with
the following three strokes, designated S, L or E,
respectively:
0178-931 - ENG
Rev. 27.10.03
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.
Long Block
• 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.
31/288
SMC /TSMC 100 Mk4 - Engineering Manual
4. Technical Description

The operating limits (including number of revolu- ongoing process, please make sure that the dia-
tions) depend on the compressor type and refrig- gram in question is the latest revision before mak-
erant. As the extension of the operating limits is an ing 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 Se-
ries in Section 6, Technical Data.
The type and version of the various compressors
can be read from the name plate shown below.
A name plate is fixed on every compressor.
Similarly, the serial number of each compressor is
stamped into the compressor block. The letter S,
L or E, which refers to the compressor stroke, is
stamped into the end surface of the crankshaft.
Whenever contacting YORK Refrigeration
about a compressor, please state its
serial number.

Refrigeration
DK 8270 Højbjerg 2516-327

Compressor No Year
Type

Nominal Speed RPM

Swept Volume m3/h
Allowable Pressure bar

Test Pressure bar

32/288 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 sec-
tion.
Fig. 4.3 SMC 100 Cylinder Liner Complete
The compressors are equipped with replaceable
cylinder liners, pos. 19A, Fig. 4.3, which are
made of special cast iron and are easy to disman-
tle for inspection. They are honed and surface
hardened, which makes them very wear resistant.
Underneath each top cover there are always two
cylinders.

21

20

19H
04 technical description.fm

19A

The pistons, pos. 18, are made of aluminium with ring ensuring optimum tightness, low oil consump-
two hard-plated piston rings and one oil scraping tion as well as long life.

0178-931 - ENG 33/288

Rev. 27.10.03
SMC /TSMC 100 Mk4 - Engineering Manual
4. Technical Description
Fig. 4.4 Piston
18
Suction valve, pos. 19H, which is of the ring plate
type, is fitted at the top of the cylinder liner and
can be removed together with the cylinder liner.
Discharge valve, pos. 20, forms the top of the
cylinder and is kept in place by a powerful spring,
pos. 21. This spring is also called the safety
spring as it enables the complete discharge valve
to lift a little at particularly high pressures in the
cylinder due to liquid or oil in the compressed gas
(liquid slugging). Thus overloading of the bearings
in the connecting rod is avoided.
The compressor is designed for operation with liq-
uid slugging for a short time only. If liquid slugging
occurs (the sound of hard metal hammering), the
compressor must be stopped and the cause must
be removed.
Connecting rod, pos. 17, Fig. 4.5 is made of cast
iron with a large elongation after fracture. It has re-
placeable slide bearings, pos. 17A and B, at both
ends on single stage compressors and on the first
stage (LP) on TSMC. On the second stage (HP)
on TSMC, the small end bearing is of the rolling el-
ement type.
The reason for this is that the top of the HP pistons
are affected by the intermediate pressure, which
is higher than the suction pressure, and thus gives
34/288
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
17B
17A SMC and
TSMC LP
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 effec-
tively filters off the dirt particles conveyed with the
gas from the refrigeration plant to the compressor.
The suction filters are made of stainless steel and,
by dismantling the covers, pos. 34E, they are easy
to pull out and clean.
When a compressor is delivered, a fine-meshed
filter bag, pos. 34B, has been fitted in the suction
filters. The filter bag filters off the tiny rust particles
that may pass the suction filters and is thus pro-
viding the compressor with considerable protec-
tion from dirt mixing with oil. The filter bags are
used no longer than 50 hours after initial start up
of the compressor. This also applies when chang-
es, which may cause impurities in the suction gas,
are made on the plant. After the 50 hours, the filter
bags and the inserts for the filter bags pos. 34C
must be taken out and discarded. Used filter bags
0178-931 - ENG
Rev. 27.10.03
 SMC /TSMC 100 Mk4 - Engineering Manual
4. Technical Description

must be disposed of according to existing environ-

mental legislation, see also Section 11 Mainte-
nance Instructions and Section 20 Final Disposal.
Fig. 4.6 SMC 100 Filter Section and by-pass valve

24

34A
04 technical description.fm

34E 34C

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 compres-
sor against unintended over-pressure in case the
Fig. 4.7 SMC/TSMC 100 - By-pass Valve
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.

24C 24B

0178-931 - ENG 35/288

Rev. 27.10.03
SMC /TSMC 100 Mk4 - Engineering Manual
4. Technical Description

The by-pass valve is delivered pre-set, sealed and Fig. 4.9 TSMC 112-116 Long Block
adjusted to the following opening pressures:
– Standard for SMC and TSMC (HP
stage) compressors: 24 bar [348 psi].
– Special for SMC - and TSMC (HP stage)
compressors: 22 bar [319 psi]; this is
only delivered following a specific order
and applied in accordance with local
rules and regulations concerning pres-
sure vessels as e.g. oil separators. The
current set pressure is stamped into the
49A
name plate pos. A.
– Standard for TSMC (LP stage) compres- The crankshaft, pos. 16, Fig. 4.8, rests in large
sors: 12 bar [174 psi]. slide main bearings pos. 5 and 6 which are able to
absorb both radial and axial loads. Both the main
The by-pass valve is of the high-lifting type,
bearings and the connecting rod bearings at the
which makes it robust and durable.
large end of the connecting rod are easy to re-
Moreover, the by-pass valve is independent of the place in connection with an overhaul of the com-
pressure on the suction side of the compressor. pressor and need no additional finishing after re-
Consequently, it opens only when the pressure on mounting. The bearings are available in 0.5 mm
the discharge side exceeds the set pressure com- undersize to be used for crankshafts that are
pared to that of the atmosphere. ground to 0.5 mm undersize during a renovation.
Note: The by-pass valve should not be consid- After having been ground to undersize, the crank-
ered a safety valve. shaft needs no surface hardening or the like, but
can be used directly as bearing surface. The
Fig. 4.8 SMC 104-108 Short Block
crankshaft is dynamically balanced for a smooth
and vibration free operation and need no further
balancing after the above-mentioned machining
to undersize. In the SMC 112-116 compressors
the crankshaft is also supported by an intermedi-
5 ate bearing, pos. 49A, .

6
16

36/288 0178-931 - ENG

Rev. 27.10.03
 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

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 Fig. 4.12 oil suction strainer
04 technical description.fm

compressor and driven by the crankshaft by

means of a coupling. The oil pump is a self-prim-
ing gear pump which takes the oil from the oil
Pos. 33A
sump through an oil suction strainer in the crank-
case, pos 33A, Fig. 4.12 and forces it through the
full flow filter into the lubricating system.
The oil pressure regulating valve, pos. 22,
Fig. 4.11 regulates the oil pressure in the com-
pressor lubricating system. It can be adjusted
from the outside by means of a screw driver when
the pointed screw, which locks the regulating
screw, has been loosened. For variable speed External oil filter, pos. 9A. After the oil pump, the
driven compressors, the oil pressure has to be ad- oil is furthermore filtered in an external oil filter of
justed to the minimum oil pressure at minimum the full flow filter type, pos. 9A, before it is led into
speed. Due to rising pressure drop at high oil flow, the lubricating system. The filter element is a dis-
the pressure will rise when running at maximum posable filter and must be replaced by a new one
rpm. as soon as its filtering ability has been used up.
The replacement can be carried out without re-
ducing the refrigerant pressure on the compres-
sor.

0178-931 - ENG 37/288

Rev. 27.10.03
SMC /TSMC 100 Mk4 - Engineering Manual
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 4L

4F 11B
4K 4E
9A 11A 4F 4D
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 prelubrica-
tion valve.
Prelubrication of the compressor must always be
carried out before the initial start up and after a
long period of standstill.
This way the bearings and the oil system are lubri-
cated and the oil pump is filled with oil. The hose
from the prelubrication pump must be connected
The shaft seal, pos. 10, is a sealing component
which prevents oil and refrigerant from the com-
pressor interior from leaking into the atmosphere.
The shaft seal is of the slide ring type, consisting
of a plane, lapped cast iron slide ring which ro-
tates with the crankshaft and seals against a sta-
tionary spring-loaded slide ring made of special
carbon. The shaft seal is of the balanced type and
consequently serves a universal purpose in view
of operating conditions, refrigerants and oil types
used for the compressor.
The design of the shaft seal and coupling of the
motor is such that the shaft seal can be removed
from the compressor without removing neither
compressor nor motor. This facilitates mainte-
nance considerably.

38/288 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 H

4D-1 9A 4K-1
04 technical description.fm

11A-1
H

4E-1

33A-1

0178-931 - ENG 39/288

Rev. 27.10.03
SMC /TSMC 100 Mk4 - Engineering Manual
4. Technical Description
Fig. 4.16 Shaft seal
Pos. 10
The heating rod, pos. 57, Fig. 4.17 keeps the oil
warm when the compressor is not in operation.
This reduces the refrigerant content in the oil and
eliminates starting-up problems caused by oil
foaming and subsequent insufficient oil pressure.
While the compressor is operating, the heating
cartridge can be switched off, but if it is problem-
atic to maintain the oil temperature sufficiently
high, it may be an advantage to keep the heating
cartridge on during operation.
40/288
Fig. 4.17 SMC 100 block Pump end
23 57
1B
Oil draining valve, pos. 23, for draining and
charging of oil. An inner socket at the draining
valve ensures that the oil sump is properly drained
so that the compressor does not have to be
opened when changing oil and filters.
The oil level glass, pos.1B, indicates the pre-
scribed oil level in the crankcase. See Section 6,
Technical Data - Charging the Compressor with
Oil.
Evacuating valve, pos. 42, Fig. 4.18, for evacu-
ating the compressor of refrigerant or air after
service.
0178-931 - ENG
Rev. 27.10.03
 SMC /TSMC 100 Mk4 - Engineering Manual
4. Technical Description

Fig. 4.18 SMC 104 - 108 Short Block flanges for connection to ISO and ASME standard
25-3 42 pipes. Pipe dimensions are indicated on the di-
25-4 mension sketches in Section 5, Physical and Con-
necting data.
Instrumentation: As standard equipment the
compressors are fitted with either an analogous
reading and safety system consisting of pressure
gauges, pressure switches and thermostat, or
with a SABROE microelectronic reading and con-
trol system, UNISAB II, as shown in Fig. 4.19.
Both systems are described in detail later in this
section.
Cooling of compressor and oil: On request the
compressor can be delivered with a built-in cool-
ing system with either water or refrigerant as de-
The stop valves, pos. 25-3 and 25-4, are fitted on
scribed in the section, Cooling Systems for Com-
the compressor discharge and suction flanges for
04 technical description.fm

pressors.
efficient blocking off of the compressor from the
refrigeration plant. The stop valves have welding

0178-931 - ENG 41/288

Rev. 27.10.03
 42/288
Fig. 4.19
Instrumentation
4. Technical Description

39A -- 1

99

UNIS AB II
31A
30A 39B -- 1
31C -- 1
39 31C -- 1
SMC /TSMC 100 Mk4 - Engineering Manual

D Analogous control and

45J -- 1 safety system
D
45
Name plate

39A -- 1

99
UNISAB II
31A
30A
39B -- 1 31C -- 1
39 31C -- 1

D
Analogous control and
45J -- 1 D safety system
Name plate 45

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 com-
pressed in two stages. The compressor is divided
into a low-pressure section, LP, and a high-pres-
sure section, HP. The cylinders in the low-pres-
sure section compress the gas from evaporating
pressure, PE, to intermediate pressure, PI.
During the compression the gas is heated and
must consequently be cooled down in the interme-
diate cooling system before it reaches the
high-pressure stage.
At the high-pressure stage, the gas is compressed
from PI to the condensing pressure PC.
The system is described in detail in Cooling of the
04 technical description.fm
intermediate discharge gas on TSMC compres-
sors later in this section.
The TSMC 100 compressors are available with 8
or 16 cylinders, divided as indicated:
TSMC 108:
6 low-pressure (LP) cylinder
2 high-pressure (HP) cylinder
TSMC 116:
12 low-pressure (LP) cylinder
4 high-pressure (HP) cylinder
0178-931 - ENG
Rev. 27.10.03
TSMC 100 compressors are connected to instal-
lations where the compression ratio (PC/PE) is
higher than the permissible compression ratio π
for one-stage compressors. This is described in
detail in Section 6, Technical Data, Operating Lim-
its.
As mentioned previously all compressor types in
the SMC 100 and TSMC 100 series - with a few
exceptions - are built up of the same components
and with the same facilities.
However, the TSMC 100 compressors
deviate on the following points:
Compressor Block
The interior of the compressor block is construct-
ed with suction chambers for both low pressure
and high pressure stages. The pressure in the
crankcase is the same as the suction pressure of
the LP stage.
43/288
SMC /TSMC 100 Mk4 - Engineering Manual
4. Technical Description

Piston Pin Bearing Fig. 4.20 TSMC 100 Cylinder Liner Complete
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.17B- 17B
2, has been fitted. This is because HP pistons on TSMC HP
17B
two-stage compressors - as opposed to single 17A TSMC LP
stage and LP pistons - are often subject to uni-di-
rectional force.

17

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

intermediate pressure chamber from the crank-
case in which there is evaporating pressure.
Fig. 4.21 TSMC cylinder liner

19M

44/288 0178-931 - ENG

Rev. 27.10.03
 SMC /TSMC 100 Mk4 - Engineering Manual
4. Technical Description

Suction Filters
In the TSMC compressors the two suction filters In the high-pressure stage a suction filter of the
vary in design. The suction filter for the LP stage same size as the one for the LP stage has been
is of the same type as the ones for the SMC com- fitted, but this has round holes in the shell and is
pressors and is characterised by square holes in closed at one end.
the shell and openings at both ends.
Fig. 4.22

TSMC 108

HP

Closed end and O-ring

sealing
04 technical description.fm

LP
TSMC 116

LP HP

Depending on the type of refrigerant and the suc-
tion and discharge pressures, a by-pass system
is sometimes used to regulate the intermediate
pressure PI in order to prevent it from falling below
the specified pressure.
The system is either built onto the compressor at
the factory or mounted on the refrigeration plant if
several two-stage compressors work in parallel.
The by-pass system is described in detail later in
this section under Cooling of the Intermediate Dis-
charge Gas on TSMC Compressors.
The TSMC 100 compressors can be delivered
with one or two oil separators depending on the
type of refrigerant and area of application. Other-
wise, the terms of delivery are the same as the
ones described for one-stage compressors.

0178-931 - ENG 45/288

Rev. 27.10.03
SMC /TSMC 100 Mk4 - Engineering Manual
4. Technical Description
Conversion of TSMC Compressors
from Two-stage to One-stage
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 re-
frigerant from R717 to HFC/HCFC at the
same time
c. Altering the compressor and changing the re-
frigerant from HFC/HCFC to R717 at the
same time
Generally, the conversion includes the following
points:
1. Replacing the suction filter with a normal
one-stage suction filter on the HP side.
2. Dismantling the pipe connection on the HP
suction side and installing a standard cover,
pos. 34 E.
46/288
3. Changing the pipe connections on the
discharge side. As the built-in channel,
which connects the top covers on a one-
stage compressor, does not exist between
the HP and LP top covers, this connection
must be established externally.
4. Changing the HP stage connecting rods to
the single stage type (journal bearing in
small end). The piston pins must be
changed.
5. Ensuring that the correct suction and dis-
charge valves are fitted.
6. Installing the correct by-pass valves.
7. Adjusting the safety pressure controls.
Moreover, it is necessary to replace the compres-
sor name plate and the name plates on the safety
valves.
Please contact YORK Refrigeration’s After Mar-
ket Sales Department for further information.
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 Fig. 4.24 Oil Separator
kinds of operating conditions - to separate the oil
A
which is conveyed with the disharge gas out of the
compressor so that it will be led back to the com-
pressor crankcase.
The oil separator is mounted on the compressor
unit and connected to the discharge gas outlet of
the compressor as indicated in the drawing, B
Fig. 4.23.
On some units the oil separator is not mounted.
Fig. 4.23 Standard Compressor Unit
Oil Separator
04 technical description.fm

Mode of Operation L

The discharge gas from the compressor flows A: Discharge gas inlet
B: Discharge gas outlet
through the oil separator, Fig. 4.24, from A to B, L: Oil return to compressor

passing a number of filters in which the oil is sep-

arated from the discharge gas. The filters consist
of a stainless steel wire mesh which usually needs
no cleaning and which is not worn down. Conse-
quently, the filters cannot be removed from the oil
separator.
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.

0178-931 - ENG 47/288

Rev. 27.10.03
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 crank-
case by means of the differential pressure be-
tween the pressure of the oil separator, PC, and
that of the crankcase, PE.
As the return of gas from the discharge side to the
suction side will have a negative effect on the
plant, it is desirable to lead only the separated oil
back to the crankcase. This is controlled by using
a thermodynamic liquid trap (TLT) combined with
a reliable solenoid valve which blocks the system
at standstill. Furthermore, it makes it possible to
delay the opening of the oil return after start up
and thus allowing condensed refrigerant, if any, in
Fig. 4.25 Solenoid Valve Controlled Oil Return
the oil separator to evaporate and not be led back
to the crankcase.
For plants which do not allow solenoid valves, a
reliable float valve controlled system can be deliv-
ered at an additional price.
A: Solenoid Valve Controlled Oil Return
As illustrated in the drawing, Fig. 4.25, the oil from
the oil separator is led to the compressor crank-
case via valve block A and the TLT.
In the oil separator at position C the pipe is insert-
ed 10 mm into the end plate whereby any sedi-
ment can settle at the bottom of the oil separator.
Compressor

Oil separator

Valve block A
Pos. 80A-1
Solenoid valve

Orifice
Pos. 80B-1

stop valve

Filter TLT valve

Pos. 80C-1

48/288 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 pass-
es a stop valve which is normally completely
open. This is not a regulating valve and it is
closed only during maintenance work on the com-
pressor and during cleaning of the filter in the
valve block.
Fig. 4.26 Valve Block, pos. A, Oil Return
Inlet
Nozzle
04 technical description.fm
closed at dead coil whenever the compressor is
stopped. When the compressor is operating, the
solenoid valve is open, allowing the oil to flow to
the compressor.
As stated above it is recommended, however, to
keep the solenoid valve closed for 20 to 30 min-
utes after start-up by means of a time relay (which
may be ordered as an accessory part). Thus the
oil is not returned to the compressor before the oil
separator is warm and has evaporated any refrig-
erant which may have mixed with the oil at the bot-
tom of the oil separator.
This time function is built into the UNISAB II sys-
tem.
The solenoid valve seat is available with various
boring diameters and nozzle sizes. For this pur-

pose Ø3.3 mm must be used.

The coil for the solenoid valve can be delivered as
Outlet a standard part with the following data:
Table 4.1
Wire mesh Coil Sizes

220/230 Volt 50/60 Hz 10 Watt

From the stop valve the oil passes a wire mesh, 115 Volt 50/60 Hz 10 Watt
which can be removed and cleaned.The filtered oil 240 Volt 50 Hz 10 Watt
now passes the solenoid valve, which must be

0178-931 - ENG 49/288

Rev. 27.10.03
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 dis-
charge gas mixed with the oil will cause the com-
pressor capacity to decrease.
Fig. 4.27 Thermodynamic Liquid Trap TLT
The trap remains tightly closed until the loss of
heat through the trap body lowers the control
chamber pressure, allowing the inlet pressure to
raise the disc and repeat the cycle.
One side of the disc (3) is plain with a single
scratch towards the outer edge, whereas the oth-
er side of the disc has a machined circular groove.

3 The trap is supplied with the grooved side of the

disc towards the seating faces and is suitable for
2
clean operating conditions.
If there are irregularities in the oil return, it may be
due to impurities in the oil. The problem can be
4 solved by unscrewing the cap, preferably using a
ring spanner, and turning over the disc so that the
1
plain side with a bleed scratch is towards the seat-
6 ing faces.
5 Replace the cap - no gasket is required but a suit-
able high temperature anti-sieze grease without
copper should be applied to the threads.
1 : Housing 4 : Strainer Mounting
2 : Cap 5 : Strainer Cap
3 : Disc In principle, the liquid trap can function in all posi-
6 : Gasket
tions but to minimise uneven wear (and thereby
achieving maximum life time) mounting it in a hor-
The TLT valve works in the following way:
izontal line with the cap up or down is recom-
A thermodynamic liquid trap uses a disc to control mended. See also Fig. 4.25.
the release of liquid and to trap gas. The trap cy-
The surface of the connection is machined to
cles open and close to discharge liquid and closes
make a tight sealing using Al gasket.
tightly between discharges. The disc, which is the
only moving part, rises and falls in response to dy- Fig. 4.28 Principle piping diagram
namic forces produced by the gas flowing through
Oil separator
the trap.
Liquid and/or gas enters the trap through the cen-
tral orifice, lifts the disc and is discharged through
TLT 15 EVRB
the outlet orifice. The gas passes along the under-
side of the disc at high velocity and collects in the
control chamber above. The resulting pressure Reciprocating 245893
compressor
Nozzle ø 3.3 mm
imbalance forces the disc downward onto the
seating surfaces and stops the flow.

50/288 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 ves-
sel, mounted on the side of the base frame and
connected to the oil separator and compressor as
illustrated on Fig. 4.29.
Fig. 4.29 Float Valve Control Oil Return
B
04 technical description.fm
The pipe connection with valve B acts as a pres-
sure equalizer between the two vessels. The float
can be dismantled for servicing.
Oil Return in Connection with Parallel
Operation
If several compressors are running in parallel on
the same refrigeration plant, it is expedient to ad-
just their oil level in the crankcase by means of an
automatic system. This is particularly necessary
in the case of HFC and HCFC plants in which the
oil is returned to the compressors with the suction
gas as it is not distributed evenly on all the com-
pressors.
However, also in modern, automated R717 refrig-
eration plants an automatic oil equalizing system

can contribute to greater reliability, thus reducing

C
the daily inspection tours.
The following passages A, B and C include a de-
scription of the three systems most commonly
To the compressor
used.
A D
The following passages describe each of the
The separated oil is drained through stop valves A
three systems in general. For more detailed infor-
and filter D to the float vessel C, and here the float
mation, please contact YORK Refrigeration.
valve opens at an increasing oil level and returns
the oil to the crankcase.

0178-931 - ENG 51/288

Rev. 27.10.03
SMC /TSMC 100 Mk4 - Engineering Manual
4. Technical Description

System A
System A is used where two or more compres- Principle diagram, Fig. 4.30, is an example of a
sors are working in parallel and where either HFC, plant with two compressors working in parallel on
HCFC or R717 is used as the refrigerant. It is a the same suction and discharge line.
condition, however, that the compressors keep
working at the same suction pressure.
Fig. 4.30 Principle Diagram
Standard
Oil seperator with solenoil valve
controlled oil return Alternative
Oil seperator with float valve
controlled oil return

5 5 5
1 1
2 2
6 6
3 3 8 12
14
4 7 4 7 11 13
9
10
15
9 16
14

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 The oil vessel, pos. 9, is illustrated by the principle
fitted on each of the compressors in front of the oil drawing, Fig. 4.32. Its size is calculated so that an
level glass. This makes the oil level in the float extra amount of oil is available to ensure the oil
house equal to that in the crankcase. This can be level in the compressor.
checked visually in the oil level glass. The com- The total volume of the vessel should be approx.
plete float valve can be seen in Fig. 4.31. 50% of the oil volume in all the compressors, and
Fig. 4.31 Float Valve Housing with Float Valve the vessel should not be charged to more than
50%.
Pipe
connection Vent valve
This means that the amount of oil in the vessel
Oil level glass
on compressor corresponds to 25% of the total amount of oil in
the compressor.
The oil vessel must be equipped with:
- heating rod, 240 W, pos. 14
- oil charging valve, pos. 15
- oil level glass, pos. 16
04 technical description.fm

From the top of the oil vessel, pos. 9, a pipeline is

taken to the suction side of the plant.
A non-return valve, pos. 10, Fig. 4.30, has been
The float controls a needle valve which opens at a
inserted in the pipeline, and this valve opens at a
falling oil level, letting the oil flow from the oil ves-
differential pressure of 1 bar. This way the pres-
sel, pos. 9, return to the compressor. This ensures
sure in the oil vessel will be 1 bar higher than the
a constant oil level in the compressor.
suction pressure in the plant. This is sufficient in
Fig. 4.32 Oil Vessel, pos. 9 order to squeeze the oil through the float valves,
To common
suction line pos. 2, without causing foaming in the float valve
15
houses.

16

14

240 W Max. oil level

To float
valves

0178-931 - ENG 53/288

Rev. 27.10.03
SMC /TSMC 100 Mk4 - Engineering Manual
4. Technical Description

The Oil Return Systems from the Oil Separa- float valves, pos. 2. Solenoid valve, pos. 11, clos-
tors are the same as the ones described in Oil re- es when the plant stops and all the compressors
turn to the compressor in this section. The only dif- are stopped.
ference is that the oil return system is not connect- Fig. 4.33 Oil separator with float valve control-
ed to the compressor but taken to the common oil led oil return
vessel, pos. 9.
Solenoid valve, pos. 6, closes whenever the actu- 5
al compressor stops.
In case the oil return system from the oil separa-
tors is controlled by a float valve, which is also de-
scribed in this section, it will be necessary to 8 12
mount a pipe connection to the discharge pipe as
14
illustrated in Fig. 4.33. 11 13
9
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 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 compres- Principle diagram, Fig. 4.34, is an example of a
sors are working in parallel but where they do not plant with two compressors working in parallel but
have any joint suction line. The refrigerant may be which do not have the same suction pressure,
HFC, HCFC or R717. PE+, PE-.
Fig. 4.34

To condenser

ET - Alternative
5 5 Oil seperator with float valve
ET+ controlled oil return

5
6 6
A B
8 12
04 technical description.fm

14
6a 2a 6b 2b 11 13
7 7 9
10
15
3 3
9 16
4 4 14

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 55/288

Rev. 27.10.03
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.
There is a risk, however, that the differential pres-
sure between the oil vessel, pos. 9, and the crank-
case on compressor B may become so great that
the oil conveyed via the solenoid valve 6a starts
foaming. Usually, this foaming does not cause any
problems as the oil is supplied to the compressor
56/288
above oil level. Any foaming that may occur will
soon be dissolved in the crankcase.
The system has one further advantage as the oil
does not pass the level switch vessels 2a and 2b.
Should foaming occur, this is not going to interfer
with the working of the level switch.
In case the oil return system is regulated by
means of a float valve as described under System
A, the same system as the one shown in Fig. 4.35
should be used.
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 op-
erating in parallel with the same condenser. It is
not a requirement that the suction pressure is the
same on the two compressors. The float valve is
of the same type as the one used in system A.
The oil level equalizing system is illustrated in
Fig. 4.35.
It works by pressing the oil from one compressor
to the next by means of the oil pump pressure
(4.5 bar), pos. 3, in each of the compressors.
Fig. 4.35
04 technical description.fm
The oil level in the crankcase is regulated by a
float valve, pos. 2a or 2b, which opens at a falling
oil level in the compressor.
If e.g. the oil level in compressor A is too low, the
float valve, pos. 2a, will open. The oil pump in
compressor B will now supply oil through the sole-
noid valve (nozzle incl.), pos. 1a, until a normal oil
level has been established, whereupon the float
valve will close. The solenoid valve pos. 1 is open
when the compressor in question is running.

3a
A
ø10/8

4a
1a 2a

ø10/8
SNV8 CD

3b B

4b
1b 2b

1a - 1b: Solenoid valve

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

0178-931 - ENG 57/288

Rev. 27.10.03
SMC /TSMC 100 Mk4 - Engineering Manual
4. Technical Description
Capacity Regulation of Compressor
All compressors have a built-in capacity regulat-
ing system which continually adjusts the compres-
sor capacity to the cooling requirements of the
plant. Even at reduced capacity the compressor
works very efficiently. This makes it very well-suit-
ed for plants with reduced cooling requirements
for lengthy operating periods.
Fig. 4.36 Capacity Regulating Mechanism
13
The capacity regulating system including the
frame, pos. 13, is activated by the compressor oil
pressure and controlled by means of solenoid
valves fitted on the compressor. At a capacity re-
duction two suction valves are forced open at a
time. In this case no compression takes place in
the relevant cylinders as the sucked in gas in the
cylinders is pressed back to the suction chamber
through the suction valves.
The above forced opening of the suction valves is
also used when starting up the compressor. The
system works as follows: At compressor standstill
all the suction valves are forced into an open po-
58/288
sition and cannot be closed until the compressor
is in operation and the oil pump has built up the oil
pressure in the lubricating system. With an open
suction valve there is no compression resistance
in the compressor and this reduces its starting
torque considerably. Thus, a motor dimensioned
to suit the operating conditions of the compressor
can easily start up the compressor also by using
the star/delta starting system.
For compressors fitted with extra capacity stages
(extended unloading), one cylinder (SMC 104-
106-108) or two cylinders (SMC 112-116) will be
in operation all the time, also at start up.
See extended unloading.
Capacity Regulation and Unloading of
Compressor
Capacity Regulation
As mentioned in the introduction to this section all
SMC and TSMC compressors are fitted with a hy-
draulic capacity regulating system by means of
which the compressor capacity can be adjusted to
the refrigerating requirements of the plant.
When reducing the compressor capacity, two or
more suction valves (on compressors with ex-
tended unloading: one or more suction valves) are
forced open so that compression does not occur
in the cylinders in question.
The suction valve is forced open when the unload-
ing ring together with the pins, pos. 19B, are
pressed up under the suction valve, thus keeping
the valve in open position as shown in Fig. 4.37.
0178-931 - ENG
Rev. 27.10.03
 SMC /TSMC 100 Mk4 - Engineering Manual
4. Technical Description

Fig. 4.37 Cylinder Liner Complete The unloading frame, which is controlled by two
brackets with guiding pins, does always activate
two cylinders at a time. The unloading frame is
moving back and forth by means of the unloading
cylinder, pos. 12. If oil pressure is put on the cylin-
der during operation, the unloading frame will
move to the left as shown in Fig. 4.38. Thus the
angle of slope of the rocker arms is changed so
that the unloading, ring pos. 19F, is able to move
19F 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
19B
right, thereby raising the rocker arms. The unload-
ing ring with pins, pos. 19B, are pressed up under
the ring plate and the suction valve is forced open,
19A thereby unloading the cylinder.
04 technical description.fm

Fig. 4.38 Unloading System

15A
12
13 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 59/288

Rev. 27.10.03
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 pres-
sure, all the unloading cylinders are unloaded and
consequently there is no compression resistance
during start-up.
This unloading during start-up reduces the start-
ing torque of the compressor considerably.
Fig. 4.39
12
The solenoid control valve is an electromagnetic
three-way valve which, with a dead coil, connects
the unloading cylinder, pos. 12, with the crank-
case (the passage of the oil flow from pipe 2 to
pipe 3 is open), Fig. 4.39
If the coil is energized, the valve will reverse so
that the passage of the oil flow from oil discharge
60/288
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 sole-
noid valves, Fig. 4.39, which receive opening and
closing signals from a connected regulator. This
could e.g. be a programme device or the YORK
electronic control system, UNISAB II, as de-
scribed later in this section under Instrumentation.
3
1
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.
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 cylin-
der (pipe b).
Regulating Sequence
As described earlier, the compressors are always
completely unloaded during start up exept for
the compressor with extra capacity stages (ex-
tended unload), which will always have one or two
cylinders loaded during start up (SMC104-108)
and (SMC 112-116).
0178-931 - ENG
Rev. 27.10.03
a
Standard compressors, however, with 2 cylinders
on the SMC 104, 106 or 108 compressors or 4 cyl-
inders on SMC 112 and 116 will be set to work
when the compressor oil pump has worked up an
oil pressure in the lubricating system.
The cylinders mentioned are connected directly to
the oil system without any solenoid valve as
shown in . This makes it the lowest capacity stage
on the compressors.
The standard SMC 100 compressors can be reg-
ulated with the following capacity stages, repre-
sented by the hatched fields in Table 4.4.
61/288
SMC /TSMC 100 Mk4 - Engineering Manual
4. Technical Description

Schematic Drawings, Standard

SMC/HP 104 SMC 112 TSMC 108

TSMC 188
5
2 1 1 3
%
% HP
1 1 S
100
100 1 3
% S 2
50 S
N
L 83 100 1
Y 67 2
4 33
2 6 0 N
67
L
SMC/HP 106 Y
2
SMC 186
50 4
33 N
3
L
1 2 Y
%
100 1
SMC 116 TSMC 116
67 2
33 N
L %
Y 3 1 2 S
% 100 1
1 5 1 5
100 1 83 2
3 5
SMC/HPC 108
SMC 188 87 5 S

67
75
4 1
%
2 3 63 S 4
100 4 6
1 50
75 2 2 8 3 S
50 2 S
50 3 3
4
25 37 33 4
N 6
L 25 L
Y N
L
Y Y

62/288 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, addi-
tional capacity cannot be loaded until the mo-
tor has reached its full torque.
The recommended run up time is 10 sec. The min-
imum speed according to the operating limit dia-
gram is 5 sec (also applies to variable speed driv-
en compressors).
Fig. 4.41 illustrates the regulating system in prin-
ciple. The percentages indicate the compressor
capacity at every stage. When unloading a com-
pressor without extra capacity stages, the sole-
noid valves are unloaded in numerical order: 1 ->
2 -> 3 -> 4. When loading, the order is: 4 -> 3 ->
2 -> 1.
Note: On TSMC 116 compressors the solenoid
04 technical description.fm
valves nos. 3 and 4 must always be loaded simul-
taneously as they control both the LP and the HP
cylinders.
Further, the TSMC compressors can, as standard
equipment, be totally unloaded as described in
the following.
Total Unloading
Besides the standard equipment as described in
the previous passage the compressor can be fit-
ted with a solenoid valve marked S (optional).
Fig. 4.41.
The TSMC compressors, however, are always
equipped with this S solenoid valve.
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 reg-
ulation as the compressor will heat up excessively
during a lengthy operating period at 0% capacity.
The S solenoid valve must therefore only be used
as follows:
• When total unloading is required until the
motor has reached its maximum torque mo-
ment.
• When a refrigeration plant has sudden brief
operational stops for a short time and com-
pressor stop is not required. In this case the
compressor must not be allowed to run for
more than 5 minutes at 0% capacity. If the
compressor is equipped with a refrigerant
cooled oil cooler type OOSI (R717) or
OOKH (HFC/HFCF) and liquid refrigerants
are available so that the cooling system can
operate, idling is allowed for up to 30 min-
utes.
The regulating sequence can be seen from the
schematic drawings in Fig. 4.41.
Capacity Stages:
The SMC 100 compressors can be regulated with
the following capacity stages, represented by the
hatched fields in Table 4.4.
63/288
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 1 1
S
% % S 2 3
S 100 1
100 1 75 2
50 50 3
N
0 2 25
Relief cylinder 0
L N
Y L
3
Oil return Y
1
Oil pressure
SMC/HPC 106
SMC 186

SMC 112 SMC 116

S
1 2
% S
100 1
% A
67 2
S S 3
33 S
% A 1 3 100 1
0 N 1 5
S 3
L 100 1 87
Y 5
3
75
SMC/HPC 108 83

63
% 67 4 B 4 6
S 1 B 2 S 50 2
2 S
100 1 50 S 4
2 3
75 2 2 37 6
50 3 33 4 25 S
25 S 0 0
N
L L N
0
N Y Y
L
Y

64/288 0178-931 - ENG

Rev. 27.10.03
 SMC /TSMC 100 Mk4 - Engineering Manual
4. Technical Description

Table 4.4

Compressor Capacity per Stage in %

Type 25 33 37 50 63 67 75 83 87 100

SMC 104

SMC 106

SMC 108

SMC 112

SMC 116

TSMC 108

TSMC 116

As illustrated in Table 4.4, the SMC 100 standard pacity regulate the compressor in steps of one cyl-
compressors can only be capacity regulated in inder per stage with the following capacity stages
steps of two cylinders, which is sufficient in most represented by the hatched fields in Table 4.5.
04 technical description.fm

cases. Table 4.6 displays the numbers of the solenoid

However, it will occasionally be required to feature valves which must be activated to obtain the stat-
more stages and for this reason a system called ed capacity stages (load).
“extended unloading” has been developed to ca-

0178-931 - ENG 65/288

Rev. 27.10.03
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 tems by means of reconstructing kits supplied by
an order for a new compressor is placed. YORK Refrigeration's After Market Service De-
Already delivered SMC 100 compressors can be partment.
converted for extended or totally unloaded sys-

66/288 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
104 106 108 112 116

12.5% 0 0

16.7% 0 0

18.8% A

25.0% 0 S A AB

31.3% 6A

33.3% S AB

37.5% 3 6AB

41.7% 4A

43.8% 56B
04 technical description.fm

50.0% S 2 3S 4AB 56AB

56.3% 456A

58.3% 34B

62.5% 23 456AB

66.7% 2S 34AB

68.8% 3456B

75.0% 1 23S 234A 3456AB

81.3% 23456A

83.3% 12 234AB

87.5% 123 23456AB

91.7% 1234B

93.8% 123456B

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

0178-931 - ENG 67/288

Rev. 27.10.03
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 con-
nected.
Note: When the mentioned systems are used,
the compressor will not start up completely un-
loaded but with capacity as shown in Table 4.7.
Table 4.7
104 106 108 112 116
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

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

68/288 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

8 4
6 3
4 2 7 3
5 S
3 S 6 S
4 1
5 1

SMC 104 SMC 106 SMC 108

16 12 S 4
12 9 S 3
04 technical description.fm

15 11 7 3
11 S 5 2
14 S 6 2
10 7 4 1
13 9 5 1

SMC112 S MC116

The valve body as for “Total unloading” is used to
regulate the capacity stages instead of the stand-
ard valve body and the corresponding connecting
pipes are mounted.
The increased starting torque must therefore be
taken into consideration when choosing motor
and start system.
For this purpose, the start up torque curves for
R717 compressors and for HFC/HCFC compres-
sors might be useful. These figures can be seen
in Section 6, Technical Data, Starting torque of the
compressor. Please note that the max rpm is
shown in the Operating Limits Diagrams in section
6.
Please note that if the motor is started up by
means of a Y/∆ starter, the starting torque of the
compressor may exceed the starting torque of the
motor at a high differential pressure. In these cas-
es the compressor must be equipped with a
by-pass system which makes the pressure on the
discharge side of the compressor equivalent to
the suction pressure as illustrated in Fig. 4.44.

0178-931 - ENG 69/288

Rev. 27.10.03
SMC /TSMC 100 Mk4 - Engineering Manual
4. Technical Description

Fig. 4.44 YORK Refrigeration's recommendations as to the

Nonreturn valve or
cooling of the compressor. These recommenda-
Solenoid automatically controlled tions can be found in the Operating Limits dia-
valve stop valve grams.

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

70/288 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 stand-
ard units with base frames adapted to IEC electric
motors. Against additional payment base frames
can also be delivered for non-standard electric
motors. On the base frame one oil separator can
Fig. 4.45
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.

SMC 100 Unit - Direct Couple SMC 100 Unit - V-belt Driven
04 technical description.fm

The compressors can be connected to an electric frame as standard units as illustrated on dimen-
driving motor or a combustion motor. The trans- sion sketches in Section 6, Technical Data, see
mission can be either direct through a coupling also Dimension and Piping diagrams. Further-
that is flexible in both radial and longitudinal direc- more, it is possible to have compressors built into
tion but which is also rigid in its contorsion, there- non-standard units following a specific agreement
by stabilising the compressor rotation. The trans- with YORK Refrigeration.
mission can also take place by means of a V-belt A standard compressor is delivered without oil in
drive, which, through the selection of standard the crankcase but charged with Nitrogen N2 to 0.2
belt pulley diameters, is able to provide the com-
bar [3 psi] overpressure.
pressor with the correct number of revolutions and
consequently, the desired compressor capacity. A yellow label, Fig. 4.46, on the compressor indi-
For more information, read Section 6, Technical cates this Nitrogen charge.
Data. Fig. 4.46
Please note that the compressor must be modified
Påfyldt beskyttelsesgas N2
in order to change the direction of rotation: the oil Charged with inert gas
Enthält Schutzgas 0,2 bar
pump must be changed on Mk4. Chargé du gaz protecteur 3 PSI
Contiene gas protector 1534-169
Extent of Delivery
The compressors can be delivered as blocks
only in standard execution or mounted on a base

0178-931 - ENG 71/288

Rev. 27.10.03
SMC /TSMC 100 Mk4 - Engineering Manual
4. Technical Description

Instrumentation
In the standard version the compressors are avail-
able with one of the following two systems: In its standard execution the analogue sys-
A: analogue reading and safety system tem consists of controls, built onto the com-
B: UNISAB II reading, safety and capacity pressor on delivery, but without electrical
regulating system connections.

The compressors are designed so that either the The controls are not factory adjusted and
analogue system or the UNISAB II system can be should therefore be adjusted before the ini-
fitted without changing the compressor. They tial start-up of the compressor.
each have their own characteristics, however, as As may be seen from the drawing Fig. 4.47
described in the following: some of the controls have a dual function,
i.e. the type designation KP15 indicates that
A: Analogue Reading and Safety System
1 is the low pressure and 5 the high pres-
The analogue system only has reading and
sure cut-out function. KP98 e.g. has two
safety functions and cannot control the com-
temperature systems incorporated.
pressor capacity.
The specific controls are mentioned in the
Capacity control is handled by an external
following, with reference to the numbers in
system built into the electrical switchboard
Fig. 4.47.
and connected to the compressor on the
mounting site. Some mounting costs must Fig. 4.47
be expected.
The control system can be one of many
types and makes. It must, however, be able
to send out opening and closing signals to
the solenoid valves of the compressor in the
prescribed unloading and loading sequence
as already described in this section, Capac-
ity Regulation and Unloading of Compres-
sor.
In special cases a manually operated switch
system can be used instead of the automat-
ic one. This makes it possible to regulate the
compressor capacity by hand. 6 5 4 3 2 1

72/288 0178-931 - ENG

Rev. 27.10.03
 SMC /TSMC 100 Mk4 - Engineering Manual
4. Technical Description
1. High Pressure Cut-out KP15
Adjusted to stop the compressor if the dis-
charge pressure rises to a pressure 2 bar
[29 psi] lower than the setting pressure of
the by-pass valve.
The pressostat has a manual
reset function.
2. Low Pressure Cut-out KP15
Adjusted to stop the compressor if the suc-
tion pressure drops to a pressure corre-
sponding to 5K lower than the lowest evap-
orating pressure.
The pressostat has an automatic
reset function
and will therefore restart the compressor
04 technical description.fm
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. Oil Differential Cut-out MP55
Adjusted to stop the compressor if the pres-
sure in the lubricating system drops below
3.5 bar [51 psi] compared to the pressure in
the crankcase.
The pressure cut-out has a built-in time de-
lay of 60 sec. which keeps it idle during the
start-up of the compressor until the correct
oil pressure has been established.
0178-931 - ENG
Rev. 27.10.03
The pressostat has a manual
reset function
as well as a yellow indicator lamp which,
when illuminated, indicates that the electric
circuits are working. Normal oil pressure in
the compressor is 4.5 bar [65 psi] which is
indicated on the manometer 9 on Fig. 4.48.
5. Discharge Pipe Thermostat KP98
Adjusted to stop the compressor if the
discharge gas temperature exceeds:
150 °C [302 °F] for R717
120 °C [248 °F] for HFC/HCFC
This adjustment can, however, be set to
20°C [68 °F] above the normal discharge
gas temperature, once this is known from
experience. This makes it possible to safe-
guard the compressor against excessive
temperatures.
The thermostat has a manual
reset function.
6. Oil Thermostat KP98
Adjusted to stop the compressor whenever
the oil temperature in the crankcase ex-
ceeds 80°C [176 °F].
The thermostat has a manual
reset function.
7. Oil Filter Differential Pressostat
Indicates when oil filter pos. 9A needs to be
replaced. Connections on the pressostat
has a transparent housing and will indicate
power supply with green LED and filter re-
placement with red LED.
73/288
SMC /TSMC 100 Mk4 - Engineering Manual
4. Technical Description
Manometers
For reciprocating compressors the following three
types of manometers are available:
Fig. 4.48
10 8-9
8. High Pressure Manometer
High pressure manometer indicating the
discharge pressure of the compressor and
used in SMC compressors. Fig. 4.48
9. High and Intermediate Pressure Manom-
eter
High and intermediate pressure manometer
indicating the discharge pressure for the HP
and LP stages on TSMC compressors,
Fig. 4.48.
This manometer has two manometer works
and two arrows, a red one for high pressure
and a black one for intermediate pressure.
74/288
10. Low Pressure and Oil Pressure
Manometer
Low pressure and oil pressure manometer
indicating the compressor suction pressure
and oil pressure in the lubricating system of
the compressor. Used in the SMC and
TSMC compressors.
This manometer has two manometer works
which are interconnected so that one of the
works indicate the suction pressure with an
arrow whereas the oil pressure is indicated
by means of a dial in the middle of the ma-
nometer and turned round by the other
works. The figure on the dial right below the
arrow indicates the oil pressure.
This makes it possible to read the oil pres-
sure directly from the manometer.
The manometers can be used with several
refrigerants.
• HFC/HCFC manometers for R22, R134a,
R404A
• R717 manometers
• R410A, R744 (CO2) manometers
On delivery of compressors using other re-
frigerants the manometers are graded for
that particular refrigerant. The standard
units on the scale is bar/°C but others can
be delivered on request.
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 devel-
oped to fit all YORK Refrigeration's
SABROE reciprocating and screw compres-
sors, i.e. the same UNISAB unit is used for
both compressor types. It is only necessary
to select type of compressor, refrigerant and
a few other functions - and the UNISAB will
be ready for operation. UNISAB II is based
on YORK Refrigeration's extensive experi-
ence with design and operation of compu-
terized compressor control systems.
Fig. 4.49 Computerized Control and Monitoring
04 technical description.fm
UNISAB II is designed for safe control, mon-
itoring and optimization of compressor oper-
ation 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 lan-
guages, and it is possible to switch to the
English version at any time.
Easy to Operate
UNISAB II has a systematic and easily ac-
cessible user interface which does not re-
quire any special knowledge or education.
Operational data and status appear from the
distinct display which features four lines with
twenty characters each. The user interface
also has arrow keys for menu selection, set
key for parameter changing as well as keys
for selection of manual/automatic operation,
start/stop, manual capacity regulation and
resetting.
75/288
SMC /TSMC 100 Mk4 - Engineering Manual
4. Technical Description

Safety Monitoring and Control pressure and temperature transducers as

UNISAB II provides safe monitoring by well as position transmitters on the com-
means of warning and alarm values/settings pressor. On one-stage reciprocating com-
for all measuring points. If a set value is ex- pressors three pressure and three tempera-
ceeded, a red diode will flash slowly in warn- ture transducers are mounted while
ing situations without stopping the compres- two-stage reciprocating compressors are
sor, and quickly in alarm situations with equipped with four pressure and tempera-
compressor shut down. A display text will ture transducers.
show the cause of the alarm. In both warn- Screw compressors are fitted with four pres-
ing and alarm situations separate relays are sure and three temperature transducers as
activated for connection of a remote lamp, well as one or two slide position transmit-
bell or alarm panel. ters.
It is easy to find all the set values and their Furthermore, a thermistor input is available
warning and alarm values through the for motor protection.
straightforward menu system.
Factory Test
Besides monitoring the compressor pres-
Every UNISAB II is tested during the pro-
sures and temperatures, the UNISAB II also
duction process and when it is mounted on
calculates the suction pressure vapour
the compressor. A computer test is per-
overheating, monitors the capacity slide po-
formed including a test certificate before the
sition and oil flow, and calculates the oil filter
compressor leaves the factory.
differential pressure on screw compressors.
Please note that UNISAB II cannot directly
For correct fault diagnosis in case of a com-
combine the capacity of compressors with
pressor shut down, the UNISAB II immedi-
extended capacity control; only SMC 104
ately stores the alarm situations in its mem-
can be controlled directly by UNISAB II
ory which can be displayed and analyzed on
when it is equipped with a simple box
the display at any time.
(this has to be configured as a HPC 108 or
Instrumentation SMC 108).
Depending on compressor type the
UNISAB II is equipped with a number of

76/288 0178-931 - ENG

Rev. 27.10.03
 SMC /TSMC 100 Mk4 - Engineering Manual
4. Technical Description

Cooling of the Intermediate Discharge Fig. 4.50 SMC 100 compressor

Gas on TSMC Compressors
Oil separator CT
At two-stage operation it is necessary to cool the Oil separator
Equalizing pipe
discharge gas from the LP stage before it enters
the HP stage. This intermediate cooling is carried IP HP
Mixing
out with the systems described below, depending LP
chamber
IP
on the type of refrigerant used. HP Solenoid
valve
Common for these intermediate cooling systems LP
Float valve
is that they must cool the intermediate pressure
gas sufficiently and at the same time ensure that Intermediate Liquid subcooling
cooler type spiral
no liquid is admitted into the HP stage since liquid DVEA Oil drain off
may result in liquid slugging in the HP cylinders
Fig. 4.51 TSMC 100 Compressor
and excessive wear on the moving parts. It is Oil separator Oil separator
therefore important to check the systems as de-
scribed below. CT

Intermediate Cooling System with IP HP

LP
04 technical description.fm

Intermediate Cooler Type DVEA, R717 LP IP

Mixing chamber
The two-stage R717 plant may consist of two
compressors, one low-pressure compressor (LP)
and one high-pressure compressor (HP) as illus-
trated in Fig. 4.50 The plant may also consist of
Equalizing pipe
one or more two-stage compressors as shown in
Fig. 4.51. Solenoid valve

Intermediate
In both cases the compressors are connected to cooler Float valve
an intermediate cooler in which the warm gas from
the LP-stage is cooled down before it flows on to Liquid subcooling
spiral
the HP-stage.
In the intermediate cooler the liquid level of R717 Oil drain off

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

0178-931 - ENG 77/288

Rev. 27.10.03
SMC /TSMC 100 Mk4 - Engineering Manual
4. Technical Description

As a matter of precaution a solenoid valve Connection, pos. B, pipe dimension OD 10 mm,

should be used in the liquid line to the float so that emerges from receiver or priority vessel as de-
it may shut off the liquid flow to the intermediate scribed in Cooling with thermopump - R717 later
cooler whenever the system is stopped. in this section. The intermediate discharge pipe is
At regular intervals the intermediate cooler must built onto the compressor on delivery as a block or
be drained of oil through the oil drain valve. a unit. On delivery of a compressor block the liquid
system including the expansion valve must be
Intermediate Cooling System with Liquid mounted on site.
Injection into the Intermediate Discharge Gas,
R22 and R717 2. Intermediate Cooling with Thermostatic
Two-stage compressors type TSMC can be Injection Valve Type:
equipped with a pipe connection from the LP TEAT (HCFC)
stage discharge branch to the HP stage suction The intermediate cooling system is designed as il-
branch as shown in Fig. 4.52. lustrated in Fig. 4.53. Here the intermediate cool-
In the pipe connection the warm discharge gas ing is carried out by a thermostatic injection valve
from the LP stage is cooled by injection of liquid of the TEAT type and the subcooling takes place
refrigerant into the intermediate pipe. This can be in a HESI heat exchanger.
achieved with the following two systems: Fig. 4.53
KP 77
1. Intermediate Cooling with Thermostatic
T
Expansion Valve Type:
Oil separator
TEA (R717) or TEX (R22)
CT
Fig. 4.52
LP IP HP Mixing chamber
TSMC LP IP
Oil separator
LP
CT A

TEAT
LP Liquid supply

From receiver To evaporator

Mixing chamber
HESI

Opt

The sensor of the TEAT valve is placed in a sen-

B
Stop valve sor pocket at the HP discharge branch of the com-
TEA or TEX
Filter pressor, and a proper thermal contact is obtained
Solenoid valve
by means of the heat conducting compound. The
In the system in Fig. 4.52 the liquid refrigerant
solenoid valve is opened by the KP77 thermostat
conveyed to the intermediate pipe is regulated by
whenever the temperature of the pressure pipe
a thermostatic expansion valve type TEA
exceeds 55°C [131°F].
(R717) or TEX (R22) with a sensor placed on the
intermediate pipe close to the HP stage.

78/288 0178-931 - ENG

Rev. 27.10.03
 SMC /TSMC 100 Mk4 - Engineering Manual
4. Technical Description
Automatic Regulation of Intermediate
Pressure IP
In two-stage plants with reciprocating compres-
sors it should be pointed out that the intermediate
pressure is not allowed to drop excessively.
A low intermediate pressure reduces the damping
effect of the gas on the valve plates in the LP
stage discharge valves. The danger is that a
breakdown may occur in the form of broken valve
plates.
In order to prevent this it may be necessary to
mount a by-pass system between the HP side and
IP side. Thus a suitable amount of gas is led back
to the IP side. The system is illustrated in
Fig. 4.54.
The lower limits for IP have been fixed at:
04 technical description.fm
-15°C [5°F] for R717 plants
- 25°C [-13°F] for HFC and HCFC plants.
The by-pass system is additional equipment and
is usually mounted by YORK Refrigeration direct-
ly on the internal pipe connections on the com-
pressor block .
The diagrams, Fig. 4.50 to Fig. 4.53, do only show
the principle of the different systems and must not,
therefore, be used directly.
Fig. 4.54
TSMC
PM main valve
CVC pilot valve -0.75 -> 7 bar
Oil separator
IP HP
LP LP LP
LP
Opt.
0178-931 - ENG
Rev. 27.10.03
Determining the Intermediate Pressure
IP
The intermediate discharge temperature of the
compressor is dependent on the evaporating tem-
perature ET, the condensing temperature CT and
of the ratio between the capacity at the LP and HP
stages, corres-ponding to the number of cylinders
that is working at each stage.
If a TSMC compressor is working at 100% capac-
ity, the ratio between the number of cylinders is
3:1 as indicated in the Table 4.8.
When unloading the cylinders, this ratio is
changed to 2:1 or 1:1 and the intermediate pres-
sure will drop accordingly.
The intermediate discharge pressure is deter-
mined by entering the suction tempera-ture ET
and the condensing temperature CT into the cal-
culation programme COMP 1. The lower limits for
the intermediate discharge pressure are the same
as stated above:
-15°C [5°F] for R717 plants and
-25°C [-13°F] for HFC and HCFC plants.
To ensure correct operating conditions all partial
load possibilities must be calculated. If the result
of the calculation shows values below the stated
limits, a by-pass must be fitted as described
above.
However, it is also possible to connect the capac-
ity regulating system in such a way that the com-
pressor cannot operate at the capacity stages
which produce suction temperatures lower than
the limiting value of the refrigerant in question.
As described in the section Capacity regulation
the TSMC compressors can be capacity regulated
at the following stages:
79/288
SMC /TSMC 100 Mk4 - Engineering Manual
4. Technical Description

Table 4.8
Number of
Compressor Capacity
Cylinders Ratios
Type %
Working
LP HP
100 6 2 3:1
TSMC 108 66 4 2 2:1
33 2 2 1:1
100 12 4 3:1
83 10 4 2.5:1
TSMC 116 67 8 4 2:1
50 6 2 3:1
33 4 2 2:1

80/288 0178-931 - ENG

Rev. 27.10.03
 SMC /TSMC 100 Mk4 - Engineering Manual
4. Technical Description

Cooling Systems for Compressors lease any surplus heat in the compressor into the
To preserve the optimum lubricating capacity of environment, see Fig. 4.55 and Fig. 4.56.
the oil it may become necessary to cool during Fig. 4.55 Air-cooled Top Cover
compressor operation. Depending on the operat-
ing conditions and the type of refrigerant the plant
uses, a number of cooling systems are available.
See Section 6, Technical Data, Operating Limits
Diagrams.
Fig. 4.56 Air-cooled Side Cover
The following standard cooling systems can be
delivered for the compressors, depending on
which type of refrigerant the compressor is oper-
ating with as well as the compressor type itself.

Standard Cooling Systems for

Compressors
1. R717
04 technical description.fm

a. SMC only:
Air-cooled top and side covers and
There is therefore no need for forced cooling
refrigerant-cooled oil cooler.
air flow past the covers.
b. Water-cooled top and side covers.
It is, however, necessary to cool the oil in the com-
c. SMC only: pressor by means of a built-in oil cooler, which is
Compressor cooling with thermopump cooled by the refrigerant in the plant. The cooling
2. R22-R134a-R404A-R507-R410A-R744 system is built onto the compressor. It operates as
illustrated in piping diagram, Fig. 4.57, for a nor-
a. Air-cooled top and side covers.
mal one-stage compressor and in Fig. 4.58 for a
b. Air-cooled top covers and water-cooled booster compressor.
side covers.
The cooling system consists of an oil cooler
c. Air-cooled top and side covers and mounted on the oil pipe which connects the oil
refrigerant-cooled oil cooler. pump with the shaft seal. The oil cooler is dimen-
sioned to maintain the oil temperature at 50-70°C
Description [122 - 158 °F].

1a: Air-cooled Top and Side Covers with The expanding gas is led through pipe, pos. 1,
Refrigerant-cooled Oil Cooler R717 Fig. 4.57, to the compressor suction side. On the
Air-cooled top and side covers are covers without outside of the pipe the sensor for the thermostatic
cooling fins, but with a surface large enough to re- expansion valve, type TEA, is fitted.

0178-931 - ENG 81/288

Rev. 27.10.03
SMC /TSMC 100 Mk4 - Engineering Manual
4. Technical Description

The expansion valve, type TEA, is particularly The pipe pos. 1 on the booster and two-stage
suited for R717. In the liquid line there is also a so- compressor is led to the IP side as illustrated in
lenoid valve which closes when the compressor is Fig. 4.58 and Fig. 4.59. Thus the compressor ca-
stopped. pacity is not affected by the oil cooling system.
Fig. 4.57 Normal One-stage Compressor R717 The liquid supply is regulated by a thermostatic in-
jection valve of the TEAT type whose sensor is
T placed on the discharge pipe of the compressor.
This gives the cooling system two cooling func-
Oil separator
LP
tions. One is to cool the oil in the crankcase the
other to cool the discharge gas and consequently
HP
1
the discharge side of the compressor.
LP
Fig. 4.58 Booster Compressor R717
T
Liquid from
receiver
Oil
Oil cooler TEA Stopvalve separator
Filter
Solenoid valve LP
IP

The filter filters off any dirt particles in the liquid. 1

The filter element can be removed and cleaned.
The stop valve can block the cooling system from Liquid from
the refrigeration plant. receiver
Oil cooler
A thermostat T is connected to the cooling system TEAT Filter Stopvalve

and its sensor is placed in the oil of the crankcase. Solenoid valve

The thermostat is set to open the solenoid valve

Fig. 4.59 Two-stage TSMC Compressor R717
whenever the oil temperature exceeds 55°C Oil
[131 °F]. In this way it is made sure that the oil IP HP Separator
Oil
heats up quickly and separates as much refriger- Separator
ant as possible. UNISAB II controls the solenoid LP IP
IP HP
valve directly based on the measured oil temper- LP IP
1
ature.
Booster Compressor
As illustrated in Fig. 4.57, the pipe pos. 1 is taken
to the LP side of the compressor. This means that
the compressor must compress the gas coming
Liquid from
from the oil cooler which makes up only a very receiver
TEAT
small part of the compressor capacity. Filter
Stop valve Solenoid valve

82/288 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 com- Fig. 4.60 Water-cooled Top Cover
pression chamber of the compressor via the oil
cooler in order for the discharge gas to maintain a
temperature between +55 and 95°C [131 °F and
203 °F].
The diagrams, Fig. 4.57 to Fig. 4.59, do only show
the principle of the different systems and must not
be used directly.
1b: Water-cooled Top and Side Covers - R717 Note: Do not use sea water as cooling water on
The water cooling system must cool the entire top covers.
compressor block. In principle, it consists of plane Fig. 4.61 Water-cooled Side Cover
covers which are fixed on the top and side covers
with a gasket in between as shown in Fig. 4.60
and Fig. 4.61.
A system of canals is thus created between the
two covers in which the water is distributed evenly
04 technical description.fm

and cools effectively.

As the water covers can be dismantled without re-
moving the top covers and depressurizing the
compressor, the pipe system and the inner faces
of the water cover can easily be cleaned of any
impurities.
It is fairly easy to build this water cooling system Mounting of Cooling Water Hoses
on an air-cooled compressor. Note, however, that
On delivery of the compressor, the cooling water
the air-cooled side covers must be replaced with
covers are mounted, but they are not connected
covers with cooling fins on the inside. This may be
with water hoses. These are delivered separately
seen by comparing Fig. 4.56 with Fig. 4.61.
to avoid damaging the hoses and connecting
branches during transportation and mounting.
The cooling water hoses are mounted as shown in
the drawing which is delivered with the compres-
sor. A copy of this drawing can be seen in
Fig. 4.62.

0178-931 - ENG 83/288

Rev. 27.10.03
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 1 C 715
2 C 115
3 3 C 505
3 4 C 645
2 5 A 835
1

SMC 106 3185-231

Pos. No. Hose Type L (mm)
5 1 C 730
4
2 C 125
6 3 D 335
4 C 375
3
3
5 C 515
2

1
6 C 1100

SMC 108 TSMC 108 3185-232

Pos. No. Hose Type L (mm)
4
4
1 C 760
2 C 150
6 3 C 340
4 E 255
3
3 5 C 230
2
1 6 A 1090

84/288 0178-931 - ENG

Rev. 27.10.03
 SMC /TSMC 100 Mk4 - Engineering Manual
4. Technical Description

Fig. 4.63
Cooling of side covers only
SMC 104-106-108-112-116 and TSMC 108-116 Side covers 3185-235 SMC 104-
106-108 and TSMC 108
Pos. No. Hose Type L (mm)
1 C 715
2 C 175
3 C 230
4 C 765

Side covers SMC 112 3185-246

3
Pos. No. Hose Type L (mm)
4
SMC 112
2
1 1 A 750
2 A 130
3 C 750
4 A 220
04 technical description.fm

Side covers 3185-236 SMC 116

and TSMC 116
3 3 Pos. No Hose Type L (mm)
3 3
SMC 116
TSMC 116
1 A 740
4 1
2 A 160
2 1
3 C 770
4 B 215

0178-931 - ENG 85/288

Rev. 27.10.03
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
4
Pos. no. Hose type L (mm)
1 C 815
6 2 C 1830
3 3 C 605
3
2 4 C 245
1 5 C 1165
6 C 595

SMC 188/TSMC 188 3185-243

5

4
Pos. no. Hose type L (mm)
4 1 E 335
2 A 1755
6
3 C 535
3
4 C 245
3
2 5 C 1175
1
6 C 340

Side covers only 3185-244

Pos. no. Hose type L (mm)
1 C 1165
2 C 245
3 C 1315
4 C 410
3

1
2

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.
• In the supply pipe to the water system a so-
lenoid valve must be fitted which shuts off
the water flow in the refrigerating system
when the compressor is not in operation. It
is recommended, however, to continue the
water cooling for approx. 10 minutes after
the compressor has been stopped to protect
the cooling water hoses against excessive
temperatures.
• Dimensions of the inlet and outlet pipes for
the cooling water system are indicated in
04 technical description.fm
Section 5, Physical and Connection Data -
Table of Water Connection.
0178-931 - ENG
Rev. 27.10.03
Necessary Water Consumption
To achieve satisfactory distribution of cooling wa-
ter and hence proper compressor cooling, the fol-
lowing limiting values should be followed.
Min. Water Flow
5.5 litres per hour per kW motor output. On water
circulation plants greater water flow is recom-
mended. See Fig. 4.65.
Max. permissible inlet temperature:
+40°C [104°F]
Min. permissible inlet temperature:
+10°C [50°F]
Max. permissible outlet temperature:
+55°C [151°F]
Max. permissible temperature rise from inlet
to outlet on compressor:
15°C [59°F]
Max. permissible cooling water pressure:
8 bar.
87/288
SMC /TSMC 100 Mk4 - Engineering Manual
4. Technical Description

Pressure Loss in the Cooling System in SMC/TSMC Compressors

Totally for Side and Top Covers – Fresh ground water
Fig. 4.65 Pressure loss diagram – Water from cooling towers or condens-
TSMC 108
Pressure loss
p(mWc)
SMC 108 ers
SMC 106 SMC 104

– Closed water systems in which the water

is cooled and recirculated
SMC
112 – Salt water (Brine)
T/SMC
116
Note: Do not use sea water as cooling water on
top covers.
SMC
186
T/SMC
188
Obviously, it is very important that the water does
not cause algae to grow or calcareous deposits to
100 500 1000 Volumetric flow
develop in the cooling system. This means that
V(l/hour)
when water is recirculated in a closed system, a
Water Quality water treatment plant will usually be required. In
Water that can be used as cooling water: such cases YORK Refrigeration recommends
that a local dealer in water treatment plants be
– Water from the water works or sea water
contacted.

88/288 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 inde-
pendent of the cooling water. The system is there-
fore very applicable in areas where there is a
shortage of water resources or where the water
quality is poor. The thermo pump system can only
be used with R717.
The purpose of the thermo pump is both to cool
the oil in the crankcase and to cool the compres-
sor discharge gas in order to lower the tempera-
ture in the whole compressor.
Fig. 4.66 Short Block with Thermopump
04 technical description.fm
The thermo pump is mounted as a side cover on
the compressor and works by pressing the refrig-
erant into the canal system on the top covers and
into the oil cooler which - depending on the oper-
ating conditions - is built into the crankcase.
0178-931 - ENG
Rev. 27.10.03
On TSMC compressors cooling only takes place
in the high pressure stage top covers and no oil
cooler is used in the crankcase.
The thermo pump works under the influence of
heat coming from the oil in the crankcase. In this
way it also regulates its own pump capacity. This
means that the thermo pump works slowly when
the oil is cold, e.g. right after start-up of the com-
pressor, but as the oil temperature gradually rises,
the pump capacity will increase accordingly.
The thermo pump does not start, however, until
the discharge gas temperature exceeds 80°C
[176 °F].
The pumping cycle of the thermo pump, i.e. a fill-
ing and an evacuation period, lasts between 4 and
8 minutes depending on the number of cylinders
of the compressor, its capacity, the oil tempera-
ture in the crankcase and the operating pressure
and temperatures of the plant. The filling period
takes about 45 sec.
The thermo pump has an important advantage,
namely that the refrigerant pumped by the thermo
pump is led directly into the discharge gas of the
compressor. Consequently, this will have no in-
fluence on the compressor capacity.
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 Side Cover with Thermo Pump
98G 98D B 98B
98H
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
from the oil bath in the crankcase. The cooling
cover is equipped with cooling fins in order to en-
sure a proper thermal contact with the oil.
98A
98Q
98C
• Connection pos. B emerges from the plant
receiver or the priority tank (will be de-
scribed later) and goes right to the valve
block pos. 80.
• Connection pos. C is connected to the bot-
tom of the pump vessel pos. 98 as well as to
the top covers and the oil cooler pos. 98T
through a number of nozzles, pos. 98M.
0178-931 - ENG
Rev. 27.10.03
 SMC /TSMC 100 Mk4 - Engineering Manual
4. Technical Description

Fig. 4.68 SMC 108 Filling and evacuation of the pump vessel is con-
98U trolled by two level sensors, pos. 98C, Fig. 4.67.
By means of the control box, pos. 98B, the sen-
98M 98M 98M 98Z sors control the solenoid valves, pos. 98G and
pos. 98H, so that they open and close simultane-
4 1 HP
98X ously.
2 LP
3 98G The thermo pump is safeguarded by the following
98T 98B systems as shown in Fig. 4.67, Fig. 4.68 and
Fig. 4.69:
98 98M

98H a. A thermostat built into the control box pos.

C 98B with sensors pos. 98X fitted on the com-
B
98K 98K pressor discharge pipe.
80 98V
98Y
D The thermostat is factory set to start up the
thermo pump once the discharge gas tem-
perature is above 80°C [176 °F].
Fig. 4.69 TSMC 108
04 technical description.fm

b. An evacuation system emptying the pump

98M
vessel through solenoid valve pos. 98V
whenever the thermo pump stops.
98Z 1 S
IP 98X
HP Please, note that the pipe connection pos. D
2 98G
S to the plant evaporating side must be at a
98B place where there is suction pressure and no
98 risk of the liquid flowing back to the compres-
sor through the suction line. Connection
98H
should e.g. be made to the liquid separator or
B
C the evaporator.
98K 98K
80
c. A safety circuit with a non-return valve, pos.
98V
98Y 98Z, which opens for the flow in the pump
D
vessel at a pressure 3 bar [44 psi] higher
than the one in the compressor discharge
gas line.

0178-931 - ENG 91/288

Rev. 27.10.03
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 sen-
sor, the control box will activate the solenoid
valves pos. 98H in valve block pos. 80 and pos.
98G.
- after cooling of the oil - is taken to the compres-
sor discharge side.
Once the liquid in the pump vessel has returned to
its lowest level, it is registered by the bottom sen-
sor and the control box opens the two solenoid
valves for a new pumping cycle.

Thus solenoid valve, pos. 98G, opens in the pipe
connection to the compressor suction side and
the pressure in the pump vessel decreases slight-
ly. At the same time solenoid valve pos. 98H
opens and refrigerant liquid starts flowing to the
pump vessel through pipe connection B.
Emptying the Pump Vessel
When the top sensor, pos. 98C, has registered
that the liquid has reached the top level, both so-
lenoid valves will be closed by the control box.
The pressure in the pump vessel will now rise as
a consequence of the heat impact from the com-
pressor oil and will - when it exceeds the pressure
on the compressor discharge side - make the re-
frigerant flow through the pipe connection C to the
top covers and the oil cooler.
At the top covers the refrigerant expands through
Capacity Regulation of Thermo Pump
When reducing the compressor capacity, it will be
necessary to reduce the cooling effect of the ther-
mo pump as well. This is done as follows:
SMC 104-106-108, TSMC 116
The pipe connection from the pump vessel to the
top covers is divided into two pipe lines. In one of
these pipe lines a solenoid valve, pos. 98U, is fit-
ted.
This solenoid valve is wired to the capacity regu-
lating system of the compressor and it closes
when the compressor capacity has been reduced
as indicated in the following table, Table 4.9.
Table 4.9
Compressor Solenoid Valve pos. 98U
Capacity
Open Closed

the nozzles, pos. 98M, directly into the hot dis- SMC 104 100% 50%
charge gas, resulting in immediate cooling of the SMC 106 100 - 67% 33%
SMC 108 100 - 75% 50 - 25%
discharge gas. TSMC 116 100 - 83 - 67% 50 - 33%
The oil cooler OOSI (not always required) is a
heat exchanger in which the expanding refrigerant 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.

92/288 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 98M 98M 98Z

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

98H 98K
D
98K 98K 98D

98V 98M 98M 98M

98D 98M
98Y
98M 98M 98M HP
3 7
B 7 LP
1 98G
98 5
98T
98Z 98B
B 3 LP
B 98M
1 98H
5 A
04 technical description.fm

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

Fig. 4.72 TSMC 116

98K 98K C
98V
80 98Y 98M 98M
D

S 4
HP IP A
3 S 98G

98B

98
98H
98K C
B 98K 98V
98D 98Y 98U

1 5

98T

98M

0178-931 - ENG 93/288

Rev. 27.10.03
SMC /TSMC 100 Mk4 - Engineering Manual
4. Technical Description

The total capacity of the thermo pumps is adapted side of the plant. See the previously mentioned
to the compressor capacity by stopping and start- point b.
ing the thermo pump marked with an X on the
principle drawing. Ensuring Liquid to the Thermo Pump
The stopping and starting is achieved through the The thermo pump must always be ensured liquid
wire connection of the thermo pump via terminals from the plant, irrespective of whether the plant
5 and 6/7 or 8 to the capacity regulating system of lacks liquid or if some other factor prevails.
the compressor. The supply voltage to the thermo
Thus, the thermo pump must also be ensured liq-
pump must be switched off once the compressor
uid during a possible pump down by means of the
capacity has been reduced to the values indicated
compressor.
in the Table 4.10.
In other words: During operation the compressor
Table 4.10
must never be short of cooling.
Compr. Thermo Pump at Compressor
Capacity Shaft End This safety is achieved either by taking the liquid
directly from the receiver, pipe connection B, or by
Working Not Working
building a priority tank into the liquid line of the
SMC 112 100 - 83 - 67% 50 - 33% plant, Fig. 4.73.
SMC 116 100-87-75-63% 50 - 37 - 25%
The liquid volume A of the priority vessel must be
When the compressor is stopped, the current to minimum 10 litres per thermo pump.
the thermo pump is cut off, closing the solenoid The liquid tube from the priority vessel to the ther-
valves pos. 98H and pos. 98G. At the same time mo pump must be dimensioned to prevent the for-
solenoid valve pos. 98V opens and drains the liq- mation of flash gas along the way.
uid in the thermo pump back to the evaporating

94/288 0178-931 - ENG

Rev. 27.10.03
 SMC /TSMC 100 Mk4 - Engineering Manual
4. Technical Description

Fig. 4.73
1
1

Receiver
3

3
B

B 2
1: Refrigerant liquid from condenser/receiver
2: Refrigerant liquid to evaporator
3: Refrigerant liquid reserve for oil cooling
B: Refrigerant liquid for oil cooling
04 technical description.fm

Power Connection Fig. 4.74

K1
The control box is geared for the 3 voltages listed
below.
Terminal 1
Voltages:
110V - 50/60Hz K3
220V - 50/60Hz Terminal 2
PT100 sensor
240V - 50Hz M1
Terminal 1 N
GND
The control box contains a terminal strip as shown
in Fig. 4.74. Terminal 4 K2 GND
M2
Terminal 2
N
Upper level sensor
L
GND

Terminal 1 N
Lower level sensor

Main voltage selector

VS1

230
115

0178-931 - ENG 95/288

Rev. 27.10.03
SMC /TSMC 100 Mk4 - Engineering Manual
4. Technical Description

2a: Air-Cooled Top and Side Covers Table 4.11

R22 - R134a - R404A - R507 Pos No Hose type Length (mm)
Use the same cover mounting as described in par-
1 C 715
agraph 1a. As indicated in the Operating Limits Di-
agrams in Section 6, Technical Data, there is no 2 C 175
need for oil cooling. 3 C 230

2b: Air-Cooled Top Covers and Water 4 C 765

Cooled Side Covers
R22 - R134a - R404A - R507
If water is available and a need for cooling exists
according to the Operating Limits Diagrams, Sec-
tion 6, Technical Data, this system is an excellent
solution.
The water-cooled side covers are mounted as de-
scribed in paragraph 1b, Fig. 4.63.
Fig. 4.75 Cooling of Side Covers only
2c: Air-Cooled Top and Side Covers
and Refrigerant-Cooled Oil Cooler
R22 - R134a - R404A - R507
Use the same cover mounting as the one de-
scribed in paragraph 1a.
In principle, the oil cooling system is constructed
as illustrated in Fig. 4.57 for one-stage compres-
sors, in Fig. 4.58 for booster compressors and in
Fig. 4.59 for two-stage compressors.

1
2

96/288 0178-931 - ENG

Rev. 27.10.03
 SMC /TSMC 100 Mk4 - Engineering Manual
4. Technical Description
fCompressor Accessories
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 dimen-
sioned 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
• Extended set of tools. Besides the
normal set of tools, this set contains all
necessary standard hand tools.
• Spare parts set in various sizes.
When servicing compressor and unit, it is al-
ways an advantage if you, as our customer,
have some of the most commonly used
spare parts at your disposal. This enables
you or a summoned YORK Refrigeration
service engineer to carry out the necessary
service work without having to spend extra
time on getting the spare parts required.
Spare parts can be delivered as described
in the following. When contacting the local
YORK Refrigeration representative, it is
possible to receive a list of the spare part
sets recommended by YORK Refrigeration.
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 suit-
able selection of O-rings as well as valve
ring plates and valve spring.
• Extended spare parts set: In addition to
the parts included in the standard spare
parts set, the set contains a cylinder liner
and discharge valve as well as an extended
number and types of gaskets and fittings.
• Certificate spare parts set: In addition to
the parts from the extended spare parts
set this set contains a major number of
components and wearing parts selected by
the classification societies.
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 wear-
ing parts the number of parts have been ex-
tended.
For the Different Compressor Units:
• Standard spare parts set: This is a set
consisting mainly of O-rings and gaskets for
some of the components included in the
unit.
• Certificate spare parts set: In addition to
the parts from the standard spare parts set
this set contains other components selected
in accordance with the requirements of the
classification societies.
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 equip-
ment,
• to give complete information concerning the
requirements of the surrounding
system.
The safety precautions are intended for all user
categories.
This document was produced by:
YORK Refrigeration
Chr. X’s Vej 201
DK-8270 Hoejbjerg
Denmark
05 physical and connection data.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.
WDanger!
Risk of injury to personnel and damage to equip-
ment! Always read the safety precautions belong-
ing to this equipment before start. Failure to com-
ply with safety precautions may cause death or in-
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 re-
garding pipe bend, flange design, etc.
Electrical connection must be carried out so
that it complies with current legislation with-
in the area in question.
Electric cables must be dimensioned on the
basis of the maximum power consumption
of the plant. The cabling must be made so
that the cables do not touch any moving
parts.
It is recommended to place the cables in ca-
ble trays.
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 Dimen-
sions and Piping Diagrams.
Connection Data
Refrigerant Suction Side
On the compressor suction side the pipe connec-
tion is made to the stop valve pos. 1 - see Dimen-
sions and Piping Diagrams. The pipe connection
is welded on the connecting branch of the valve,
see Table 5.1.
Note: Be aware of the measures which must be
taken in order to avoid damaging the valve and
other parts of the unit when welding. See Section
7, Installation Instructions.
Refrigerant Discharge Side
On the compressor discharge side the pipe con-
nection is made to the stop valve pos. 2 - see Di-
mensions and Piping Diagrams. The pipe connec-
100/288
tion is welded on the connecting branch of the
valve. See Table 5.1
Note: Be aware of the measures which must be
taken in order to avoid damaging the valve and
other parts of the unit when welding. See Section
7, Installation Instructions.
Connections to the Compressor
The tables in Table 5.1 and Table 5.2 show the
pipe connection on standard compressors. On de-
livery from YORK Refrigeration the compressors
are fitted with standard welding nipples on suction
as well as discharge side.
The tables Table 5.3 to Table 5.5 include a list of
applicable welding nipples.
The table Table 5.6 show the possible connec-
tions of the compressor. In the table some of the
connections are marked plugged, which means
that the thread hole is closed by means of a plug
and a gasket.
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)

Oil
Suction Discharge Interstage LPD+) Interstage HPS+)
Separator
Compressor
Conn. Conn. Conn. Conn. Conn.
SABR. SABR. SABR. SABR. SABR.
type type type type type

SMC 104 129.5 65 80 90.5 65 65 90.5 65 65 FS 50 50 FP 65

SMC 106 80 100 90.5 65 65 65
SMC 108 80 100 90.5 65 65 65
TSMC 108 80 100 F 50 50 65/50
++)

SMC 112 154.5 125 125 129.5 100 100 129.5 100 100 FS 80 80 FP 100
SMC 116 125 125 129.5 100 100 100
TSMC 116 125 125 90.5 65 65 100/
65++)

Table 5.2
Nominal diameters for standard welding connections (in inch.)
05 physical and connection data.fm

Oil
Suction Discharge Interstage LPD+) Interstage HPS+)
Separator
Compressor
Conn. Conn. Conn. Conn. Conn.
SABR. SABR. SABR. SABR. SABR.
type type type type type

SMC 104 129.5 2 1/2" 3" 90.5 2 1/2" 2 1/2" 90.5 2 1/2" 2 1/2" FS 2" 2" FP 2 1/2"
SMC 106 3" 4" 90.5 2 1/2" 2 1/2" 2 1/2"
SMC 108 3" 4" 90.5 2 1/2" 2 1/2" 2 1/2"
TSMC 108 3" 4" F 2" 2" 2 1/2"
/2"++)

SMC 112 154.5 5" 5" 129.5 4" 4" 129.5 4" 4" FS 3" 3" FP 4"
SMC 116 5" 5" 129.5 4" 4" 4"
TSMC 116 5" 5" 90.5 2 1/2" 2 1/2" 4"/
2 1/2"
++)

Table 5.3
Available Welding Connections

Connec. Pipe Nominal Diameters for Welding Connections, Sabroe part no. 2322-1)
type type
32 40 50 65 80 100 125 150

90.5 R-KB 095 100 102 102

ANSI 122 124 126 127

129.5 R-KB 105 107 108

ANSI 129 131 132

154.5 R-KB 109 110

ANSI 133 134

219.5 R-KB 111

ANSI 135

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

0178-931 - ENG 101/288

Rev. 27.10.03
SMC /TSMC 100 Mk4 - Engineering Manual
5. Physical and Connection Data
+) HPS: High pressure suction side
PD: Low pressure discharge side
++) The first value: connection for the low
pressure Oil Separator.
The second value: connection for the high
pressure Oil Separator.
F Fixed connection
FS Fixed connection, delivered separately
102/288
FP Fixed pipe
R-KB Boiler pipe according to DIN 2448
ANSI Pipe according to ANSI B31.5 schedule 80
and 40 (DN 32 and 40 ~ schedule 40).
Note: In this connection two types of standard
welding nipples are available. This should be
specified when ordering.
0178-931 - ENG
Rev. 27.10.03
 SMC /TSMC 100 Mk4 - Engineering Manual
5. Physical and Connection Data

Standard welding nipples are available from – If you wish to connect the welding nip-
YORK Refrigeration under the designation of R- ples to a pipe with a thicker wall, the nip-
KB nipples, following the standard of DIN 2448 ples can be shortened and thus the in-
and with pipe dimensions as indicated in the table ternal diameter is reduced and the wall
in Fig. 5.1 (OD, s, ID1). thickness increased as illustrated in
The welding nipples are universal as their welded Fig. 5.1. This makes it possible also to
ends have dimensions according to DIN 2448. use the welding nipples for pipes in due
form according to ANSI B31.5, schedule
80 and 40.
Fig. 5.1 Welding Nipples for R-KB Pipes
305

1
ID2 ID3 ID2 I
OD1 OD ID1 OD2
05 physical and connection data.fm

155

S
L
A

Table 5.4
Standard welding end for R-KB 1)
pipes according to DIN 2448
INCH DN OD s ID1 OD1 OD2 ID 2 ID3 A L Mat.
2" 50 60.3 2.9 54.5 76.0 90.5 52.5 57.0 55 4.0 2
2 1/2" 65 76.1 2.9 70.3 76.1 90.5 62.7 57.0 65 14.0 2
2 1/2" 65 76.1 2.9 70.3 113.5 129.5 62.7 93.0 75 14.0 1
3" 80 88.9 3.2 82.5 113.5 129.5 77.9 93.0 70 9.0 2
4" 100 114.3 3.6 107.1 114.3 129.5 102.3 93.0 65 9.0 2
5" 125 139.7 4.0 131.7 144.0 154.5 128.1 125.0 80 7.0 2
1) Smallest inner diameter = ANSI B31.5

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

0178-931 - ENG 103/288

Rev. 27.10.03
SMC /TSMC 100 Mk4 - Engineering Manual
5. Physical and Connection Data

– Instead of the welding nipples for R-KB – The welding nipples are shown in
pipes, it is possible to order welding nip- Fig. 5.2 and must be specified when or-
ples solely used for standard pipes in ac- dering a compressor.
cordance with ANSI B31.5, schedules
80 and 40.
Fig. 5.2 Welding Nipples for ANSI Pipes
305

1
ID1 ID2 ID1 ID2
OD1 OD OD2

Table 5.5
Standard welding end
for ANSI B31.5 pipes
schedule 80 + 40

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

2" 50 60.3 3.9 76.0 90.5 52.5 57.0 51.0 2

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

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

3" 80 88.9 5.5 113.5 129.5 77.9 93.0 61.0 2

4" 100 114.3 6.0 - 129.5 102.2 93.0 56.0 2

5" 125 139.7 5.8 144.0 154.5 128.1 125.0 73.0 2

Material:
1: RST 37-2 DIN 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 1 AF
Q 4 H

P
E
L N
C T
V O G
D B A U

Fig. 5.4 SMC 112-116 Mk4

05 physical and connection data.fm

1
4 Z

H AF

AE
AH AD

AK
Y
AJ Y
AA

0178-931 - ENG 105/288

Rev. 27.10.03
SMC /TSMC 100 Mk4 - Engineering Manual
5. Physical and Connection Data

Fig. 5.5 TSMC 108 Mk4

1
AC AF
2
M
H

4
R

Fig. 5.6 TSMC 116 Mk4

1
AF H, AL
2 4 M
R AG
AD
Y
Y
AK 3

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

Fig. 5.9 Pump end

BD BL

BX BB
05 physical and connection data.fm

BE BT BP BN BJ BS BA BQ

Fig. 5.10 Shaft seal end

F
K
AB AM

0178-931 - ENG 107/288

Rev. 27.10.03
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

Table 5.6

AIR-COOLED WITH

WITH BUILT-IN OIL

wATER-COOLED
(COMP. TYPE)

APPLICATION
TERMOPUMP
AIR-COOLED

BUILT-IN OIL
(ISO228/1-G)

PRESSURE

OR LIQUID
OIL, GAS

NORMAL
COOLER

COOLER
THREAD

FIG. NO.
POS

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

B 3/4 Suction Oil + + + Oil charging valve Fig. 5.3
C 1/2 Suction Oil + + + Oil temperature Fig. 5.3
D 1/2 Suction Oil Plugged + Plugged Oil temperature Fig. 5.3
E 1/4 Suction Gas Plugged Plugged Plugged Available Fig. 5.3
Oil pressure to unloading
F 1/4 Oil Oil + + + Fig. 5.10
cylinder
G (1) 1/2 Suction Gas Plugged + + Return from built-in oil cooler Fig. 5.3
G (3) 1/2 Suction Gas Plugged + Plugged Return from built-in oil cooler Fig. 5.3
G (2+4) 1/2 Suction Gas plugged Plugged Plugged Available Fig. 5.3
Fig. 5.3, Fig. 5.4,
H 1) 1/4 Discharge Gas + + + High pressure connection
Fig. 5.5 and Fig. 5.6
J 1/4 Suction Gas + + + Oil return from solenoid valves Fig. 5.3
K 1/4 Oil Oil + + + Oil pressure to solenoid valves Fig. 5.10
L 1/4 Suction Gas + + + Low pressure connection Fig. 5.3
Intermediate pressure
M1) (3+4) 1/4 Intermediate Gas + + + Fig. 5.5 and Fig. 5.6
connection
N 1/4 Suction Gas + + + Oil return from oil separator Fig. 5.3
O 1/2 Suction Gas Plugged Plugged Plugged Available Fig. 5.3
P (1+2+3) 1/4 Suction Gas Plugged + Plugged Return from built-in oil cooler Fig. 5.3
Return from oil cooler
Q (1+2+4) 1/4 Discharge Gas Plugged Plugged + Fig. 5.3
(thermopump)
Q (3) 1/4 Discharge Gas Plugged Plugged Plugged Available Fig. 5.3
Suction pressure to unloading
R (3+4) 1/4 Suction Gas + + + Fig. 5.5 and Fig. 5.6
cylinder
S 1/4 Discharge Gas Plugged Plugged + Refrigerant cooled top cover Fig. 5.7
Equalization to suction end of
T 1/4 Suction Gas Not included Not included + Fig. 5.3
thermo pump
U 1/4 Discharge Liquid Not included Not included + Liquid supply to top covers Fig. 5.3
V 1/2 Suction Oil Plugged + + Connection to built-in oil cooler Fig. 5.3
X 1/2 Discharge Gas + + + Discharge gas temperature Fig. 5.8
Plug for fixing intermediate
Y (2+4) 3/4 Suction Gas Plugged Plugged Plugged Fig. 5.5 and Fig. 5.6
bearing
AN (3) 1/2 Intermediate Gas Plugged Plugged Plugged Available Fig. 5.8
Purge valve (discharge pres-
Z (2) 3/4 Discharge Gas + + + Fig. 5.4
sure)
Purge valve (discharge pres-
Z (4) 1/2 Discharge Gas + + + Fig. 5.8
sure)
Purge valve (discharge pres-
Z (1+3) 1/2 Discharge Gas + + + Fig. 5.8
sure)
AA (2+4) 1 1/4 Suction Oil + + + Heating rod Fig. 5.4 and Fig. 5.6
AB 3/8 Suction Oil Plugged Plugged Plugged Available Fig. 5.10

108/288 0178-931 - ENG

Rev. 27.10.03
 SMC /TSMC 100 Mk4 - Engineering Manual
5. Physical and Connection Data

AIR-COOLED WITH

WITH BUILT-IN OIL

wATER-COOLED
(COMP. TYPE)

APPLICATION
TERMOPUMP
AIR-COOLED

BUILT-IN OIL
(ISO228/1-G)

PRESSURE

OR LIQUID

NORMAL
OIL, GAS

COOLER

COOLER
THREAD

FIG. NO.
POS

Suction temperature (super- Fig. 5.3, Fig. 5.4,

AC 1/2 Suction Gas Used in connection with UNISAB
heat) Fig. 5.5 and Fig. 5.6
AD (2+4) 1/4 Suction Gas + + + Return from solenoid valve Fig. 5.4 and Fig. 5.6
AE (2) 1/4 Suction Gas Plugged + + Return from built-in oil cooler Fig. 5.4
AF (1+2) 1/4 Discharge Gas Plugged Plugged + Return from built-in oil cooler Fig. 5.3 and Fig. 5.4
AF (3+4) 1/4 Discharge Gas Plugged + + Return from built-in oil cooler Fig. 5.5 and Fig. 5.6
Equalization from thermopump
AG (4) 1/4 Intermediate Gas Plugged Plugged + Fig. 5.6
for intermediate pressure
Equalization to suction end of
AH (2) 1/4 Suction Gas Not included Not included + Fig. 5.4
thermo pump
AJ (2) 1/4 Suction Gas Not included Not included + Liquid supply to top covers Fig. 5.4
AK (2+4) 1/2 Suction Gas Plugged + + Return from built-in oil cooler Fig. 5.4 and Fig. 5.6
Purge valve
AL (3) 1/2 Intermediate Gas + + + Fig. 5.8
(intermediate pressure)
05 physical and connection data.fm

Purge valve
AL (4) 1/2 Intermediate Gas + + + Fig. 5.6
(intermediate pressure)
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
BB 1/4 Oil Oil + + + Fig. 5.9
bearings
BD 1/4 Oil Oil Plugged Plugged Plugged Not recommended for use Fig. 5.9
BE 1/2 Suction Oil Plugged Plugged Plugged Not recommended for use Fig. 5.9
BJ 1/8 Oil Oil Plugged Plugged Plugged Not recommended for use Fig. 5.9
BL 1/4 Suction Oil Plugged Plugged Plugged Not recommended for use Fig. 5.9
See Oil pressure after oil filter
BN 1/4 Oil + + + Fig. 5.9
application
See Oil pressure before oil filter
BP 1/8 Oil + + + Fig. 5.9
application
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
See Oil pressure before oil filter
BT 1/4 Oil Used in connection with UNISAB Q Fig. 5.9
application
Fig. 5.3, Fig. 5.4,
1 Low pressure suction stop valve
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
Fig. 5.3, Fig. 5.4,
4 High pressure discharge stop valve
Fig. 5.5 and Fig. 5.6

1) Positioning on the different block types may vary

0178-931 - ENG 109/288

Rev. 27.10.03
SMC /TSMC 100 Mk4 - Engineering Manual
5. Physical and Connection Data

Electrical Connections
Fig. 5.11

Electromechanical Control TT7 Computer Control, UNISAB II

TT5
PT2
7
PT1

6 5 4 3 2 1 PT3 TT6 8 9

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

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

4 Differential oil pressure cut-out MP55 PT3 Oil pressure

5 Discharge gas thermostat KP98 TT5 Discharge gas temperature

6 Oil thermostat KP98 TT6 Oil temperature

7 Computer control, UNISAB II TT7 Suction gas temperature

8 Heating element

9 Oil filter differential pressure

UNISAB II: MOTOR

Supply voltage: 115 VAC Connection data for VAC
230 VAC supply voltage:
24 VAC Permissible variation: +10%/-15%
Permissible variation: +10%/-15% Frequency: 45-65 Hz
Frequency: 45-65 Hz Power: kW
Power: 50 VA

Where UNISAB II is supplied with 24 VAC, the Supply voltage and motor power appear from the
connecting terminals supplying the heating ele- order sheet.
ments must be supplied with 115 or 230 VAC, see
Installation Manual for UNISAB II.

110/288 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, electro-
mechanical control.
b. UNISAB II reading, safety and capacity regu-
lating system.
Re a:
Wiring connection appears from the
wiring diagram included in each delivery.
The system requires an external control
board for the control of the capacity regula-
tion. Control and safety automatics is de-
scribed in detail in Section 4, Technical De-
scription - Instrumentation.
05 physical and connection data.fm
Re b:
UNISAB II is described in detail in a
separate Instruction Manual. This manual
also includes a description of UNISAB II's
general controls. Key diagrams and installa-
tion descriptions are included in a separate
Commissioning Manual for UNISAB II.
With a Control System not Delivered by
YORK Refrigeration
This section describes the instrumentation of the
compressor/unit - see data for electrical compo-
nents in Section 21, Appendices. The fundamen-
tal requirements which must be complied with in
order to operate the unit are also described.
If other control systems than the ones prescribed
by YORK Refrigeration are used,
YORK Refrigeration disclaim the responsibility for
the correct control of the unit. Moreover,
YORK Refrigeration will not be liable to pay dam-
ages for personal injuries or for damage to the unit
or the refrigeration plant if caused by malfunction-
ing of the control system.
0178-931 - ENG
Rev. 27.10.03
On delivery the compressor is fitted with instru-
ments, but not with any other electrical installa-
tions.
Note:
If UNISAB II is installed as the control system of
the unit, the components mentioned below will be
standard components. Moreover, the wiring will
have been carried out from factory.
1. Pressure Transmitters marked PT1,
PT2 and PT3
As standard, the product is delivered with pres-
sure transmitters of the type: AKS32 and
AKS2050 from Danfoss - see data sheet in Sec-
tion 21, Appendices.
Connection data: Connect a three-wire cable to
the terminals of the plug fitted at the end of the
pressure transmitters.
Supply voltage: 5 VDC
Output signal: 4-20 mA
Pressure transmitters are used for measuring:
1.1 Suction Pressure, PT1
The measurement is used to protect against
too low suction pressure. Low suction pres-
sure must stop the compressor. The control
system can be adjusted in such a way that
the compressor starts automatically at too
high suction pressure. The set values must
be within the permissible working range for
compressors as stated in Section 6, Techni-
cal Data.
1.2 Discharge Pressure, PT2
The measurement is used to protect the
compressor against too high discharge
pressure. Too high discharge pressure must
stop the compressor without automatic re-
start. The set values must be within the per-
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 com-
pressor 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 tem-
perature sensors of the type P2208. See data
sheet in Section 21, Appendices.
Connection data: The sensor is fitted with a plug
of the type IEC 947-5-2 with four conductors. The
connection is carried out by means of a
PG9-screw-joint.
The sensors are used for measuring:
112/288
2.1 Suction Gas Temperature,
TT7 measuring range: -50°C to +180°C
[-60°F to +356°F]
2.2 Discharge Gas Temperature,
TT5 measuring range: -50°C to +180°C
[-60°F to +356°F]. The measurement is
used to protect the compressor against a
too high temperature in the discharge gas
pipe. Too high a temperature in the dis-
charge gas pipe must stop the compressor
without automatic restart. The set values
must be within the permissible working
range for the compressor as stated in Sec-
tion 6, Technical Data.
2.3 Oil Temperature,
TT6 measuring range: -50°C to +180°C
[-60°F to +356°F]. The measurement is
used to protect the compressor against too
high an oil temperature. Too high an oil tem-
perature must stop the compressor without
automatic restart.
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.
NV 50
Watt
G 1 1/4”
Volt
Manu. date

Ø30
30
50

L1
80 L2

Table 5.7 Table of Power and Application

Heating rods Used for

Power Voltage L1 L2
05 physical and connection data.fm

Watt V mm mm

270 250 CMO - TCMO - SMC 100 - TSMC 100

270 230
270 115*
158 175
460 250 HPO - HPC, SMC 180 - TSMC 180
460 230 VMY 347 /447 - 536
460 115* 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 113/288

Rev. 27.10.03
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:
• Data for compressor
• Data for unit
• Working range
• Handling the compressor
• Area of application
• Laying the foundation
• Noise level data
• Vibration data
• Test pressure for compressors
• Assessing the oil
06 technical data.fm
• Selecting lubricating oil
This document is primarily intended for
designers, service engineers, sales personnel
and prospective customers.
This document was produced by:
YORK Refrigeration
Chr. X’s 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.

0178-931 - ENG 115/288

Rev. 27.10.03
SMC /TSMC 100 Mk4 - Engineering Manual
6. Technical Data

Technical Data for the SMC 100 Series

Table 6.1
Compressor type Number of Bore Stroke Max/min Swept Weight of Weight of
cylinders speed volume compressor compressor
mm nominal at max block block
rpm speed
1) 2) m3/h kg lb

SMC 104S 4 271 580 1279

SMC 106S 6 407 675 1488

SMC108S 8 80 1800/700 542 740 1631

SMC112S 12 815 1250 2756

SMC 116S 16 1086 1350 2976

SMC104L 4 283 580 1279

Single stage

SMC106L 6 424 675 1488

SMC108L 8 100 565 740 1631

SMC112L 12 848 1250 2756

SMC116L 16 1131 1350 2976

SMC104E 4 100 1500/700 339 600 1323

SMC106E 6 509 700 1543

SMC108E 8 120 679 770 1698

SMC112E 12 1018 1300 2866

SMC116E 16 1357 1400 3086

TSMC108S 6 LP + 2 HP 80 339 775 1709

TSMC116S 12 LP + 4 HP 679 1400 3086

Two stage

TSMC108L 6 LP + 2 HP 100 424 775 1709

TSMC116L 12 LP + 4 HP 848 1400 3086

TSMC116L 6 LP + 2 HP 120 509 800 1764

TSMC116E 12 LP + 4 HP 1018 1450 3197

1) LP = Low pressure cylinder

HP = High pressure cylinder
2) 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 104 830 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 Incl. in-
TSMC 108 1400 3086 1410 3109 termediate cooler

TSMC 116 1900 4189 2080 4586 Excl. intermediate cooler Incl. in-
TSMC 116 2350 5181 2530 5578 termediate cooler
The weight is exclusive of electric motor
06 technical data.fm

0178-931 - ENG 117/288

Rev. 27.10.03
SMC /TSMC 100 Mk4 - Engineering Manual
6. Technical Data

Weight of Electric Motors

Sizes MOTOR TYPE

SHORCH LEROY SOMER

IP 23 IP 54 PLS LS FLS

kg lb kg lb kg lb kg lb kg lb

IEC 160L 102 225 80 176 78 172 120 265

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

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

IEC 200M 240 529 165 364

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

IEC 225S 309 681 205 452 290 639

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

IEC 250S 455 1003 335 739

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

IEC 280S 625 1378 570 1257 460 1014 445 981 475 1047

IEC 280M 680 1499 630 1389 515 1135 490 1080 565 1246

IEC 315S 875 1929 900 1984 720 1587 850 1874

IEC 315M 945 2083 940 2072 730 1609 785 1731 1000 2205

IEC 315L 1050 2315 1200 2646 830 1830 1050 2315

IEC 355S 1500 3307

IEC 355M 1790 3946 1600 3527 855 1885

IEC 355L 2095 4619 1750 3858 1510 3329

IEC 355L (LA)1900 1550 3417

(LB)2150

118/288 0178-931 - ENG

Rev. 27.10.03
 SMC /TSMC 100 Mk4 - Engineering Manual
6. Technical Data

Compressor Capacity Alternatively, contact your local dealer who can

Compressor capacity is calculated by means of help dimensioning the compressor.
the COMP 1 program in the YORK Match Master
suite of programs.
06 technical data.fm

0178-931 - ENG 119/288

Rev. 27.10.03
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, pres-
sure sentive and thermostats, or with a UNISAB II
system with display and safety facilities as well as
capacity regulation of the compressor.
To illustrate the structure of the dimension sketch-
es, three examples have been included, Fig. 6.1,
120/288
Fig. 6.2 and Fig. 6.3. Moreover, reference is
made to Dimension and Piping Diagram, which in-
cludes dimension sketches of all compressors
and units.
However, during the final planning the latest di-
mension sketches from YORK Refrigeration are
required.
0178-931 - ENG
Rev. 27.10.03
 06 technical data.fm

Fig. 6.1
A (OVERALL LENGTH)
9
MIN

Rev. 27.10.03
620 B 1455 F

E 600 141

0178-931 - ENG
6. Technical Data

SABROE
D
C (OVERALL HEIGHT)

I
32

510
25
205

80
4 5 200 G MIN 400
650 275 MIN 250
SMC /TSMC 100 Mk4 - Engineering Manual

1100 200
710 2 1
1500
4XM22 HOLES 6
8
1 FOR OPERATING STOP VALVES
SMC 100, V-belt Driven, Anolog System

900
2 FOR WITHDRAWING V--BELT GUARD

3 FOR WITHDRAWING CRANKSHAFT

CONNEC.FOR
COOLING SYSTEM
LIQUID REFRIG.
R22 OIL COOLER G1/4
4

K
R717 OIL COOLER (BOOSTER) G1/4 III
5 R717 THERMOPUMP.SYSTEM G1/4

WATER INLET AND OUTLET G3/8 I II

H MAX
6
(COMPR. WITH WATER COOLING ONLY)

WELDING CONNECTIONS
COMPR. R717 (H)CFC
SMC 104 M76.1x4.5 M88.9x3.2
7 SUCTION SMC 106
M88.9x4.85 M114.3x3.6
SMC 108

8 DISCHARGE ALL M76.1x2.9

FOR UNITS WITH UNISAB

9
ADD 80MM 4 5 7
MOTOR
OVERALL LENGTH AND WIDTH
TYPE H MAX
WEIGHT VARIES ACCORDING TO MAKE
IEC
COMPR MOTOR A B C D E F G I K FOUND. OF UNIT OF MOTOR AND TYPE
TYPE TYPE MAX DRWG. EXCL. 200 915 FOR EXACT LENGTH USE
IEC MM MM MM MM MM MM MM MM MM NO. MOTOR 225 1015 DIMENSION H IN TABEL
250 1135 4833--001_0
SMC104 200--315M 2050 1115 1095 1000 275 440 350 635 635 171438 880 KG
SMC106 200--315M 2010 1090 1130 1035 275 395 395 645 620 171438 970 KG 280 1235

SMC108 200--315M 2020 1130 1125 1030 300 405 405 665 635 171438 1030 KG 315 1335

121/288
 Fig. 6.2
A (OVERALL LENGTH)

122/288
1455 F
MIN 620 B
E 600 141

3
6. Technical Data

D
C (OVERALL HEIGHT)

I
32

510
25
205

80
4 5 200 G MIN 400
650 275 MIN 250
SMC /TSMC 100 Mk4 - Engineering Manual

1100 200
710 2 1
1500
4XM22 HOLES 6
8
1 FOR OPERATING STOP VALVES
900
2 FOR WITHDRAWING V--BELT GUARD

3
SMC 100, V-belt Driven, UNISAB II System

FOR WITHDRAWING CRANKSHAFT

CONNEC.FOR
COOLING SYSTEM
LIQUID REFRIG.
R22 OIL COOLER G1/4
4

K
R717 OIL COOLER (BOOSTER) G1/4 III
5 R717 THERMOPUMP.SYSTEM G1/4

WATER INLET AND OUTLET G3/8 I II

6
(COMPR. WITH WATER COOLING ONLY)

H MAX
WELDING CONNECTIONS
COMPR. R717 (H)CFC
SMC 104 M76.1x4.5 M88.9x3.2
7 SUCTION SMC 106
M88.9x4.85 M114.3x3.6
SMC 108

8 DISCHARGE ALL M76.1x2.9

4 5
7

MOTOR
OVERALL LENGTH AND WIDTH
TYPE H MAX
WEIGHT VARIES ACCORDING TO MAKE
IEC
COMPR MOTOR A B C D E F G I K FOUND. OF UNIT OF MOTOR AND TYPE
TYPE TYPE MAX DRWG. EXCL. 200 1015 FOR EXACT LENGTH USE
IEC MM MM MM MM MM MM MM MM MM NO. MOTOR 225 1115 DIMENSION H IN TABEL
SMC104 200--315M 2050 1168 1095 1000 275 440 350 635 635 171438 880 KG 250 1235
280 1335 4833--011_0
SMC106 200--315M 2010 1053 1130 1035 275 395 395 645 620 171438 970 KG
1030 KG
SMC108 200--315M 2020 1193 1125 1030 300 405 405 665 635 171438 315 1435

0178-931 - ENG
Rev. 27.10.03
 06 technical data.fm

Fig. 6.3

Rev. 27.10.03
MIN FOR OPERATING STOP VALVES
620 A APPROX B (OVERALL WIDTH) 1

E F 555 FOR WITHDRAWING PISTONS AND SUCTION

2
FILTER
3 141

0178-931 - ENG
3 FOR WITHDRAWING CRANKSHAFT

CONNEC.FOR
COOLING SYSTEM
6. Technical Data

LIQUID REFRIG.
R22 OIL COOLER
4 G1/4
R717 OIL COOLER (BOOSTER)

5 R717 THERMOPUMP.SYSTEM G1/4

6 WATER INLET AND OUTLET G3/8

H
WELDING CONNECTIONS

C (OVERALL HEIGHT)
COMPR. R717 (H)CFC

32
SMC 104 M76.1x2.9 M88.9x3.2

L
7 SUCTION SMC 106

510
M88.9x3.2 M114.3x3.6
SMC 108

25
205
8 DISCHARGE ALL M76.1x2.9

250 80 500
M 560
SMC /TSMC 100 Mk4 - Engineering Manual

G 1250 D

4xM22 HOLES 4 5 6
OVERALL LENGTH AND WIDTH
WEIGHT
7 5 4 8 VARIES ACCORDING TO MAKE MOTOR
COMPR A B C D E F G H K L FOUND. OF UNIT
OF MOTOR AND TYPE TYPE MAX
TYPE DRWG. EXCL.
FOR EXACT LENGTH USE
SMC 100, Direct Driven, UNISAB II System

IEC MM MM MM MM MM MM MM MM MM MM NO. MOTOR

DIMENSION M IN
160--180 1900
2 TABEL BELOW
SMC 200 171427
2100 270
104 225--250 S 995 1095 135 900 393 1000 830 635 830 KG
204847
250M 2150

MIN 200
280 2250 440 171426
II 160--180 1950
M
200 171427
MOTOR 2150 270
SMC 225--250 S
TYPE MM 995 1130 160 875 418 1035 875 645 925 KG

390
106 250M 2200 204847
IEC
280 2300
III 440 171426
160 222 315 2400

K
180 209 180 2000 171427
200 197 200
2200 270
225 181 SMC 225--250 S
250 162 1005 1125 185 875 443 1030 900 665 204847 990 KG
I 108 250M 2250
280 140 280 2350
440 171426
315 114 315 2450

4843--021_0

MIN 400
1

123/288
SMC /TSMC 100 Mk4 - Engineering Manual
6. Technical Data

Planning the Machine Room

When planning the machine room, make sure that Space 1: 500 mm [20”]
there is enough space around the compressor. Space 2: 400 mm [16”]
The minimum spacing is indicated below, see Space 3:
Fig. 6.4, Fig. 6.5 and Fig. 6.6.
SMC 104-106-108, TSMC 108 600 mm [24”]
SMC 112-116, TSMC 116 1100 mm [43”]

Fig. 6.4

Fig. 6.5 Compressor Block with Fig. 6.6 Compressor Block with
Analog System UNISAB II System

3 3

Enough room must be left around the compressor sufficient space to make it possible to take out the
to allow the operating personnel to operate the crankshaft without dismounting the compressor
compressor ➀and carry out service work on the from the base frame.
compressor ➁. Space should be considered ➂as

124/288 0178-931 - ENG

Rev. 27.10.03
 SMC /TSMC 100 Mk4 - Engineering Manual
6. Technical Data

Operating Limits Diagrams 2. Max Permissible Differential Pressure

To make sure that YORK Refrigeration’s custom- across the Pistons:
ers experience a satisfactory compressor opera- Fig. 6.8
tion within the specified operating periods be- TC
tween the service intervals, it is essential that the 2
operating conditions are kept within certain per-
mitted operating limits.
The operating limits are specified in the following
Operating Limits Diagrams. YORK Refrigeration
is only liable in so far as the operating limits con-
ditions of the compressor are kept within the limi-
tation of the curvas. Similary, the recommenda-
tion concerning the number of revolutions and TE

cooling of the compressor must be observed. 3. Permissible Compression Ratios π:

The limitation curves have been determined on The compression ratio is calculated into the
the basis of both constructional and operating diagram with the following values:
conditions. Max. value or π for:
06 technical data.fm

1. Max Permissible Condensing Pressure: - R717 8 (7 for SMC 100 E)

The pressure limit corresponds to the test - R134a 12
pressure which is applied to all compressors - R22 10
and as indicated under Test Pressure in this - R207C 10
section.
- R404A 14
Fig. 6.7 - R507 14
TC
1 Fig. 6.9
TC

TE

TE

3a. Limitation of the Compressor rpm:

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

0178-931 - ENG 125/288

Rev. 27.10.03
SMC /TSMC 100 Mk4 - Engineering Manual
6. Technical Data

Fig. 6.10 Fig. 6.12

TC TC
3a

5
TE TE
4. The Lowest Permissible Suction 6. Minimum Difference between Condens-
Pressure: ing and Evaporating Temperature:
The limit has been fixed at approx 0.5 bar If there is less difference than specified, the
and 5.6 bar for R744 (CO2 triple point). compressor will not get sufficiently warm.
Lubrication problems may occur when the
Fig. 6.11
TC
refrigerant content in the oil is too high with
a subsequent risk of oil foaming in the com-
pressor.
It should also be noted that some of the
equipment in a refrigeration plant requires a
certain pressure difference in order to func-
4
tion 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.
7.
6
TE
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.

126/288 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 lu-
brication problems. The HFC and HCFC re-
frigerants, which are relatively heavy, will
raise the pressure drop through the dis-
charge and suction valves and this will im-
pede the proper functioning of the valves.
Fig. 6.13
TC
06 technical data.fm
TE
0178-931 - ENG
Rev. 27.10.03
7a. The Highest Permissible Evaporating
Pressure:
The limitation curves represent the highest
permissible suction pressure without reduc-
ing the number of revolutions.
Fig. 6.14
TC
7a
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 be-
low are described in detail in Section 4, Technical
Description - Cooling Systems for Compressors.
127/288
SMC /TSMC 100 Mk4 - Engineering Manual
6. Technical Data

TC
°F °C

R717
140 60
Operating Limits
122 50
One Stage
1
104 40
4 Compressor
Condensing temperature

86 30 Type
68 20 3 2 CMO & SMC
50 10
BOOSTER
32 0 OPERATION

14 -10

-4 -20

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

Evaporating temperature
T0111123_1 VIEW 2

TYPE AREA rpm COOLING NOTE

max. min.
1-2 Air cooled top- and side covers # or water-cooled
CMO20 1800 900
3-4 Thermopump or water-cooled 1)
1-2 Air cooled top - and side covers # or water-cooled
SMC100S/L 1500 700
3-4 Thermopump or water cooled 1)
1 750 Water-cooled
SMC180 450
2-3-4 1000*

* SMC 188: 840 - 920 RPM not allowed.

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

128/288 0178-931 - ENG

Rev. 27.10.03
 SMC /TSMC 100 Mk4 - Engineering Manual
6. Technical Data

TC
°F °C

140 60
R717
122 50
Operating Limits
One Stage
104 40 2 Compressor Type
SMC100E
Condensing temperature

86 30

68 20
1
50 10

32 0 OPERATION

14 -10

-4 -20

-22 -30
06 technical data.fm

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

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

Evaporating temperature
T0111140_0 view 6

TYPE AREA rpm COOLING NOTE

max. min.
1
SMC100E 1500 700 Thermopump or water cooled
2 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 150°C (302°F) at full load and at part load.
1) Discharge temperature at part load has to be checked.

0178-931 - ENG 129/288

Rev. 27.10.03
SMC /TSMC 100 Mk4 - Engineering Manual
6. Technical Data

TC
°F °C
158 70 R717
140 60 Operating limits
122 50
Two Stage
Compressors
104 40 1 TCMO
TSMC 100 S-L-E
Condensing temperature

86 30 2 TSMC 180
68 20

50 10

32 0

14 -10

-4 -20

-22 -30
0177128_0 VIEW 3,1

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

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

Oil cooling is always necessary.

Thermopump: 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
°F °C
R22
158 70
Operating Limits
140 60 One Stage
122 50 4 CMO & SMC
3
Condensing temperature

104 40

86 30
1
68 20 2
50 10

32 0

14 -10

-4 -20
06 technical data.fm

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

TYPE AREA RPM OIL COOLING REQUIRED1) REMARKS

MAX. MIN.
1 No
1500
2 No
CMO20 900
3 At less than 50% capacity
1800
4 Yes
1 1000 No
2 1200 No
SMC100S 700
3 At less than 50% capacity
1800
4 Yes
1 2)
2 1000 No
SMC100L
3 700 At less than 50% capacity yes
1200
4 Yes
1-2 2)
SMC180 3 At less than 50% capacity yes
750 450
4 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 131/288
Rev. 27.10.03
SMC /TSMC 100 Mk4 - Engineering Manual
6. Technical Data

TC
°F °C
R22
140 60
Operating Limits
Condensing temperature

122 50
1 Two Stage
104 40 2 Compressor type
86 30 TCMO & TSMC
3
68 20

50 10

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

TYPE AREA RPM OIL COOLING 1) NOTE

MAX. MIN.
1-2 1500
TCMO 900 No
3 1800
1 1000
TSMC100S 2 1200 700 Yes 2)
3 1800
1 3)
TSMC100L 2 1000
700 Yes 2)
3 1200
1-2 3)
TSMC180
3 750 450 Yes 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
°F °C

176 80

158 70
R134a
1 Operating Limits
140 60 2
One Stage
122 50
CMO & SMC
104 40
3
Condensing temperature

86 30

68 20

50 10

32 0

14 -10

-4 -20
06 technical data.fm

-22 -30

-40 -40
40°C
T0177128_ V8,1

-70 -60 -50 -40 -30 -20 -10 0 10 20 30

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

TYPE AREA RPM OIL-COOLING 1) NOTE

MAX. MIN.
1200 No
1-2
At less than 50% capacity
CMO 1500 900
No
3
1800 At less than 50% capacity
1 1000 No
2 700 No
SMC100S 1200
No
3
1500 At less than 50% capacity
1 2)
2 No
SMC100L 1000
700 No
3
1200 At less than 50% capacity

Top and side covers: Air-cooled

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.
2) Not applicable.

0178-931 - ENG 133/288

Rev. 27.10.03
SMC /TSMC 100 Mk4 - Engineering Manual
6. Technical Data

TC
°F °C
158 70
R134a
140 60 1 Operating limits
2 Two Stage
122 50

3 Compressors
104 40
TCMO
Condensing temperature

86 30 TSMC 100 S-L

68 20

50 10

32 0

14 -10

-4 -20

-22 -30

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

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

Evaporating temperature

Type Area rpm Oil-cooling required 1) Note

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

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 0178-931 - ENG

Rev. 27.10.03
 SMC /TSMC 100 Mk4 - Engineering Manual
6. Technical Data

TC
R404A
°F °C
140 60
Operating Limits
CMO & SMC
122 50
One Stage
104 40
Condensing temperature

86 30

1
68 20

50 10

32 0

14 --10

--4 --20

--22 --30
06 technical data.fm

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

TE
--76 --58 --40 --22 --4 --14 32 50 68 86 °F
Evaporating temperature
T0111164_2

TYPE AREA RPM OIL COOLING 1) NOTE

MAX. MIN.
1500 No
CMO20 1 900
1800 At less than 50% capacity
1200 No
SMC100S 1 700
1500 At less than 50% capacity
SMC100L 1 1200 700 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.

0178-931 - ENG 135/288

Rev. 27.10.03
SMC /TSMC 100 Mk4 - Engineering Manual
6. Technical Data

TC
°F °C

140 60
R404A
122 50 Operating Limits
Two Stage
Condensing temperature

104 40 TCMO & TSMC

1
86 30

2
68 20

50 10

32 0

14 -10
-70 -60 -50 -40 -30 -20 -10 0 °C
TE
32 °F
274263.3 Rev. 0

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

Evaporating temperature

TYPE AREA RPM OIL COOLING NOTE

MAX. MIN.
1
1800 900 No
TCMO 28 2
1 1200
700 No 1)
2 1500
TSMC100S
1 1000
700 No 1)
TSMC 100L 2 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 0178-931 - ENG

Rev. 27.10.03
 SMC /TSMC 100 Mk4 - Engineering Manual
6. Technical Data

°F
TC
°C
R507
140 60 Operating Limits
122 50 One Stage
CMO & SMC
Condensing temperature

104 40

86 30

68 1
20

50 10

32 0

14 --10

--4 --20
06 technical data.fm

--22 --30

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

TE
--76 --58 --40 --22 --4 --14 32 50 68 86 °F
Evaporating temperature
T0111166_2

TYPE AREA RPM OIL COOLING 1) NOTE

MAX. MIN.
1500 No
CMO20 1 900
1800 At less than 50% capacity
1200 No
SMC100S 1 700
1500 At less than 50% capacity
SMC100L 1 1200 700 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.

0178-931 - ENG 137/288

Rev. 27.10.03
SMC /TSMC 100 Mk4 - Engineering Manual
6. Technical Data

TC
°F °C
R507
140 60
Operating Limits
122 50
Two Stage
Compressor
TCMO & TSMC
Condensing temperature

104 40

1
86 30

68 20
2

50 10

32 0

14 -10
-70 -60 -50 -40 -30 -20 -10 0 °C
TE
32 °F
274263.4 Rev. 0

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

Evaporating temperature

TYPE AREA RPM OIL COOLING NOTE

MAX. MIN.
1
TCMO28 1800 900 No
2
1 1200
TSMC100S 700 No 1)
2 1500
1 1000
TSMC100L 700 No 1)
2 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

140
60 R407C
Operating Limits
122 50
One Stage
104 40 1 Compressor type
Condensing temperature

86 30 CMO & SMC

68 20
3 2
50 10

32 0

14 -10

-4 -20
06 technical data.fm

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

Type Area rpm Oil-cooling Note

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

0178-931 - ENG 139/288

Rev. 27.10.03
SMC /TSMC 100 Mk4 - Engineering Manual
6. Technical Data

Direction of Rotation of the Compressor

The normal direction of rotation for the compres-
sors is anti-clockwise when looking at the com-
pressor from the shaft end.
Fig. 6.15 Direction of rotation for compressor
seen from A
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

• Clockwise compressor rotation:

Marking in cover to the left of the logo.
Fig. 6.18
A

At times it may be necessary that the crankshaft Guide pin

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

140/288 0178-931 - ENG

Rev. 27.10.03
 SMC /TSMC 100 Mk4 - Engineering Manual
6. Technical Data
Choice of Electric Motor
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
When selecting an electric motor, the following
factors must be taken into consideration:
06 technical data.fm
Motor Dimension
The size of the motor is determined on the basis
of the power demands of the compressor under
the current operating conditions calculated by
means of the YORK COMP1 PC program.
However, for various reasons, always choose a
motor a little bigger. The reason for this is ex-
plained in the following:
A. Generally speaking, the calculated power de-
mand should be increased by one of the fol-
lowing factors in order to ensure that the mo-
tor has sufficient driving power, both during
start-up, at minor deviations from the worked
out operating conditions and with regard to
mechanical transmission loss for instance in
the V-belt drive:
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. Do consider, however, which type of plant the
compressor is going to work on, and then di-
mension the motor in accordance with the fol-
lowing rules:
a: For plants in which a higher ET may be
expected, and consequently also a higher
CT in the start-up phase, the motor must be
dimensioned to meet the higher operating
temperatures. Usually, this does not incor-
porate factor 1 and 2.
Likewise, special consideration should be
given concerning the booster compressors.
b: Alternatively, the motor can be connected
to a system for Ampere limitation which re-
duces the compressor capacity until the
planned operating temperatures have been
reached. This element is found in
UNISAB II, which must be linked to the
Amp. signal, however. In this case, factor 1
and 2 should also be omitted.
Note: YORK Refrigeration would like to point out
that when using a motor with a class F insulation
(105K) for operating conditions like for class B
(90K), approx. 10% continual overloading of the
motor will be acceptable in connection with the
nominal effect.
As mentioned previously, all compressors are as
standard completely unloaded during the
start-up phase. This reduces the power consump-
tion of the compressor considerably as may be
seen from the starting torque curve, Fig. 6.20.
As standard, the SMC 100 can only be capacity
regulated in steps of two cylinders, which is usual-
ly satisfactory. If required, extended unloading
can be ordered when the order is placed or it can
be mounted at a later time.
For more information on this subject, see Section
4, Technical Description - Extended unloading of
the Compressor.
141/288
SMC /TSMC 100 Mk4 - Engineering Manual
6. Technical Data

The starting torque for compressors with extend-
ed unloading appears from and Fig. 6.22.
Please note that moment of inertia is not included
in the diagrams. Further pay attention to the fact
that the motor should reach its maximum torque
moment before the non-adjustable cylinders are
put into operation.
Fig. 6.20
Starting torque at 0% load
500
The maximum time for reaching minimum rpm
(TSMC 100 : 750 rpm.) is 5 sec. and nominal
speed should be reached after max. 10 sec.
For more information on this, see Section 4, Tech-
nical Description - Capacity Regulation and Un-
loading of the Compressor.

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

350 112S
R717 (TE = +55C)
HFC/HCFC (R507 TE = +55C)

300
Torque (Nm)

250
108S

200
106S
116S
150
104S
112S
100
108S
106S
50 104S

0
0 250 500 750 1000 1250 1500 1750 2000
RPM (/min)
STARTING TORQUE FOR COMPRESSOR SMC/TSMC/HPC100

142/288 0178-931 - ENG

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 De-
scription - Capacity Regulation and Start Unload-
ing of the Compressor.
At times, however, it may be a good idea to com-
pare the starting torque curve of the compressor
Fig. 6.21 Starting Torque Curve for Electromotors
to the starting curve of the motor (this information
can be obtained from the motor manufacturer).
Especially, when the compressor starts at a plant
pressure below normal and when power limiting
systems are used to start up the motor, e.g. a Y/
∆ starter, it may be necessary to work out a dia-
gram as the one shown in Fig. 6.21. The hatched
area represents the torque moment available to
the motor when speeding up the compressor.

Kpm
[Lb.ft.]
06 technical data.fm

Motor starters

Motor Y starters

Compressor

0178-931 - ENG 143/288

Rev. 27.10.03
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

Dp
06 technical data.fm

0178-931 - ENG 145/288

Rev. 27.10.03
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) SMC 100 L (100 mm stroke) SMC 100 E (120 mm stroke)

No of cylinders: 4 6 8 12 16 4 6 8 12 16 4 6 8 12 16
SMC/TSMC 100

HPC 100 4 6 8

Compressor with 0.154 0.189 0.218 0.376 0.427 0.196 0.234 0.269 0.464 0.579 0.254 0.321 0.340 0.593 0.705
free shaft end

V-belt driven 4 1.529 1.564 1.593 1.751 1.802 1.571 1.609 1.644 1.839 1.954 1.629 1.696 1.715 1.968 2.080
compressor
with shaft
pulley

No of V-belts 6 1.404 1.439 1.468 1.626 1.677 1.446 1.484 1.519 1.714 1.829 1.504 1.571 1.590 1.843 1.955

Profil SPB 8 1.779 1.814 1.843 2.001 2.052 1.821 1.859 1.894 2.089 2.204 1.879 1.946 1.965 2.218 2.330

Direct driven com- 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
pressor with com-
plete AMR coupling

Table 6.4 Moment of Inertia (Ib.ft2) for SMC/HPC/TSMC 100 Compressors

Type SMC 100 S (80 mm stroke) SMC 100 L (100 mm stroke) SMC 100 E (120 mm stroke)

No of cylinders: 4 6 8 12 16 4 6 8 12 16 4 6 8 12 16
SMC/TSMC 100

HPC 100 4 6 8

Compressor with 3.66 4.49 5.18 8.93 10.14 4.66 5.56 6.39 11.02 13.75 6.03 7.62 8.08 14.09 16.75
free shaft end

V-belt driven 4 36.31 37.15 37.84 41.59 42.80 37.32 38.22 39.05 43.68 46.41 38.69 40.29 40.74 46.75 49.41
compressor
with shaft
pulley

No of V-belts 6 33.35 34.18 34.87 38.62 39.83 34.35 35.25 36.08 40.71 43.44 35.72 37.32 37.77 43.78 46.44

Profil SPB 8 42.26 43.09 43.75 47.53 48.74 43.25 44.16 44.99 49.62 52.35 44.63 46.22 46.67 52.68 55.34

Direct driven com- 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
pressor with com-
plete AMR coupling

146/288 0178-931 - ENG

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 SMC 104-106-108 and TSMC 108
designed ventilation wings to reduce the noise Anti-clockwise, Fig. 6.24.
level. These motors have a specified direction Fig. 6.24
of rotation which must be considered when con-
necting them to a compressor. If the motor is con-
nected by means of a coupling, it must rotate
clockwise when looking at it from the shaft end,
Fig. 6.23.
Fig. 6.23

SMC 112-116 and TSMC 116

Clockwise, Fig. 6.25.
Fig. 6.25

If the motor is connected by means of a V-belt pul-

06 technical data.fm

ley, the direction of rotation should be as follows:

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

be closest to the base frame.

0178-931 - ENG 147/288

Rev. 27.10.03
SMC /TSMC 100 Mk4 - Engineering Manual
6. Technical Data

Handling of Compressor and Unit the wires do not get stuck and thus damage the
When lifting the compressor, only use the lifting pipes or any other components on the unit.
eyes M20, Fig. 6.26, which are fitted in the thread- Fig. 6.27
ed holes at the top of the block. The weight of the
compressor block is indicated in Table 6.1 in the
beginning of this section.
Note: It is only the compressor block which may
be lifted in the lifting eye. The same applies to the
motor.
Fig. 6.26

Alternatively, the unit can be lifted with a forklift

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

The unit is lifted in the lifting eyes, which are weld-

ed onto the base frame and clearly marked with
The weight of the unit can be seen in the shipping
red paint. When the unit is lifted, make sure that
documents or in Table 6.2.

148/288 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
Fig. 6.30
06 technical data.fm
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 bal-
anced from factory. This makes special de-
mands on the accuracy of the boring proce-
dure.
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.
AMR Coupling Flange to Motor Shaft

Boring of Hub
C A
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 cus-
tomer prefers to bore the hub himself, the follow-
ing procedure should be observed: B

It is recommended to use the types of coupling as

stated for SABROE compressors. If the neces- Max. 0.02 mm
sary data is not known on delivery of the compres-
sor, the coupling flange for the motor will be deliv-
Alignment must be kept within the values
ered pilot bored and the boring must be completed
stated in Table 6.5.
on site.

0178-931 - ENG 149/288

Rev. 27.10.03
SMC /TSMC 100 Mk4 - Engineering Manual
6. Technical Data

Table 6.5 Fig. 6.31

Max. axial untruth measured at 0.02 mm
H7
point A

Max. radial untruth measured at 0.02 mm

point B

Boring is carried out to the immediate motor

+0.2/0.3 mm
shaft diameter with an H8 tolerance. Please,
note that the max. boring diameter is 95 mm
and that two key grooves must be engraved
in the key of the motor shaft in order to main-
tain balance. H8

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 Max. dia. 95 mm
and hub of 0.2-0.3 mm, Fig. 6.31
As seen in the above drawing, Fig. 6.30, the
coupling hub is slit up axially and clamped to
the motor shaft with two screws.
Read more about the coupling in the follow-
ing section.

150/288 0178-931 - ENG

Rev. 27.10.03
 SMC /TSMC 100 Mk4 - Engineering Manual
6. Technical Data

Coupling
An AMR coupling is used for
YORK Refrigeration's Sabroe reciprocating com-
pressors. This coupling is resistant to torsional
stress but radially and axially flexible. Torsional
resistance is achieved by a transmission of the ro-
tational force of the motor through a number of
thin laminated steel sheets (laminas) collected in
two "parcels" (disc packs) A and fixed on the
flanges with screws, Fig. 6.32.
Fig. 6.32
A B A
06 technical data.fm
provided that the motor comes from
YORK Refrigeration. Intermediate piece and par-
cels with laminas are delivered separately and
must be mounted on site. Remember that com-
pressor and motor must be aligned as de-
scribed in Section 7, Installation Instructions.
Intermediate piece B also makes it possible to re-
move the shaft seal of the compressor without
having to move motor or compressor. The length
C of the intermediate piece (Fig. 6.33) and the
lamina parcels cover a distance - after they have
been dismantled - that makes it possible to dis-
mount the coupling flange and the shaft seal of the
compressor.
Fig. 6.33

With the torsionally resistant coupling the oscilla-

tory weight of the rotor in the electric motor works
as a "flywheel", providing the compressor with a
B
stable and vibration free operation during all kinds C

of operating conditions and capacity stages.

Table 6.6
Radial flexibility is achieved by means of the inter-
mediate piece B which, together with the two lam- Compressor Distance
C mm
inas "parcel A", creates a cardanic effect. In this
way the two flanges are able to move a little radi- HPC/SMC 104 - 106 - 108
102
TSMC 108
ally in relation to each other, thus equalizing minor
lateral movements of motor and compressor. SMC 112 - 116
113
TSMC 116
The compressor unit is delivered with coupling
flanges mounted on the compressor and motor,

0178-931 - ENG 151/288

Rev. 27.10.03
SMC /TSMC 100 Mk4 - Engineering Manual
6. Technical Data

The procedure for alignment of compressor and After boring, the coupling flanges are balanced.
motor is described in Section 7, Installation In- This is characterized by one or more holes on the
structions. side of the flange. Max. permissible imbalance
Balancing must be made before the key groove is can be seen from the table, Table 6.7.
engraved.
Table 6.7
Compressor HPC/SMC 104-106-108 SMC 112-116 Balancing G
TSMC 108 TSMC 116 mm

Coupling hub - motor AMR 312 S AMR 350 S 550

Coupling hub - compressor AMR 312 AMR 350 400

152/288 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
By letting the electro motor drive the compressor
through a V-belt drive, the speed of the compres-
sor can be selected so that the max. capacity cor-
responds to the capacity requirements of the
plant.
06 technical data.fm
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 nor-
mal operating conditions they do not require any
service and are shape-permanent, which means
that they can be characterised as S = C plus,
which is stamped on the outside of the belts, see
Fig. 6.36. Moreover, the V-belts are made with
0178-931 - ENG
Rev. 27.10.03
such narrow tolerances that they can be fitted im-
mediately, which means that it is no longer neces-
sary to check whether the belts match. A V-belt
drive which has been set up and adjusted correct-
ly will usually have a service life of approx. 20,000
operating hours.
Fig. 6.36
Transmission Ratio
The required transmission of speed between mo-
tor and compressor is achieved by choosing the
right combination of pulley diameters as stated in
the Table 6.8. It appears from the table that there
is only one pulley diameter for the compressors
and that the transmission ratios are achieved by
choosing among the standard motor pulleys.
Thus the Compressor Speed for Motor Speed
1460 rpm (50Hz) and 1760 rpm (60 Hz) stated in
the table is achieved. The nominal V-belt length is
stated in the column Length of V-belt, and the
same length is stamped on the outside of the
V-belts as in the example shown in Fig. 6.36.
153/288
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 Compressor speed compared Length of V-belts
Diameter mm to Motor speed mm
Compressor Motor 50 Hz 1460 rpm 60 Hz 1760 rpm 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
400 250 912 1100 2800 2000
265 976 1166 2800 2000
280 1022 1232 2800 2000
315 1150 1386 2800 2120
335 1273 1474 3000 2120
355 1295 1562 3000 2240
400 1460 1760 3000 2240

* SMC 104 - 108 and TSMC 108 only

154/288 0178-931 - ENG

Rev. 27.10.03
 SMC /TSMC 100 Mk4 - Engineering Manual
6. Technical Data

Power Transmission of V-belts which must be used to transmit the

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 fol-
lowing tables, Table 6.9 and Table 6.10.
Note: To obtain a smooth transmission, the
number of V-belts must be chosen so that the belt
drive loads at its maximum as stated in the table.
The motor pulleys are always delivered with the
number of grooves corresponding to the number
maximum power of the motor to the V-belt drive in
question, thus indicating how many V-belts must
be fitted.
The compressor pulleys, however, are only de-
livered with the number of grooves shown below.
Thus it may occur that there are more grooves on
the compressor pulley than on the motor pulley.
SMC/TSMC 100
The compressor pulleys are always delivered with
4 - 6 or 8 grooves.

Table 6.9 Max. Power Transmission SMC104-106-108 and TSMC108

Number of Motor speed 1460 rpm (50 Hz)
V-belts
730 817 912 976 1022 1150 1295 1460 rpm
2 22 22 30 30 30 37 45 45
06 technical data.fm

3 30 37 45 45 45 55 55 75
4 37 45 55 55 55 75 90 90
kW
5 45 55 75 75 90 110 110
6 55 75 75 90 90 110 132 132
8 75 90 106 110 118 132 150 169
Number of Motor speed 1760 rpm (60 Hz)
V-belts
792 836 880 985 1100 1166 1232 1386 1474 rpm
2 26 36 36 36 44 44
3 26 26 36 44 44 54 54 66 66
4 36 44 44 54 66 66 66 90 90
kW
5 54 54 54 66 90 90 108 108
6 66 66 90 108 108 132 132
8 66 90 90 108 127 132 143 158 171

0178-931 - ENG 155/288

Rev. 27.10.03
SMC /TSMC 100 Mk4 - Engineering Manual
6. Technical Data

Table 6.10 Max. Power Transmission (kW) SMC112, 116 and TSMC116
Number of Motor speed 1460 rpm (50 Hz)
V-belts
730 817 912 976 1022 1150 1295 1460 rpm
3 55 55 55
4 55 55 55 75 75 90
5 55 75 75 90 90 110 kW
6 75 90 110 110 132
8 90 106 110 110 132 150 169
Number of Motor speed 1760 rpm (50 Hz)
V-belts
792 836 880 985 1100 1166 1232 1386 1474 rpm
3 54 66 66
4 54 66 66 66 90
5 54 54 66 90 108 108 kW
6 54 66 90 90 108 132
8 66 66 90 108 108 132 132 158 158

156/288 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 be- A
tween motor and compressor is 900 mm for
SMC/TSMC 104 to 108 as shown in Fig. 6.37, and
500 mm on SMC/TSMC 112 and 116 as shown in
Fig. 6.38.
Fig. 6.37 SMC 104-106-108, TSMC 108
Nominal center distance
900 mm

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
06 technical data.fm

Fig. 6.38 SMC 112-116, TSMC 112-116 nine screws on the clamping unit, see fig. 6.41.
II The screws are tightened with a torque wrench.

III
Fig. 6.40
Nominal
center
distance I

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.

0178-931 - ENG 157/288

Rev. 27.10.03
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 bush-
ing on the motor shaft, then fix the pulley to the
bushing by means of two or three screws, pos. 2
in Fig. 6.42. Mount the screws in the holes where
the thread faces the belt pulley. Thus the conical
bushing is pressed around the motor shaft so that
it both holds and centers the belt pulley. Before
tightening, the belt pulley is placed on the motor
shaft so that it is flush with the compressor belt
pulley. Tighten the screws, pos. 2, with the torque
moment as indicated in Section 21.
Fig. 6.42
1
2 Service
When dismounting the belt pulley, first dismount
the two or three screws, pos. 2, and then mount
one or two of the screws in the free hole/s where
there is only a thread in the side which faces the
bushing. By tightening the two screws evenly, it is
now possible to press the belt pulley off the bush-
ing. The bushing and the belt pulley can now be
dismounted manually.
The V-belts must only be mounted and dismount-
ed when the motor is placed close to the compres-
sor to avoid damage of the belts.
158/288
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.
For measuring the correct belt tension, use Ten-
sion Gauge II, part no. 1622.003.
Spare Parts
When delivering belt pulleys as spare parts, the
compressor pulley is always ready bored and
balanced. It can thus be fitted directly on the com-
pressor.
The motor pulley is delivered balanced and with
a conical bushing, which is ready bored for direct
fitting on the motor shaft in question.
The V-belt drive has an average service life of ap-
prox. 20,000 operating hours during which period
it is only necessary to check and perhaps adjust
the belt tension. Checking and adjusting the
V-belt drive is best carried out by means of the
special tool (Tension Gauge) mentioned above,
which is available from YORK Refrigeration Af-
ter-Market Service Department.
When replacing the V-belts, the grooves in the
V-belt pulleys should be checked for wear and
tear by means of a Belt and pulley groove
gauge, part no. 1622.001, which can also be ob-
tained from our After-Market Service Department.
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 Fig. 6.44 Unit mounted on vibration dampers
that the bed plate upon which it is placed is as
plane as possible as the rigidity of the base frame
depends on whether the base frame is supported
correctly under all its "feet".
The base frame should therefore be stress-free
and rest evenly on all its "feet" when positioned on
the foundation.
In the following paragraphs a distinction is made
between stationary plants and marine plants.
Stationary Plant
In stationary refrigeration plants the compressor
unit is either mounted directly on a concrete foun- The most preferred form of mounting today is the
dation or positioned on vibration dampers, one on vibration dampers as the unit can be po-
Fig. 6.43 and Fig. 6.44. sitioned directly on the machine floor without any
clamping and without the laying of a concrete
06 technical data.fm

Fig. 6.43 Unit mounted directly on concrete

foundation. This reduces the plant costs consider-
foundation
ably both during the initial installation and later on
during a potential rearrangement of the units in
the machine room.
Further, the use of vibration dampers is a way to
ensure that vibrations from the unit are not propa-
gated to the construction itself via the foundation.
In return, this form of mounting requires a plane
and horizontal machine floor within narrow limits
as specified in the following.
300

0178-931 - ENG 159/288

Rev. 27.10.03
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 Example of Foundation Drawing
300
Foundation bolts
125
Compressor Motor 500
125
300 1250 350
Foundation bolts, nuts and foundation plates are
delivered together with an order. Following a spe-
cific order a foundation drawing will be forwarded
and the holes poured into the foundation as indi-
cated in this drawing.
As shown in the drawing, Fig. 6.45, the unit is
placed on a concrete foundation which is usually
300 mm high. During the concreting the holes are
moulded into the concrete as indicated in the for-
warded drawing, Fig. 6.46.
160/288
Fig. 6.46 Moulding of Foundation Bolts
Foundation plate
10
250
110 x 110
After the foundation has hardened, the unit is lo-
cated, leaving it to rest on wooden blocks in a
flush position and without twisting the base frame.
The foundation plates are tightened under the
base plates of the base frame by means of steel
wire. The foundation bolts are suspended in the
holes with the nut screwed down flush with the
end of the foundation bolt as illustrated in the
drawing.
The concrete poured round the foundation bolts
should only contain very little water in order that it
may be stamped down properly round the bolts. A
low water content does not cause contraction of
the setting concrete.
10-14 days should be allowed to pass before the
joists are removed and the nuts of the foundation
bolts tightened. Remember to remove the steel
wire and check that no space is left between base
frame and foundation plates. Otherwise, place the
liners between the plates before tightening.
0178-931 - ENG
Rev. 27.10.03
 SMC /TSMC 100 Mk4 - Engineering Manual
6. Technical Data

Mounting of Vibration Dampers

By placing the compressor unit on vibration damp- nominally 2 mm. A good and rigid support of the
ers, Fig. 6.44, calculated and delivered by unit is thereby achieved as well as a proper damp-
YORK Refrigeration, an optimum damping of vi- ing coefficient.
brations from the unit to the foundation and con- The rotating parts in the compressor are com-
sequently to the construction will be achieved. pletely balanced for forces of the 1st order and
As already mentioned, the unit with the vibration consequently, damping is primarily necessary for
dampers is usually placed directly on the floor forces of the 2nd order, which rotates at double
which must be strong enough to be able to carry speed.
the weight of the unit. In the table in Fig. 6.47 the normative values for
The vibration dampers need not be clamped to the damping can be read in relation to the number of
floor as the bottom side has a rubber coating, the revolutions:
friction of which prevents them from sliding around Fig. 6.47 Guide for Selection of Suitable Deflec-
on the floor. tion
This makes it easy and quick to align the units on rpm Suitable de- Damping of 1st Damping of
a plane floor and they are easily moved during a flection order order 2nd order
vibrations vibrations
potential later rearrangement of the machine
06 technical data.fm

950 2.3-3mm 25-50% 87-92%

room. 1150 1.6-2.4mm 30-60% 87-92%
1450 1.2-2.0mm 40-72% 90-94%
Vibration Dampers: 1750 0.8-1.4mm 40-74% 89-94%

From the table in Fig. 6.48 it is possible to read

how much the damping of a vibration damper de- In the diagram in Fig. 6.48 the vibration damping
pends on its deflection when loaded. with various vibration speeds can be read in de-
YORK Refrigeration recommends that vibration pendence of the deflection of the vibration
dampers be selected and loaded to a deflection of dampers:

0178-931 - ENG 161/288

Rev. 27.10.03
SMC /TSMC 100 Mk4 - Engineering Manual
6. Technical Data

Fig. 6.48 Diagram for Damping of Vibrations

3000

Damping
98% 2500
97%
2000
95%

Vibrationspeed rpm
90%
85%
1400
80%
70%

50%
0% 1000

Natural
frequency
700

500

30 20 16 12 10 8 6 5 4 3 2 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.
As a consequence, vibration dampers with differ-
ent bearing capacity will be used on a unit and
these must be placed correctly in accordance with
the Mounting Instruction supplied by
YORK Refrigeration for that particular unit.
Fig. 6.49 is an example of such an instruction.

162/288 0178-931 - ENG

Rev. 27.10.03
 SMC /TSMC 100 Mk4 - Engineering Manual
6. Technical Data

Fig. 6.49

1 3 1 3 5
Vibration absorber type

Pos. A-B-C D

1 LM LM
Compressor Motor Compressor Motor 2 LM LM

Unit A
3 LM LM
Unit B
4 LM LM

5 LM

2 4 2 4 6 6 LM

Vibration dampers can be adjusted in height by
means of screw, pos.1, Fig. 6.50 which is finally
locked by tightening nut, pos. 2. The height H can
now be changed within the limits stated in the ta-
ble and are thus able to even out any minor differ-
06 technical data.fm
a loaded state, corresponding to the deflection re-
ferred to in the diagram in Fig. 6.48.
When designing the piping connections to the
compressor, care must be taken that these do not

influence the push and pull forces of the unit. The

ences in the planeness of the floor. length of the pipes changes with the temperature
Fig. 6.50 and this makes it necessary to make the pipings
1 flexible as shown in the drawing, Fig. 6.51.
Fig. 6.51
2

Base-
frame h

H
1 2

D h H
Make sure, however, that the pipes are supported
LM1 80 30 38
so that they do not start oscillating, thereby affect-
LM3-4T025 120 37 49
ing the unit.
LM3-33 120 32 44
After alignment of the unit as described above,
compressor and motor must be aligned in relation
After this equalizing a further tightening of screws
to each other.
will lead to a deflection of the vibration damper.
This reduces the measure h from an unloaded to

0178-931 - ENG 163/288

Rev. 27.10.03
SMC /TSMC 100 Mk4 - Engineering Manual
6. Technical Data

Specific Requirements to Vibration Damping In case of questions, please contact

In places where particularly strict requirements YORK Refrigeration whose employees are al-
are set up in order to prevent vibrations from being ways ready to place their expertise at your dispos-
propagated to the building construction itself and al.
causing noise nuisance, specific measures
should be taken. Marine Installations
This could be in connection with housing and of- Units in marine refrigeration plants are always
fice buildings or e.g. hospitals. placed on vibration dampers as they serve a two-
In such cases the best results are achieved by fold purpose in so far as they dampen both the vi-
fastening the whole unit on a sufficiently large brations of the marine engines as well as those of
concrete foundation which is placed on vibration the compressor.
dampers with a large bearing capacity or on a rub- Fig. 6.53 Vibration dampers for marine installa-
ber mat adapted to the purpose. tions
At the same time flexible vibration eliminators
should be used in the pipe connection to the unit
in order to avoid transmission of noise through the
piping. Very often it will be necessary to insulate
the machine room against noise or to use a noise
absorbing lining on the unit, Fig. 6.52, in order to
prevent noise from spreading to the environment.
Fig. 6.52 Noise absorbing shielding of com-
pressor unit

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 com-
pressors, is fixed to the unit feet and foundation.
This keeps the unit fixed to the foundation under
all kinds of load conditions when the ship is ex-
posed to the sea. It is not possible to adjust the
height of the vibration dampers. This makes it
necessary to machine the steel foundation as
evenly as possible (max. deviation approx. 1 mm).
Fig. 6.54
In case of a larger tolerance on the planeness or
where vibration dampers of different heights are
used due to the fact that the base frame loads dif-
ferently on the surfaces of support, this must be
compensated with liner plates as shown on the
drawing, Fig. 6.53
Vibration dampers are selected by
YORK Refrigeration for a particular unit and
delivered together with a drawing indicating the
position of each damper.

1 3 1 3 5
Vibration absorber type

Pos. Unit A Unit B

1 C C

2 C C
06 technical data.fm

3 C C

4 C C

5 C

6 C
2 4 2 4 6
It is very important to observe these positions as The vibration dampers are selected to a deflection
the unit does not rest with the same weight on all of 3 to 5 mm. A damping of the forces of the 2nd
feet. order is thereby achieved as indicated in the dia-
gram in Fig. 6.54. Read more on this subject in
this section under Vibration Dampers.

0178-931 - ENG 165/288

Rev. 27.10.03
SMC /TSMC 100 Mk4 - Engineering Manual
6. Technical Data

Noise from Compressors and Units

Noise is inevitable when a compressor or unit is Fig. 6.55 Unit covered with a measuring grid
working. However, by taking this into considera-
tion during the project phase, it is possible to re-
duce noise pollution of the environment consider-
ably.
Through the years YORK Refrigeration has been
aware of this problem. As a consequence, we
have designed the compressors and units with a
view to meeting market demands concerning
maximum noise levels.
Of course, modern compressor units are loud and
must be expected to make noise, and this makes
it the more important that the sound data stated
for a compressor or unit should be evaluated cor-
rectly.
The above issue will be discussed in the following.
In this connection YORK Refrigeration would like
to point out that at a fairly low cost it is possible to
make the machine room a pleasant work place.
The use of noise absorbing materials could be
one solution to the problem.
The measuring grid is divided into fields of
1. Sound Power and Sound Pressure max.1 sq. m each. The measuring is carried out
by moving the sound level meter in a kind of back
As seen in Table 6.12 sound data is indicated as
and forth movement, as illustrated in Fig. 6.55.
sound power level LW or sound pressure level
The sound level meter now calculates the total
LP. It is essential to distinguish between these two
sound power level LW for the entire unit.
values as they are stated in dB (decibel) and
should be read as follows: The sound power level LW is, however, dependent
on the surroundings of the noise source. Conse-
1.1. Sound Power Level LW
quently, it is a somewhat theoretical value. Here,
According to ISO 9614-2 LW is measured directly the sound pressure level Lp becomes of inter-
at the unit, Fig. 6.55, by installing a measuring grid est.
as close to the unit as possible.

166/288 0178-931 - ENG

Rev. 27.10.03
 SMC /TSMC 100 Mk4 - Engineering Manual
6. Technical Data
1.2. Sound Pressure Level Lp
It is actually the sound pressure level Lp that is
measured by the sound meter. In the sound meter
this is then automatically converted to the sound
power level LW by means of its built-in calculation
programs.
The sound pressure measuring is, however, de-
pendent on the room in which the measuring is
carried out. As a consequence, this may yield dif-
ferent results from one room to another.
The arrangement of the room as well as building
materials have a considerable influence on the re-
sults of the measuring.
This is why the measured values of the manufac-
turers for sound pressures are based on standard
measures according to ISO 3989 which refers
sound pressure level LP to a free field above a re-
06 technical data.fm
flecting plane at a distance of 1 meter from the
measuring grid, as described in pt. 1.1.
Above facts should be taken into consideration
during a check measuring on the plant in question
as mentioned in points 2.1 and 2.3.
0178-931 - ENG
Rev. 27.10.03
1.3. Frequency
Sound is fundamentally a pressure wave in the air
at a given wave length (frequency).
From a compressor unit sound waves are emitted
at many different frequencies due to the different
movable parts.
The human ear can normally perceive frequen-
cies in areas ranging from 20 Hz to 20 k Hz, but it
does not perceive all frequencies equally well.
Consequently, a sound meter must measure the
sound pressure at various frequencies and then
filter the measuring corresponding to the percep-
tual capacity of the ear (the A-weighting).
To this must be added the purely subjective per-
ception of sound as most human beings feel con-
siderable unease on hearing the so-called "pure"
notes. If a frequency is followed by a sound pres-
sure of 3-6 dB above the other frequencies, this
feels annoying. In case of screw compressors, it is
a fact that 300 and 600 Hz is normally felt to be an-
noying whereas reciprocating machines issue a
more low-frequency (pleasant) sound.
167/288
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
3,0
actually measured sound and the sound that the
ear perceives, the measured values are weighted 2,5

in the sound meter. Usually, the sound meter is 2,0

set for A-weighted values called dB (A), based on
a logarithmic scale. ∆ L 1,5
dB
1,0
That is why it is so important to apply the same
unit of measure on comparing values from several 0,5
different machines.
0 5,0 10,0 15,0
Further, we would like to point out that the sound
pressure level LP measured in the machine room
Difference (L2-L1) dB
as described under pt. 1.2 will always be above
the one indicated in table, Table 6.12 Example 1:
The measured value will normally lie somewhere With two compressors in the same room
between the stated LP and LW values.
Compressor 1,LP1= 81 dB (A)
2.2.
Compressor 2,LP2= 86 dB (A)
In machine rooms with a number of compressors
Difference 5 dB (A)
the total sound pressure level can be calculated
by adding ∆ L read on the curve in Fig. 6.56 to the Total sound pressure level:
sound pressure value for the unit with the highest LP = 86 + 1.2 = 87.2 ≅ 87 dB (A)
sound pressure.
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

57,5
62,6
~ 63 dB
=

6 compressors
48 54 61 62 62 58 dB

55,0
62,0
65,0
66,7
67,2 ~ 67 dB
=

2.3. separator etc. which have all been covered by the

It is essential that during a potential check meas- measuring grid.
06 technical data.fm

uring to carry out more than one sound pressure
measuring, e.g. by measuring in fields as shown
in Fig. 6.55 as a few local measures may result in
incorrectly high measured values.
2.4.
Likewise, pay attention to the fact that the meas-
ured values stated for a certain unit should com-
prise a complete unit incl. compressor, motor, oil
Thus, on assessing the measure results it is es-
sential to know the extent of the measured surface
area in the surrounding measuring grid.
2.5.
If the compressor is working at part load, this will
generally lead to higher measured values than the
ones indicated in the tables.

0178-931 - ENG 169/288

Rev. 27.10.03
SMC /TSMC 100 Mk4 - Engineering Manual
6. Technical Data

3. How to Check Sound Data Table 6.12

3.1. Compressor block LW Lp

SMC 104 S 95 79
The only correct method is the measuring of
SMC 106 S 96 80
sound power LW on the site itself and this requires SMC 108 S 97 81
the setting up of a measuring grid as well as the SMC 112 S 99 82
SMC 116 S 100 83
use of sound intensive equipment.
SMC 104 L 96 80
3.2. SMC 106 L 97 81
If using sound pressure Lp meters only, an addi- SMC 108 L 98 82
SMC 112 L 100 83
tional measuring of the reverberation period of the SMC 116 L 101 84
room will be required. This makes it possible to
SMC 104 E 96 80
find a theoretical value of the emitted sound power SMC 106 E 97 81
provided that the background noise is too low SMC 108 E 98 82
to be of any importance! SMC 112 E 100 83
SMC 116 E 101 84

Noise Data for Reciprocating Two-stage

Compressors LW and Lp values are measured at the following
Single-stage conditions:
LW and Lp values are measured at the following Evaporating temperature ET= 35°C [-31°F]
conditions: Condensing temperature CT= +35°C [+95°F]
Evaporating temperature ET = 5°C [5°F] Refrigerant= R22/R717
Condensing temperature CT = +35°C [95°F] Number of revolutions = 1450 rpm
Refrigerant = R22/R717
Number of revolutions = 1450 rpm Table 6.13
Compressor block LW LP
Heat Pump TSMC 108 S 95 79
Evaporating temperature ET = 20°C TSMC 116 S 97 81
Condensing temperature CT = +70°C TSMC 108 L 96 80
Refrigerant = R22/R717 TSMC 116 L 98 82

Number of revolutions = 1450 rpm TSMC 108 E 96 80

TSMC 116 E 98 82

Table 6.11
Compressor block LW LP

HPO 24 91 76
HPO 26 93 78
HPO 28 94 79

HPC 104 S 97 81
HPC 106 S 98 82
HPC 108 S 99 84

170/288 0178-931 - ENG

Rev. 27.10.03
 SMC /TSMC 100 Mk4 - Engineering Manual
6. Technical Data

4. Damping Acoustic Noise in In General

a Machine Room The following paragraphs include a description of
the factors that influence the acoustic quality of a
On planning or renovating a machine room, atten-
machine room.
tion should be paid to the acoustic environment as
a minor investment is sufficient to change an
acoustically hard room to a noise damped room Reverberation Time
which is pleasant to work in. By a correct application of noise absorbing mate-
rials it is possible to change the reverberation
This is possible to achieve by choosing a sensible
time of a machine room which is defined as the
noise absorbing material, fitted on walls and ceil-
time it takes for the sound pressure level Lp to
ing or which is part of the building construction
drop 60 dB once the noise source stops.
It is recommended to seek advice from a consult-
The duration of the reverberation time depends on
ing firm experienced in noise damping in order to
the volume of the room as well as the average ab-
obtain the solution best suited to your plant.
sorption coefficient for the noise absorbing mate-
For this purpose computer calculated frequency rials that are fitted in the room as they should be.
analyses can be requested from
YORK Refrigeration for the compressor unit in Absorption Coefficient
Usually the absorption coefficient α for noise ab-
06 technical data.fm

question.
sorbing materials is 0.5 to 0.8. See the following il-
Another and very efficient solution would be to
lustration, Fig. 6.59.
noise insulate the compressor unit itself.
YORK Refrigeration is able to deliver pre-fabricat- Fig. 6.59
ed and tested noise baffle boards.
Noise damping
Fig. 6.58 material

Incident
sound power Absorbed
sound power

Transmitted
sound power

Reflected sound power

X=
Incident so’und power

0178-931 - ENG 171/288

Rev. 27.10.03
SMC /TSMC 100 Mk4 - Engineering Manual
6. Technical Data

Subjective Perception of Noise Damping half in the machine room with a subsequent
With reference to table, Table 6.14, indicating great subjective effect.
how the human ear perceives the effect of noise • When using a pre-fabricated noise baffle
insulation in a machine room, the following should board from YORK Refrigeration, the sound
be noted: pressure in the machine room will typically
• By investing in a sensible noise insulation of be reduced by 20 dB. Naturally, this must be
the ceiling of the machine room this usually considered a great improvement - subjec-
means reducing the reverberation time by tively perceived.
Table 6.14
Reduction of sound pressure Reduction of the average Subjective perception of
by noise insulation of sound pressure level the improved acoustic quality
compressor unit by noise insulation of the room
dB dB Relative
reverberation time
0 0 1 -
1 0,5 0,9 Insignificant
3 1 0,8 Perceivable
6 2 0,6 Distinct
10 3 0,5 Considerable
20 * 6 0,25 Very considerable

*The YORK Refrigeration prefabricated Version 2.0 noise baffle board for compressor units

172/288 0178-931 - ENG

Rev. 27.10.03
 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.
Vibration data for YORK Refrigeration's Sabroe
screw compressors comply with: ISO 10816
Fig. 6.60
AV
AA
xAH
BH
06 technical data.fm
Pay attention to the following, however:
• Motors comply with EN 60034-14 (CEI/IEC
34-14) Class N.
• When placing the unit on the vibration
dampers supplied by YORK Refrigeration
(additional), the vibrations against the foun-
dation are reduced by:
– 85-95% for screw compressor units
– 80% for reciprocating compressor units
• However, higher vibration level may occur if:
– motor and compressor have not been
aligned as described in the Instruction
Manual.
0178-931 - ENG
Rev. 27.10.03
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).
CV DV
BV
x DA
x
CH DHx
BA
CA
– the compressor runs at an incorrect Vi
ratio. This applies to screw compres-
sors.
– the piping connections have been exe-
cuted in a way that makes them force
pull or push powers on the compressor
unit or transfer vibrations to the unit
caused by natural vibrations or connect-
ed machinery.
– the vibration dampers have not been fit-
ted or loaded correctly as indicated in
the foundation drawing accompanying
the order.
173/288
SMC /TSMC 100 Mk4 - Engineering Manual
6. Technical Data

Fig. 6.61 Specification of Compressor Materials

The materials to be used for the individual compo- sistance to the refrigerants and oils approved for
nents of the compressors have been selected in the compressors.
view of a long life, wear resistance as well as re- The following table,Table 6.15, lists the most im-
portant components.
Table 6.15
Designation Material Form

Compressor frame SMC and TSMC Cast iron EN-GJL-250, EN 1561

Compressor frame HPC 100 Ductile cast iron EN-GJS-500-7, EN 1563
Oil pump housing HPC 100, SMC and Cast iron EN-GJL-250, EN 1561
TSMC100
Bearing cover pump end HPC 100, SMC Ductile cast iron EN-GJS-500-7, EN 1563
and TSMC100
Water covers HPC 100, SMC and TSMC100 Cast iron EN-GJL-250, EN 1561
All other covers SMC and TSMC Cast iron EN-GJL-250, EN 1561
All other covers HPC Ductile cast iron EN-GJS-500-7, EN 1563
Crankshaft HPC108 Ductile cast iron EN-GJS-800-2, EN 1563
Crankshaft all other compressors Ductile cast iron EN-GJS-700-2, EN 1563
Connecting rod Ductile cast iron EN-GJS-700-2, EN 1563
Piston pin bushing Phosphor bronze BS1400, PB1-C
Half section of bearings for White metal on a steel base
Connecting rod
Bolts for connecting rod Cr-Mo steel Cl, 12.9, DIN 898
Piston Aluminium alloy BS 1490/LM13
Piston rings and oil scraper ring Cast iron BS 1452 (W.CI7)
Piston pin Cr-steel 17Cr3, DIN 17210
Cylinder liners Cast iron w/special heat treatment EN-GJL-250, EN 1561

Suction and discharge valve Special steel

plates
Suction valve retaining plate Ductile cast iron EN-GJS-600-3, EN 1563
Safety head spring Steel spring 54SiCr6, DIN 17221
Main bearings White metal on a steel base
Shaft seal carbon ring Special carbon
Shaft seal steel ring Special steel A62P
Suction filter Stainless steel wire-mesh AISI 316
Oil level glass Glass in steel flange
Oil strainer Filter cartridge AISI 304
By-pass valve Various steel C75, DIN 17222
Buffer springs Spring steel
Gaskets Non-asbestos
O-ring seals CR Rubber (standard) Compound 2347

174/288 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 pres-
sure tested to prove their strength and tightness.
The approving authorities determine the test pres-
sure levels on the basis of various criteria. How-
ever, the test pressure requirements can be sum-
marized into a number of standard pressure levels
which in practice meet the requirements set up,
and which can therefore be approved by all au-
thorities involved.
The following table, Table 6.16, shows the stand-
ard pressure levels used by YORK Refrigeration.
In case of specific applications, the authorities
may, however, demand a higher test pressure lev-
el. Within certain limits such requirements can be
met for SABROE compressors - against an addi-
06 technical data.fm
tional price. Please, contact YORK Refrigeration
for further information.
When pressure testing compressors and vessels,
components must first prove their strength by re-
sisting the test pressure of the strength test.
This test is carried out with air. Afterwards, the
leak test is carried out, also with air, at the pre-
scribed pressure and with the component soaked
in a water basin for 30 minutes.
Units consist of components which have been
pressure tested as described in the following ta-
ble. This means that it is only necessary to leak
test the unit. Dwelling time is 20 minutes. Leak
testing is carried out with pressurized air at the
pressure stated in the table. All weldings and con-
nections are covered with a frothing liquid

which will start foaming in case of a leak.

Table 6.16
Standard Test Pressure Levels
Strength Leak Testing with
Compressor Type Compressor Side Testing Pressurized Air
bar [psi] bar [psi]
CMO High pressure side 42 [609] 25 [363]
SMC 100 27 [392] 14 [203]
Low pressure side
SMC 180
High pressure side 42 [609] 25 [363]

TCMO Low pressure side 27 [392] 14 [203]

TSMC 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
42 [609] 21 [305]
SAB 163 The entire
SAB 202 compressor block
SAB 283L/E
39 [566] 26 [377]
SAB 355 L
Compressor All types
7 [102]
Unit The entire unit
Vessels Individual pressure testing in accordance with the local rules and regulations.
in general Consequently, no table can be set up.

0178-931 - ENG 175/288

Rev. 27.10.03
SMC /TSMC 100 Mk4 - Engineering Manual
6. Technical Data

Charging the Compressor with Oil

Usually, the compressor is delivered without any Fig. 6.62 Oil level glass
oil in the crankcase. As a principal rule, the
amount of oil indicated in the table, Table 6.17,
should be charged to the compressor.
Table 6.17 Oil Charging 10 mm
Compressor Amount of oil
in crankcase

Type Size Liter US gal. T0177162_0

104 26 6.9 Table 6.18

HPC 100
106 28 7.4
SMC 100 Compressor Difference in oil
108 30 7.9
TSMC 100 level of 10 mm
112 47 12.4
Mk 4 S-L-E Type Size corresponds to:
116 50 13.2
104
After some hours of operation the compressor HPC 100 - 2 litres of oil
106
SMC 100 [0.5 US gal.]
must be recharged with oil, however, as part of the 108
TSMC 100
oil has been absorbed by the refrigerant. This is S-L-E 112 - 6 litres of oil
especially the case for HFC and HCFC refriger- 116 [1.6 US gal.]
ants.
A manually operated pump connected to the oil
The amount of oil to be recharged depends on the
charging valve pos. B can be used for the first as
size of the refrigeration plant and the amount of
well as the following oil charges.
refrigerant. Oil is charged to the middle of the oil
See Section 5, Physical and Connection Data.
level glass and the amount of oil needed in order
to increase the oil level 10 mm is indicated in the Note: On HPC 100 compressors with R717, the
table, Table 6.18. pressure must be relieved before oil charging.
Fig. 6.63 Manually Operated Oil Pump
Optional hand-operated oilpump

To compressor -

Gasket

T0177131_0V
Cap

176/288 0178-931 - ENG

Rev. 27.10.03
 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.
In order to separate this oil, an oil separator is nor-
mally used. The separator is built into the dis-
charge pipe, right next to the compressor. The
separated oil is returned to the compressor as de-
scribed in Section 4, Technical Description - Oil
Separator.
A minor part of the oil, however, present in the dis-
charge gas as vapour, cannot be separated and
Circulated amount of refrigerant Q (kg/h) x Oil consumption (ppm)
Oil consumption kg/h =
6
10
06 technical data.fm
The normal oil consumption is between 20 and 30
ppm for an SMC/HPC 100 compressor.
0178-931 - ENG
Rev. 27.10.03
will consequently continue into the plant, in which
it is condensed in the condenser.
In HFC and HCFC as well as in compact R717 re-
frigeration plants this oil will return to the compres-
sor together with the suction gas.
In return, the oil in larger and ramified R717 refrig-
eration plants should be drained off and never re-
used in the compressor. This amount of oil repre-
sents the so-called oil consumption measured in
ppm. Ppm is the abbreviation for parts per million
and is calculated by using the following formula:
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 separa-
tor is 35 ppm. Depending on the choice of lubricat-
ing oil, the oil consumption is normally much low-
er.
177/288
SMC /TSMC 100 Mk4 - Engineering Manual
6. Technical Data

Table 6.19 Oil Separators

Code no. Part no. Type Refr.

SMC 104S - B301 4241.280 OVUR 3206D

SMC 104L - B301 4241.280 OVUR 3206D
SMC 104E - B301 4241.280 OVUR 3206D
SMC 104S - B302 4241.280 OVUR 3206D
SMC 104L - B302 4241.280 OVUR 3206D
SMC 104E - B302 4241.280 OVUR 3206D

SMC 106S - B301 4241.280 OVUR 3206D

SMC 106L - B301 4241.280 OVUR 3206D
SMC 106E - B301 4241.281 OVUR 4107D
SMC 106E - B314 4241.280 OVUR 3206D
SMC 106S - B302 4241.280 OVUR 3206D
SMC 106L - B302 4241.280 OVUR 3206D
SMC 106E - B302 4241.281 OVUR 4107D
SMC 106E - B315 4241.280 OVUR 3206D

SMC 108S - B301 4241.280 OVUR 3206D

SMC 108L - B301 4241.280 OVUR 3206D
SMC 108E - B301 4241.281 OVUR 4107D
SMC 108E - B314 4241.280 OVUR 3206D
SMC 108S - B302 4241.280 OVUR 3206D
SMC 108L - B302 4241.280 OVUR 3206D
SMC 108E - B302 4241.281 OVUR 4107D
SMC 108E - B315 4241.280 OVUR 3206D

SMC 112S - B301 4241.281 OVUR 4107D

SMC 112L - B301 4241.281 OVUR 4107D
SMC 112E - B305 4241.342 OVUR 5008 HP
SMC 112E - B314 4241.281 OVUR 4107D
SMC 112S - B302 4241.281 OVUR 4107D
SMC 112L - B302 4241.281 OVUR 4107D
SMC 112E - B308 4241.342 OVUR 5008 HP
SMC 112E - B315 4241.281 OVUR 4107D

SMC 116S - B301 4241.281 OVUR 4107D

SMC 116L - B301 4241.281 OVUR 4107D
SMC 116E - B301 4241.282 OVUR 6006D
SMC 116E - B305 4241.342 OVUR 5008 HP
SMC 116E - B314 4241.281 OVUR 4107D
SMC 116S - B302 4241.281 OVUR 4107D
SMC 116L - B302 4241.281 OVUR 4107D
SMC 116E - B302 4241.282 OVUR 6006D
SMC 116E - B308 4241.342 OVUR 5008 HP
SMC 116E - B315 4241.281 OVUR 4107D

178/288 0178-931 - ENG

Rev. 27.10.03
 SMC /TSMC 100 Mk4 - Engineering Manual
6. Technical Data

Code no. Part no. Type Refr.

TSMC 108S-B301 4241.279 OVUR 2106D

TSMC 108L-B301 4241.279 OVUR 2106D
TSMC 108E-B301 4241.279 OVUR 2106D
TSMC 108S-B311 4241.279/4241.280 OVUR 2106D/OVUR 3206D
TSMC 108L-B311 4241.279/4241.280 OVUR 2106D/OVUR 3206D
TSMC 108E-B311 4241.279/4241.280 OVUR 2106D/OVUR 3206D
TSMC 108S-B302 4241.279 OVUR 2106D
TSMC 108L-B302 4241.279 OVUR 2106D
TSMC 108E-B302 4241.279 OVUR 2106D
TSMC 108S-B312 4241.279/4241.280 OVUR 2106D/OVUR 3206D
TSMC 108L-B312 4241.279/4241.280 OVUR 2106D/OVUR 3206D
TSMC 108E-B312 4241.279/4241.280 OVUR 2106D/OVUR 3206D

TSMC 116S-B301 4241.280 OVUR 3206D

TSMC 116L-B301 4241.280 OVUR 3206D
TSMC 116E-B301 4241.280 OVUR 3206D
TSMC 116S-B311 4241.280/4241.281 OVUR 3206D/OVUR 4107D
TSMC 116L-B311 4241.280/4241.281 OVUR 3206D/OVUR 4107D
TSMC 116E-B311 4241.280/4241.281 OVUR 3206D/OVUR 4107D
TSMC 116S-B302 4241.280 OVUR 3206D
TSMC 116L-B302 4241.280 OVUR 3206D
TSMC 116E-B302 4241.280 OVUR 3206D
06 technical data.fm

TSMC 116S-B312 4241.280/4241.281 OVUR 3206D/OVUR 4107D

TSMC 116L-B312 4241.280/4241.281 OVUR 3206D/OVUR 4107D
TSMC 116E-B312 4241.280/4241.281 OVUR 3206D/OVUR 4107D

For the E - version the following special conditions apply

(TE = evaporating temperature):
SMC 104E: OVUR 3206D
SMC 106E: OVUR 3206D (TE<+15°C) [+59°F]
OVUR 4107D (TE>+15°C) [+59°F]
SMC 108E: OVUR 3206D (TE<+5°C) [+41°F]
OVUR 4107D (TE>+5°C) [+41°F]
SMC 112E: OVUR 4107D (TE<+10°C) [+50°F]
OVUR 5008D (TE>+10°C) [+50°F
SMC 112E: OVUR 4107D (TE<0°C) [+32°F]
OVUR 5008D (0°C<TE<+20°C) [+32°F<TE<+68°F]
OVUR 6006D (TE>+20°C) [+68°F]

0178-931 - ENG 179/288

Rev. 27.10.03
SMC /TSMC 100 Mk4 - Engineering Manual
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. The oil changes viscosity within a few operat-
ing hours.
d. The oil dissolves (becomes very black).
The problems have been observed in connection
with several different types of mineral oil and often
occur within only a few operating hours. The con-
sequences have been severe for both compres-
sors and plants.
On the basis of the thorough investigation subse-
quently carried out by YORK Refrigeration, it was
decided to introduce a series of synthetic oils
complying with the requirements of modern refrig-
eration plants.
Mineral oils can, however, still be used in refriger-
ation plants, provided the lubricating quality is
carefully monitored. For modern high-capacity re-
frigeration plants where a long service life for both
lubricant and moving parts is expected,
YORK Refrigeration recommends the use of syn-
thetic oils.
Areas of application and specifications for the syn-
thetic oils mentioned are described in the follow-
ing pages. Supervisors and/or users of plants are
at liberty to choose between
YORK Refrigeration's own oil brands and alterna-
tive oil brands, provided they comply with the
specifications required.
180/288
General
This recommendation will only deal with the lubri-
cation of the compressor. The performance of the
lubricant in the plant (receiver, evaporator, etc.)
must, however, also be considered.
Lubricating oils with relatively high viscosity must
be used to ensure a satisfactory lubrication of re-
frigeration compressors.
To achieve the best lubrication, the oil must:
• possess the correct viscosity under all
operating conditions.
• possess acceptable viscosity at start-up.
• possess sufficient oxidation stability (the oil
must be free of moisture when charged to
the system).
• possess sufficient chemical stability when
used together with R717.
Moreover, the extent to which different refriger-
ants dissolve in the oil must be determined so that
the oil return system, etc. can be designed to per-
form at its optimum.
Stratification
Note that the oil in some plants is layered in refrig-
erant receivers and evaporators under certain op-
erating conditions and at certain oil concentra-
tions.
Plants with Several Different Compressor
Types/Makes
In plants where several different compressor
types/makes are connected, it is strongly recom-
mended to use the same type of oil in all the com-
pressors. This is very important where automatic
oil return systems are used.
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 Com-
pressors carefully.
Selecting Lubricating Oil
The correct oil is selected by means of the follow-
ing diagrams. When the general conditions con-
cerning the lubrication of the compressor have
been considered, the specific conditions of the
plant must be taken into account.
Use the oil recommendation diagrams to select
the correct oil code number.
The oil code number consists of letters indicating
the oil type and viscosity number.
Table 6.20
Code Oil types
design
M Mineral oil
06 technical data.fm
A Synthetic oil based on Alkylbenzene
PAO Synthetic oil based on Polyalphaolefin
AP Mixture of A and PAO oils
E Synthetic ester-based lubricants
In the oil recommendation diagrams it is possible
to find the code number best suited for the operat-
ing conditions in question. With the code number
it is possible to select the correct Sabroe oil for the
application in question.
Oil Types and Oil Companies
Due to the large number of oil companies offering
oil for refrigeration plants, it has not been possible
for YORK Refrigeration to test all the different oil
brands on the global market.
It is our experience that certain oil brands can
change character during use and thus no longer
correspond to the specifications stated by the oil
companies on delivery. We have thus experi-
enced changes in specifications as well as formu-
la and performance without having received infor-
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 compa-
ny YORK Refrigeration has therefore developed
a series of three different oils covering most de-
mands. Furthermore, a list of the oils which can be
supplied through YORK Refrigeration has been
prepared. Data for these oils is included in the ta-
ble Data for Sabroe Oils. We recommend that you
use these oils, which can be delivered in 20 litre
pails or 208 litre drums. When ordering, use the
part no. stated in List of Part Numbers for Availa-
ble Sabroe Oils.
It is of course possible to use similar oils from oth-
er oil companies. If this is the case, use the table
Data for Sabroe Oils.
Please note that YORK Refrigeration has not test-
ed other oils than our own brand. Thus we cannot
guarantee the quality, stability or suitability of oth-
er oils. The respective oil companies are thus re-
sponsible for the quality and suitability of the oil
delivered, and if there are any problems with
these oils in the compressor or the refrigeration
plant, contact the oil supplier directly.
When selecting oils from other oil companies,
special attention should be paid to the suitability of
the oil in the compressor and the refrigeration
plant as a whole.
Please note in particular the following points:
• Oil type
• Compressor type
• Miscibility between refrigerant and oil
• Operating data for the compressor
– Discharge gas temperature
– Oil temperature
181/288
SMC /TSMC 100 Mk4 - Engineering Manual
6. Technical Data
– Normal oil temperature in crankcase is
50-60°C
– Max. permitted oil temperature =
set point for alarm
– Min. permitted oil temperature =
set point for alarm - if there is any
• The viscosity of the oil in the compressor
during operation:
– Type of refrigerant and solubility of re-
frigerant in the oil
– Operating temperatures
– Vapour pressure in the oil reservoir
– Suction pressure and oil temperature in
the crankcase
– Compatibility with neoprene O-rings:
The aniline point indicates how the O-
ring material reacts to the oil.
– At an aniline point less than approx.
100°C the material has a tendency to
swell, and at an aniline point higher than
approx. 120°C it has a tendency to
shrink
– Thus it cannot be recommended to
change the oil type from M to PAO with-
out changing the O-rings at the same
time as a leak may otherwise easily oc-
cur in the compressor or the plant.
YORK Refrigeration recommends there-
fore the use of the Sabroe AP68 oil since
this type of oil in this case reduces con-
siderably the risk of leaks. YORK Refrig-
eration can supply a list of operating
data on request.
• Please note the viscosity limits during oper-
ation:
• Optimum viscosity limits =
20 to 50 cSt
182/288
• Max. permitted viscosity = 100 cSt
• Min. permitted viscosity = 10 cSt
• Max. permitted viscosity during start-
up of the compressor = 500 cSt
• Max. refrigerant concentration in the
oil during operation: 25% - also in
case the viscosity requirements have
been met.
Use of Mineral Oil
As described in the introduction, mineral oil in par-
ticular causes serious problems especially in
R717 plants.
When using mineral oil, it is important to monitor
the plant closely. The condition/colour of the oil
must therefore be checked on a weekly basis and
for each 1,000 to 2,000 operating hours oil sam-
ples must be taken for further analysis.
YORK Refrigeration recommends therefore
only to use M oil under moderate operating
conditions - see the following oil recommen-
dation diagrams.
YORK Refrigeration is aware that several custom-
ers have used mineral oils for many years without
any problems. The customers who wish to contin-
ue using mineral oil in existing as well as new
compressors can do so, provided that the com-
pressor type and the operating conditions are sim-
ilar to the existing ones.
YORK Refrigeration has thus decided to market
one brand of mineral oil which has been tested
and found suitable for most of the general refriger-
ation purposes.
In case another brand of mineral oil is used, follow
the specifications on the data pages in this recom-
mendation as a guideline.
Mineral oil can be used in refrigeration plants, pro-
vided the lubricating quality is carefully monitored.
YORK Refrigeration recommends, however, that
0178-931 - ENG
Rev. 27.10.03
 SMC /TSMC 100 Mk4 - Engineering Manual
6. Technical Data

you use synthetic oils for modern high-capacity Fig. 6.64

TC
plants where a long service life for both lubricant
°F °C
and moving parts is expected.
122 50

The advantage of using synthetic lubricating oils is 104 40

a much lower oil consumption and longer oil 86 30

changing intervals. Improved viscosity at low tem- 68 20 1

peratures facilitates furthermore drainage at the
50 10
cold parts of the plants.
32 0

How to Use the Diagrams in the Oil 14 -10

Recommendation: -4 -20

To find the correct code number, select refriger- -22 -30

°C
ant and compressor type in the oil recommenda- -60 -50 -40 -30 -20 -10 0 10 20
TE
-76 -58 -40 -22 -4 14 32 50 68 °F
tion diagram. Then insert the estimated operating C

conditions in the diagram.

By using the table which is situated next to the oil
Example (reciprocating compressors):
R717 recommendation diagram, select the recommend-
Refrigerant
ed code number and thus the recommended oil. In
Condensing temperature: TC +35 °C
06 technical data.fm

the example above there are thus 3 possibilities:

Evaporating temperature: TE -20 °C
Note: Sometimes plants operate under different
conditions, e.g. different evaporating tempera-
tures due to variations in the plant, or different
condensing temperatures as a result of seasonal
changes. By inserting TC and TE in the oil recom-
mendation diagram, the recommended area is
found. In this case it is oil area 1. If the intersection
is outside the area, contact YORK Refrigeration
for a detailed calculation by means of the calcula-
tion program COMP1.
PAO3, AP1 or M1. However, M1 is only recom-
mended for moderately loaded compressors.
Table 6.21
Code no. Area no. 1
PAO3 ▲
AP1 ✩/▲
M1 See note
Oil Change on Sabroe Compressors
Never change to another oil type without contact-
ing the oil supplier. Nor is it advisable to recharge
a compressor with another oil type than the one
already used for the plant or compressor in ques-
tion.
Mixing different oils may result in operating prob-
lems in the refrigeration plant or damage to the
compressor. Incompatibility between different oil
types may reduce the lubricating properties con-
siderably and may cause oil residues to form in
the compressor, oil separator or plant. Oil resi-

0178-931 - ENG 183/288

Rev. 27.10.03
SMC /TSMC 100 Mk4 - Engineering Manual
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 ob-
tained from YORK Refrigeration as well as a
number of oil companies.
It is extremely important that the new unused oil is
taken directly from its original container and that
both the brand and the type correspond to the
specifications of the plant.
184/288
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, particular-
ly polyolester oils, are extremely hygroscopic. It is
therefore recommended only to buy the oil in con-
tainers whose size correspond to the amount to
be used.
In case all of the oil is not used, make sure that the
rest of the oil is sealed in the original container
and stored in a warm, dry place. It is recommend-
ed to charge nitrogen to keep the water content
below 50 ppm.
Ideally, oil containers should be equipped with a
barrel tap to ensure an effective, airtight seal.
0178-931 - ENG
Rev. 27.10.03
 SMC /TSMC 100 Mk4 - Engineering Manual
6. Technical Data

Oil Changing Intervals It is strongly recommended to monitor the quality

A list of the recommended oil changing intervals is of the oil by performing oil analyses on a regular
included in the instruction manuals of the com- basis. This will also give an indication of the con-
pressors. This list is for guidance only. The actual dition of the plant. This service can be supplied by
oil changing intervals are often determined by a YORK Refrigeration or the oil supplier.
number of operating parameters in the plant.
Oil recommendation diagram symbols:
▲ In case of a new plant. Very suitable.
✩ In case you wish to change from mineral oil
a Max oil concentration in liquid phase at: TE: 2% W
b Max oil concentration in liquid phase: contact YORK Refrigeration
c Min. suction temperature -50°C. At TE< -50°C superheating must be introduced.
Dry expansion systems only. Flooded systems to be considered individually: contact
*
YORK Refrigeration
SH Suction gas superheat, K (Kelvin)
L Zone in which both oils are useable
06 technical data.fm

M Calculation must be performed using COMP1

0178-931 - ENG 185/288

Rev. 27.10.03
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 cSt Index grav. at COC °C °C mg
40°C 100°C 15°C °C point KOH/g
M1 63 6.4 14 0.91 202 -36 81 0.02
A3 97 8.1 13 0.86 206 -32 78 0.05
AP1 64 9.3 121 0.858 195 -51 121 0.04
PAO3 66 10.1 136 0.835 266 <-45 138 0.03
PAO5 94 13.7 147 0.838 255 <-45 144 0.03
PAO9 208 25 149 0.846 260 <-39 154 0.03
E3
E5 Due to the great difference between polyolester-based lubricants from various suppliers, it is not pos-
sible to present any typical data for these oils. When using another oil brand than the one recommend-
E9 ed 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 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) 1231-279
Sabroe H oil E11 (E370) 3914 1512 954 1) 9415 0008 000

1) 18.9 litre pail (5 US gallons)

06 technical data.fm

The oils recommended by the former Stal Refrigeration correspond to the following oils:
Stal Refrigeration oil type Sabroe oil
A Mobil Gargoyle Arctic 300 - M1 (M68)
B Sabroe Oil PAO 68 - PAO 3 (PAO 68)
C Mobil Gargoyle Arctic SHC 230 - PAO 9 (PAO 220)
H Sabroe H oil - E 11 (E 370)

0178-931 - ENG 187/288

Rev. 27.10.03
SMC /TSMC 100 Mk4 - Engineering Manual
6. Technical Data

R717 TC

°F °C
one-stage
122 50
reciprocating
compressor 104 40
Condensing temperature

86 30

68 20 1

50 10

32 0

14 -10

-4 -20

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

Code no Area no 1

PAO 3 s

AP 1 ✩/▲
M1 See note

Note: YORK Refrigeration recommends that the use of M oil is restricted to moderately loaded
compressors and that the oil quality is monitored carefully via regular oil analyses.

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

two-stage °F °C
reciprocating 122 50
compressors
104 40
Condensing temperature

86 30
1
68 20

50 10

32 0

14 -10

-4 -20
06 technical data.fm

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

Code no Area no 1

PAO 3 s

AP 1 ✩/▲
M1 See note

Note: YORK Refrigeration recommends that the use of M oil is restricted to moderately loaded
compressors and that the oil quality is monitored carefully via regular oil analyses.

j: Very suitable in case of a new plant.

✩: In case you wish to change from mineral oil.

0178-931 - ENG 189/288

Rev. 27.10.03
SMC /TSMC 100 Mk4 - Engineering Manual
6. Technical Data

R717 TC

°F °C
HPO and HPC
reciprocating 176 80
compressors
158 70
Condensing temperature

140 60
1
122 50

104 40

86 30

68 20

50 10

32 0
-30 -20 -10 0 10 20 30 40 50 °C
TE
-22 -4 14 32 50 68 86 104 122 °F
Evaporating temperature

Code no Area no 1

PAO 5 ▲

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 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 ap-
proved by YORK Refrigeration. The following list includes the information provided by the oil companies.
The oil companies are responsible for the information concerning the durability and suitability of their oils
for specific purposes. Oils tested and approved by YORK Refrigeration are included in the "List of Part
Numbers for Available Sabroe Oils".
Oil Company Oil Types
M A PAO AP E
Aral • •
Avia •
BP • • • •
Castrol • • • •
Chevron (UK: Gulf Oil) • • •
CPI Engineering Services • • •
DEA • • • •
Elf / Lub Marine 1 • • •
Esso/Exxon • • •
06 technical data.fm

Fina • • •
Fuchs • • • •
Hydro-Texaco • • • •
ICI •
Kuwait Petroleum (Q8) • •
Mobil • • • • •
Petro-Canada •
Shell • • • •
Statoil • •
Sun Oil • •

0178-931 - ENG 191/288

Rev. 27.10.03
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 operat-
ing hours.
f. The oil dissolves becomes very black).
The problems have been observed in connection
with several different types of mineral oil and often
occur within only a few operating hours. The con-
sequences have been severe for both compres-
sors and plants.
On the basis of the thorough investigation subse-
quently carried out by YORK Refrigeration, it was
decided to introduce a series of synthetic oils
complying with the requirements of modern refrig-
eration plants.
Mineral oils can, however, still be used in refriger-
ation plants, provided the lubricating quality is
carefully monitored. For modern high-capacity re-
frigeration plants where a long service life for both
lubricant and moving parts is expected, YORK
Refrigeration recommends the use of synthetic
oils.
Areas of application and specifications for the syn-
thetic oils mentioned are described in the follow-
ing pages. Supervisors and/or users of plants are
at liberty to choose between YORK Refrigera-
tion's own oil brands and alternative oil brands,
provided they comply with the specifications re-
quired.
General
This recommendation will only deal with the lubri-
cation 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 re-
frigeration compressors.
To achieve the best lubrication, the oil must:
• possess the correct viscosity under all oper-
ating conditions.
• possess acceptable viscosity at start-up.
• possess sufficient oxidation stability (the oil
must be free of moisture when charged to
the system).
• possess sufficient chemical stability when
used together with HFC/HCFC.
Moreover, the extent to which different refriger-
ants dissolve in the oil must be determined so that
the oil return system, etc. can be designed to per-
form at its optimum.
Stratification
Note that the oil in some plants is layered in refrig-
erant receivers and evaporators under certain op-
erating conditions and at certain oil concentra-
tions. This applies in particular to HFC/HCFC
plants.
The oil recommendation diagrams for SABROE
compressors with HFC and HCFC refrigerants in-
dicate the limits for Sabroe oils where stratification
occurs. The oil concentrations stated in these dia-
grams must not be exceeded. This makes it pos-
sible to adjust the oil rectification/return systems
to the oil consumption of the compressor so that
the maximum concentration is not exceeded. For
area A in the diagrams, the oil concentration in the
liquid phase must not exceed 2%. For the other
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 recom-
mended to use the same type of oil in all the com-
pressors. This is very important where automatic
oil return systems are used.
If you consider changing the type of oil, please
read the section Oil Changing on SABROE Com-
pressors carefully.
Selecting Lubricating Oil
The correct oil is selected by means of the follow-
ing diagrams. When the general conditions con-
cerning the lubrication of the compressor have
been considered, the specific conditions of the
06 technical data.fm
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 Oil types
design
M Mineral oil
A Synthetic oil based on Alkylbenzene
PAO Synthetic oil based on Polyalphaolefin
AP Mixture of A and PAO oils
E Synthetic ester-based lubricants
In the oil recommendation diagrams it is possible
to find the code number best suited for the operat-
ing conditions in question. With the code number
it is possible to select the correct Sabroe oil for the
application in question.
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 experi-
enced changes in specifications as well as formu-
la and performance without having received infor-
mation on this beforehand from the oil company.
This makes it extremely difficult for
YORK Refrigeration to give a general approval of
other oil brands.
In co-operation with a large, respected oil compa-
ny YORK Refrigeration has therefore developed
a series of three different oils covering most de-
mands. Furthermore, a list of the oils which can be
supplied through YORK Refrigeration has been
prepared. Data for these oils is included in the ta-
ble Data for Sabroe Oils. We recommend that you
use these oils, which can be delivered in 20 litre
pails or 208 litre drums. When ordering, use the
part no. stated in List of Part Numbers for Availa-
ble Sabroe Oils.
It is of course possible to use similar oils from oth-
er oil companies. If this is the case, use the table
Data for Sabroe Oils.
Please note that YORK Refrigeration has not test-
ed other oils than our own brand. Thus we cannot
guarantee the quality, stability or suitability of oth-
er oils. The respective oil companies are thus re-
sponsible for the quality and suitability of the oil
delivered, and if there are any problems with
these oils in the compressor or the refrigeration
plant, contact the oil supplier directly.
When selecting oils from other oil companies,
special attention should be paid to the suitability of
193/288
SMC /TSMC 100 Mk4 - Engineering Manual
6. Technical Data
the oil in the compressor and the refrigeration
plant as a whole.
Please note in particular the following points:
• Oil type
• Refrigerant type
• Compressor type
• Miscibility between refrigerant and oil
• Operating data for the compressor
– Discharge gas temperature
– Oil temperature
– Normal temperature in the crank case is
50-60°C
– Max. permitted oil temperature =
set point for alarm.
– Min. permitted oil temperature =
set point for alarm - if there is any
• The viscosity of the oil in the compressor
during operation and under the influence of:
– Type of refrigerant and solubility of re-
frigerant in the oil
– Operating temperatures
– Vapour pressure in the oil reservoir
– Suction pressure and oil temperature in
the crankcase
– Compatibility with neoprene O-rings:
The aniline point indicates how the
O-ring material reacts to the oil.
At an aniline point less than approx. 100°C
the material has a tendency to swell, and at
an aniline point higher than approx. 120°C it
has a tendency to shrink.
Thus it cannot be recommended to change
the oil type from M to PAO without changing
the O-rings at the same time as a leak may
otherwise easily occur in the compressor or
194/288
the plant. YORK Refrigeration recommends
therefore the use of the Sabroe AP68 oil
since this type of oil in this case reduces
considerably the risk of leaks.
YORK Refrigeration can supply a list of op-
erating data on request.
• Please note the viscosity limits during oper-
ation:
• Optimum viscosity limits
= 20 to 50 cSt
• Max. permitted viscosity = 100 cSt
• Min. permitted viscosity = 10 cSt
• Max. permitted viscosity during start-
up of the compressor = 500 cSt
• Max. refrigerant concentration in the
oil during operation: 25% - also in
case the viscosity requirements have
been met.
Use of Mineral Oil
As described in the introduction, mineral oil in par-
ticular causes serious problems especially in
R717 plants.
When using mineral oil, it is important to monitor
the plant closely. The condition/colour of the oil
must therefore be checked on a weekly basis and
for each 1,000 to 2,000 operating hours oil sam-
ples must be taken for further analysis.
YORK Refrigeration recommends therefore
only to use M oil under moderate operating
conditions - see the following oil
recommendation diagrams.
YORK Refrigeration is aware that several custom-
ers have used mineral oils for many years without
any problems. The customers who wish to contin-
ue using mineral oil in existing as well as new
compressors can do so, provided that the com-
pressor type and the operating conditions are sim-
ilar to the existing ones.
0178-931 - ENG
Rev. 27.10.03
 SMC /TSMC 100 Mk4 - Engineering Manual
6. Technical Data

YORK Refrigeration has thus decided to market Fig. 6.65

one brand of mineral oil which has been tested R134a
TC
and found suitable for most of the general refriger-
°F °C
ation purposes. 158 70

In case another brand of mineral oil is used, follow 140 60

the specifications on the data pages in this recom- 122 50

Condensing temperature
mendation as a guideline. 104 40
w w
86 30
Mineral oil can be used in refrigeration plants, pro-
68 20
vided the lubricating quality is carefully monitored.
50 10
YORK Refrigeration recommends, however, that
32 0
you use synthetic oils for modern high-capacity
14 10
plants where a long service life for both lubricant
4 20
and moving parts is expected.
22 30

The advantage of using synthetic lubricating oils is

60 50 40 30 20 10 0 10 20 30 °C
a much lower oil consumption and longer oil 76 58 40 22 4 14 32 50 68 86 °F
TE

changing intervals. Improved viscosity at low tem- Evaporating temperature

peratures facilitates furthermore drainage at the

By using the table which is situated next to the oil
06 technical data.fm

cold parts of the plants.

recommendation diagram, select the recommend-
How to Use the Diagrams in the Oil ed code number and thus the recommended oil. In
Recommendation: the example above an oil with code number E5
To find the correct code number, select refrigerant can be used.
and compressor type in the oil recommendation
Table 6.23
diagram. Then insert the estimated operating con-
ditions in the diagram. Code no. Area no.

Example (reciprocating compressors):
Refrigerant R134a
Condensing temperature: TC +35 °C
Evaporating temperature: TE -3°C
Note: Sometimes plants operate under different
conditions, e.g. different evaporating tempera-
tures due to variations in the plant, or different
condensing temperatures as a result of seasonal
changes. By inserting TC and TE in the oil recom-
mendation diagram, the recommended area is
found. In this case it is oil area 1. If TC should
change, e.g. from -3°C to +7°C, use oil area 2. As
+7°C is within the marked area, oil area 1 can,
however, also be used at this TE.
1 2
E5 ▲
E9 ▲
Oil Change on Sabroe Compressors
Never change to another oil type without contact-
ing the oil supplier. Nor is it advisable to recharge
a compressor with another oil type than the one
already used for the plant or compressor in ques-
tion.
Mixing different oils may result in operating prob-
lems in the refrigeration plant or damage to the
compressor. Incompatibility between different oil
types may reduce the lubricating properties con-
siderably and may cause oil residues to form in

0178-931 - ENG 195/288

Rev. 27.10.03
SMC /TSMC 100 Mk4 - Engineering Manual
6. Technical Data
the compressor, oil separator or plant. Oil resi-
dues may block filters and damage the moving
parts of the compressor.
Changing the oil type or brand should only be
done following a thorough procedure involving
drainage and evacuation of the refrigeration plant.
Information on a suitable procedure can be ob-
tained from YORK Refrigeration as well as a
number of oil companies.
It is extremely important that the new unused oil is
taken directly from its original container and that
both the brand and the type correspond to the
specifications of the plant.
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, particular-
ly polyester oils, are extremely hygroscopic. It is
therefore recommended only to buy the oil in con-
tainers whose size correspond to the amount to
be used.
In case all of the oil is not used, make sure that the
rest of the oil is sealed in the original container
and stored in a warm, dry place. It is recommend-
ed to charge nitrogen to keep the water content
below 50 ppm.
Ideally, oil containers should be equipped with a
barrel tap to ensure an effective, airtight seal.
0178-931 - ENG
Rev. 27.10.03
 SMC /TSMC 100 Mk4 - Engineering Manual
6. Technical Data

Oil Changing Intervals It is strongly recommended to monitor the quality

A list of the recommended oil changing intervals is of the oil by performing oil analyses on a regular
included in the instruction manuals of the com- basis. This will also give an indication of the con-
pressors. This list is for guidance only. The actual dition of the plant. This service can be supplied by
oil changing intervals are often determined by a YORK Refrigeration or the oil supplier..
number of operating parameters in the plant.
Oil recommendation diagram symbols:
▲ In case of a new plant. Very suitable.
✩ In case you wish to change from mineral oil
a Max oil concentration in liquid phase at: TE: 2% W
b Max oil concentration in liquid phase: contact YORK Refrigeration
c Min. suction temperature -50°C. At TE< -50°C superheating must be introduced.
Dry expansion systems only. Flooded systems to be considered individually: contact
*
YORK Refrigeration
SH Suction gas superheat, K (Kelvin)
L Zone in which both oils are useable
06 technical data.fm

M Calculation must be performed using COMP1

0178-931 - ENG 197/288

Rev. 27.10.03
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 cSt Index grav. at COC °C °C mg
40°C 100°C 15°C °C point KOH/g
M1 63 6.4 14 0.91 202 -36 81 0.02
A3 97 8.1 13 0.86 206 -32 78 0.05
AP1 64 9.3 121 0.858 195 -51 121 0.04
PAO3 66 10.1 136 0.835 266 <-45 138 0.03
PAO5 94 13.7 147 0.838 255 <-45 144 0.03
PAO9 208 25 149 0.846 260 <-39 154 0.03
E3
E5 Due to the great difference between polyolester-based lubricants from various suppliers, it is not pos-
sible to present any typical data for these oils. When using another oil brand than the one recommend-
E9 ed 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 Refrigera-
tion'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) 1231-279
Sabroe H oil E11 (E370) 3914 1512 954 1) 9415 0008 000

1) 18.9 litre pail (5 US gallons)

06 technical data.fm

The oils recommended by the former Stal Refrigeration correspond to the following oils:
Stal Refrigeration oil type Sabroe oil
A Mobil Gargoyle Arctic 300 - M1 (M68)
B Sabroe Oil PAO 68 - PAO 3 (PAO 68)
C Mobil Gargoyle Arctic SHC 230 - PAO 9 (PAO 220)
H Sabroe H oil - E 11 (E 370)

0178-931 - ENG 199/288

Rev. 27.10.03
SMC /TSMC 100 Mk4 - Engineering Manual
6. Technical Data

ContactYORK Refrigeration
TC
R22 °F °C

one-stage 122 50 2
reciprocating
104 40
compressors
Condensing temperature

86 30
1
68 20

50 10

32 0

14 -10 A

-4 -20

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

Code no Area no 1

A3 ▲

▲: Very suitable in case of a new plant.

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

200/288 0178-931 - ENG

Rev. 27.10.03
 SMC /TSMC 100 Mk4 - Engineering Manual
6. Technical Data

R22 TC

°F °C
two-stage
reciprocating 122 50

compressors
104 40

Condensing temperature
86 30 1
A

68 20

50 10

32 0

14 -10

-4 -20

-22 -30
°C
06 technical data.fm

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

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

Code no Area no 1

A3 ▲

▲: Very suitable in case of a new plant.

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

0178-931 - ENG 201/288

Rev. 27.10.03
SMC /TSMC 100 Mk4 - Engineering Manual
6. Technical Data

TC
R134a °F °C

one-stage 158 70
reciprocating 140 60 2
compressors
122 50
Condensing temperature

104 40

86 30

68 20 1
50 10

32 0

14 -10

-4 -20

-22 -30

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

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

Code no Area no

1 2

E5 ▲

E9 ▲

▲: Very suitable in case of a new plant.

L: 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
two-stage 158 70
reciprocating
140 60
compressors
122 50
1
Condensing temperature

104 40

86 30

68 20

50 10

32 0

14 -10

-4 -20
06 technical data.fm

-22 -30

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

E5 ▲

▲: Very suitable in case of a new plant.

0178-931 - ENG 203/288

Rev. 27.10.03
SMC /TSMC 100 Mk4 - Engineering Manual
6. Technical Data

R407C TC

°F °C
one-stage
reciprocating 122 50
compressors
104 40
Condensing temperature

86 30

68 20
1
50 10

32 0

14 -10
B
-4 -20

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

Code no Area no

E3 ▲

▲: : Very suitable in case of a new plant.

b: Max oil concentration in liquid phase: contact YORK Refrigeration
c: Min suction temperature -50°C. At TE<-50°C 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 °C
two-stage
122 50
reciprocating
compressors 104 40

Condensing temperature
86 30
1
B
68 20

50 10

32 0

14 -10

-4 -20

-22 -30
°C
06 technical data.fm

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

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

Code no Area no

E3 ▲

▲: : Very suitable in case of a new plant.

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

0178-931 - ENG 205/288

Rev. 27.10.03
SMC /TSMC 100 Mk4 - Engineering Manual
6. Technical Data

R404A TC

°F °C
one-stage
122 50
reciprocating
compressors 104 40 2
Condensing temperature

86 30

68 20

50 10 1

32 0

14 -10

-4 -20

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

Code no Area no

1 2

E3 ▲

E5 ▲

▲: : Very suitable in case of a new plant.

c: Min suction temperature -50°C. At TE<-50°C superheating must be introduced
L: 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 °C
two-stage 122 50
reciprocating
compressors 104 40
Condensing temperature
86 30
1
68 20

50 10

32 0

14 -10

-4 -20

-22 -30
06 technical data.fm

-60 -50 -40 -30 -20 -10 0 10 20 °C

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

Code no Area no

E3 ▲

▲: : Very suitable in case of a new plant.

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

0178-931 - ENG 207/288

Rev. 27.10.03
SMC /TSMC 100 Mk4 - Engineering Manual
6. Technical Data

R410A TC

°F °C
HPO and HPC
reciprocating 122 60

compressors 50
104
Condensing temperature

40
86
30
68 20

10 1
50

0
32
A
-10
14
-20
-4
-30

-22 -40

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

-76 -58 -40 -22 -4 14 32 50 68 °F

Code no Area no Evaporating temperature
1

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 °C
one-stage
122 50
reciprocating
compressors 104 40
Condensing temperature
86 30

68 20
1
50 10

32 0

14 -10

-4 -20

-22 -30
°C
06 technical data.fm

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

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

Code no Area no

E5 ▲

▲: : Very suitable in case of a new plant.

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

0178-931 - ENG 209/288

Rev. 27.10.03
SMC /TSMC 100 Mk4 - Engineering Manual
6. Technical Data

R507 TC

°F °C
two-stage
122 50
reciprocating
compressors 104 40
Condensing temperature

86 30
1
68 20

50 10

32 0

14 -10

-4 -20

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

Code no Area no

E5 ▲

▲: : Very suitable in case of a new plant.

c: Min suction temperature -50°C. At TE<-50°C 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 ap-
proved by YORK Refrigeration. The following list includes the information provided by the oil companies.
The oil companies are responsible for the information concerning the durability and suitability of their oils
for specific purposes. Oils tested and approved by YORK Refrigeration are included in the "List of Part
Numbers for Available Sabroe Oils".
Oil Company Oil Types
M A PAO AP E
Aral • •
Avia •
BP • • • •
Castrol • • • •
Chevron (UK: Gulf Oil) • • •
CPI Engineering Services • • •
DEA • • • •
Elf / Lub Marine 1 • • •
Esso/Exxon • • •
06 technical data.fm

Fina • • •
Fuchs • • • •
Hydro-Texaco • • • •
ICI •
Kuwait Petroleum (Q8) • •
Mobil • • • • •
Petro-Canada •
Shell • • • •
Statoil • •
Sun Oil • •

0178-931 - ENG 211/288

Rev. 27.10.03
SMC /TSMC 100 Mk4 - Engineering Manual
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:
• the dangers which may occur when the in-
structions and safety precautions pertaining
to the installation phase are not followed,
• how to install the equipment in a safe and ef-
fective way.
This document is intended primarily for the instal-
lation supervisors, installation technicians and
electricians. It can also be used in sales activities
to inform future customers of the requirements
made in connection with the installation of a com-
pressor unit.
YORK Refrigeration
Chr. X’s Vej 201
07 installation instructions.fm
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 equip-
ment! Always read the safety precautions belong-
ing to this equipment before starting the installa-
tion process. Failure to comply with safety precau-
tions may cause death or injury to personnel. It
may also cause damage to or destruction of the
equipment.
0178-931 - ENG
Rev. 27.10.03
Safety Precautions
Read Section 3, Safety Precautions, carefully be-
fore commencing the installation. If in doubt,
please contact YORK Refrigeration.
The safety precautions and instructions pertaining
to the individual sections of this document must
also be read and followed.
Installation Data
The physical data of the compressor are included
in Section 5, Physical and Connection Data. See
also Section 6, Technical Data - Noise from com-
pressors and units, Laying the foundation.
Installation 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 refrigera-
tion technique, possess knowledge of refrigera-
tion systems and have experience with pipe as
well as wiring installations. Where authorisation is
required, the electrician must possess an ap-
proved authorisation.
The compressors must only be connected by
an authorised refrigeration company.
213/288
SMC /TSMC 100 Mk4 - Engineering Manual
7. Installation Instructions
Preparing the Installation
This section describes the preparations which
must be carried out before commencing the instal-
lation.
Tools and Accessories
The list below shows the tools, accessories and
materials which are necessary in order to carry
out the installation correctly.
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.
Safety Equipment
WDanger!
Risk of injury to personnel and damage to equip-
ment! Always read the safety precautions belong-
ing to this equipment before start. Failure to com-
ply with safety precautions may cause death or in-
jury to personnel. It may also cause damage to or
destruction of the equipment.
When installing the equipment, use the following
safety equipment which must be in good condi-
tion:
214/288
– Safety shoes
– Gloves
– Eye protectors
– Fire-fighting appliances
– Salt water solution for eye rinsing
– Oxygen equipment
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 Di-
agrams. Note in particular the minimum distanc-
es, which must ensure that the compressor can be
serviced under all kinds of conditions, e.g. re-
placement of crank shaft or filter insert. The piping
must be laid in such a way that the access to the
top covers is not obstructed.
Preparing the Mounting Site
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 pre-
vent unauthorised personnel from being in-
jured or causing damage.
4. The mounting site must be cleared.
0178-931 - ENG
Rev. 27.10.03
 SMC /TSMC 100 Mk4 - Engineering Manual
7. Installation Instructions

Lifting Accessories and Equipment – Cooling water hoses for cooling of top
See Section 14, Transport Instructions. and side covers.
– Vibration dampers as well as drawing in-
Preparing Lifts dicating the position of the dampers.

See Section 14, Transport Instructions.

Disposal of Materials which are not
Reusable
Lifting and Loading Instructions
Materials from the packing of the unit which can-
See Section 14, Transport Instructions.
not be reused must be disposed of according to
local regulations.
Unpacking and Inspection
On receipt the unit is wrapped in PE plastic film. Moving the Equipment to the Mounting
After unpacking the unit, check for transport dam- Site after Unloading and Unpacking
age. Check also whether the delivered goods cor-
After unloading and unpacking the unit, it must
respond to the specification. Check in particular
only be lifted in the lifting eyes welded on the
that the control system and valves fitted on the
07 installation instructions.fm

frame. If the unit is moved with e.g. a forklift truck,

outside of the unit are not damaged. It must also
it must be placed on a pallet intended for the pur-
be checked whether the following parts are includ-
pose. Secure the unit so that it does not tip over
ed:
when starting, turning and braking the forklift
– Intermediate piece for coupling, inner truck. Do not lift directly under the unit.
and outer screen and perhaps loose
coupling hub for motor.

0178-931 - ENG 215/288

Rev. 27.10.03
SMC /TSMC 100 Mk4 - Engineering Manual
7. Installation Instructions
Installation Instructions
WDanger!
Risk of injury to personnel and damage to equip-
ment! Always read the safety precautions belong-
ing to this equipment before start. Failure to com-
ply with safety precautions may cause death or in-
jury to personnel. It may also cause damage to or
destruction of the equipment.
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 deliv-
ery. The following sections will deal with the indi-
vidual 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 sup-
porting surfaces.
The unit can be mounted in the following ways:
• on vibration dampers.
• directly on the foundation with foundation
bolts.
With both methods the unit must be set up before
the pipes are connected to the plant.
Depending on whether the unit is to be used on
land or on a ship, vibration dampers are supplied
as shown in the drawing Fig. 7.1.
The purpose of the vibration dampers is to damp-
en the vibrations from the unit to the foundation.
Moreover, the marine vibration dampers must
dampen the vibrations from the foundation to the
compressor unit and at the same time secure the
unit to the foundation.
It is very important that the vibration dampers are
placed correctly as illustrated in the drawing for-
warded to the customer or the dealer. This draw-
ing applies only to the unit in question.
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

2
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 where-
Industrial type Marine type
as 60 indicates the rubber hardness and is thus an
1 2
expression of bearing and damping capacity.
Flexion min 1.0 min 3.0
When using vibration dampers, the foundation is max 5.0
A1A2 max 2.0
assumed to have the necessary bearing strength
and to be level enough to enable adjustment of Height Hmax= H+12 with disks
the vibration dampers to be made within the ad- adjustment supplied as
shown
justing measurements stated on the drawing sub-
mitted. The flexion of a damper is adjusted by increasing
In order for the individual vibration damper to or decreasing the load in relation to the other sup-
dampen properly, a sufficient load must be im- ports. The foot can be raised by lowering the ad-
posed: Measure A1 and H (unloaded position) justing rod or inserting more disks between damp-
and A2 (loaded position) as shown in drawing er and foot (marine design), thereby increasing
Fig. 7.1. the load and hence also the flexion.
Once the installation has cooled down, check dur-
ing operation that the flexion of the dampers is still
correct!

0178-931 - ENG 217/288

Rev. 27.10.03
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 accord-
ance with the foundation drawing forwarded.
When the foundation has been cast - with the
holes shown for the foundation bolts - and has
cured, place the unit in a position allowing it to rest
on beams levelled at a suitable height so that the
foundation plates are recessed slightly into the
foundation.
Check that the foundation plates are right next to
the base frame. This can be achieved by binding
them to the resting surfaces of the base frame by
means of steel flex.
The concrete which is cast down around the foun-
dation bolts should only have minimal water con-
tent to allow it to be rammed well down around the
bolts. Low water content does not cause the hard-
ening concrete to shrink.
10-14 days should pass before removing the
beams and tightening the nuts for the foundation
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 compres-
sor.
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 Before performing any work on the coupling,
motor to make the shaft form an extension of the make sure that the compressor motor cannot start
crankshaft. inadvertently.
Fig. 7.2

1
Z
X 2

a
07 installation instructions.fm

B A
F C

Table 7.1
Distance mm Torque Nm
Coupling
Compressor C F A B D
size
Nominal*

SMC
312 S 102 25 147 55 44
104-106-108

SMC 112-116 350 S 113 27 147 128 44

* See final installation

0178-931 - ENG 219/288

Rev. 27.10.03
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 re-
duce the transferred torque.
• Place the hub at the compressor side, ob-
serving the measurement "F".
• Tighten the screws "D" crosswise in two or
three steps of torque. Assembly is complet-
ed when no screw can be tightened any fur-
ther (one by one) with tightening torque “D”.
• Place the hub at the motor side. Tighten the
bolts "A" and the pointed screw loosely.
• Mount the retaining plate from the coupling
screen onto the compressor and insert a
support ring for the coupling screen over the
motor flange.
• Assemble the intermediate piece and the la-
mella segments with the 8 screws, applying
the prescribed torque. Remember the
shaped washers facing the lamellas.
220/288
• Insert the coupling intermediate piece. Cre-
ate space between the flanges either by
shifting the entire motor or just the motor
coupling flange.
The intermediate piece should only be
secured to the compressor flange. Do
not insert the last four bolts in the motor
flange until the coupling has been
aligned.
As the compressor shaft rotates during the
alignment procedure, the motor must turn
with it, as the bolts in the intermediate piece
engage in the free holes in the motor cou-
pling flange.
• Line up the motor so that the free holes in
the motor feet are right above the threaded
holes in the base frame.
• Shift the motor coupling flange to make up
distance "C" in table. See Table 7.1.
• Tighten the two bolts and the pointed screw
in the hub.
• Tighten the measuring pin on the coupling
flange of the compressor, as shown in the
drawing.
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 • Insert shims of thickness "y" either under
with all four feet on the base frame. Insert any liner both front feet or both rear feet, thereby tilt-
plates needed where there is an air gap beneath ing the motor in the direction required.
the feet. Tighten the bolts loosely. • Shim thickness "y" is calculated by using the
Achieving parallel shafts in horizontal plane following formula (see also Fig. 7.3):
• Turn the coupling so that the alignment b
gauge is in upper position. See Fig. 7.2. y= X •
2xa
• Guide the measuring pin (pos. 2) towards
Fig. 7.3
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
07 installation instructions.fm

change is called "x".

• Measure the distance “b” between the motor y

feet as shown in Fig. 7.3. Measure the dis-

tance “a” from the centre of the pin pos. 2 to b

the centre of the motor as illustrated in

Fig. 7.2
• 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 Coupling size Pos 1 Pos 2

Horizontal Vertical max.

max. mm min./max. mm mm

SMC
312 S 0.2 0.1/0.3 0.2
104-106-108

SMC 112-116 350 S 0.2 0.1/0.3 0.2

0178-931 - ENG 221/288

Rev. 27.10.03
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 meas-
urement and compare the result with the ta-
ble values in pos. 1 vertical. Remember that
the centreline of the motor shaft must be at
least 0.05 mm higher than the centreline of
the compressor, corresponding to a mini-
mum of 0.1 mm distance less at the top po-
sition of the alignment gauge.
Achieving parallel shafts in vertical
plane
• The motor is now positioned at its correct
height. What remains is to push and turn the
motor at the level on which it is already lined
up.
• Turn the coupling so that the alignment
gauge faces out to one side horizontally.
• Guide both measuring pins towards the cou-
pling with a 1.0 mm feeler gauge in be-
tween.
222/288
• Turn the coupling 180° and by using feeler
gauges measure deviations from one milli-
metre at both pins.
• Move and turn the motor and repeat this
measurement, align the motor in accord-
ance with pos. 1 horizontal and pos. 2 in the
table. Remember that the motor must be
firmly secured during any measurements.
Final installation
• Tighten the foundation bolts on the motor
(see torque table).
• Fit four bolts into the motor coupling flange
so that thin shims are placed between the
flange and the lamellae, with the rounded
side facing lamella.
• Tighten the bolts to torque specified in the
table.
• Readjust the flange distance "C" so that the
lamellae are aligned, by moving the motor
flange on the shaft and fastening the motor
flange.
• Check the alignment of the coupling in hori-
zontal and vertical planes for pos. 1 and
pos. 2.
• Dismantle the measuring pin and tighten the
screw to the prescribed torque.
• Fit the coupling guard.
• Once normal operating temperature has
been achieved, double-check the coupling
alignment.
0178-931 - ENG
Rev. 27.10.03
 SMC /TSMC 100 Mk4 - Engineering Manual
7. Installation Instructions
Preliminary Installation
• Check tightening of coupling flange on com-
pressor.
• Tighten 8 coupling bolts securing lamellar
segments to intermediate piece to pre-
scribed moment stated in table. It is worth-
while doing this before placing the interme-
diate piece in position.
• Mount retaining plate from coupling screen
onto compressor and insert support ring for
coupling screen over motor flange.
• Insert coupling intermediate piece. Create
space between flanges either by shifting en-
tire motor or just motor coupling flange.
The intermediate piece should only be
07 installation instructions.fm
secured to the compressor flange. Do
not insert the last four bolts in the motor
flange until the coupling has been
aligned.
As the compressor shaft rotates during the
alignment procedure, the motor must turn
with it, as the bolts in the intermediate piece
engage in the free holes in the motor cou-
pling flange.
• Line up motor so that free holes in motor
feet are right over threaded holes in base
frame.
• Shift motor coupling flange to achieve dis-
tance "C" in table, Fig. 7.2.
• Tighten two bolts in coupling hub. On
CMO-HPO units, the motor flange must be
correctly positioned before putting the motor
into place.
• Tighten alignment gauge on coupling flange
of compressor as shown in drawing.
0178-931 - ENG
Rev. 27.10.03
Alignment
Check that the motor with loose bolts stands with
all four feet on the base frame. If necessary, insert
any liner plates where there is an air gap beneath
the feet. Tighten the bolts slightly.
Achieving Parallel Shafts in Horizontal
Plane
• Turn coupling so that alignment gauge is in
upper position, Fig. 7.2
• Guide measuring pin (Pos. 2) towards cou-
pling flange by means of a 1.0 mm feeler
gauge and fix pin. Remove feeler gauge.
• Rotate coupling 180° and measure change
in distance from measuring pin to flange by
means of feeler gauges. This change is
called "x".
• Measure the distance b between the feet of
the motor as shown in Fig. 7.4. Measure the
distance a from the centre of the pin pos. 2
to the centre line of the motor as illustrated
in Fig. 7.2
• Insert shims of thickness "y" either under
both front feet or both rear feet, thereby tilt-
ing motor in direction required. Shim thick-
ness "y" is calculated using the following for-
mula (see Fig. 7.4):
b
y = X •
2xa
223/288
SMC /TSMC 100 Mk4 - Engineering Manual
7. Installation Instructions
Fig. 7.4
y
b
• After tightening motor bolts, repeat meas-
urement and compare result with values in
table under Pos. 2, Fig. 7.2
Achieving Correct Centre Height
• Turn coupling so that alignment gauge fac-
es vertically downwards.
• Guide measuring pin (pos. 1) towards cou-
pling flange by means of a 1.0 mm feeler
gauge and fix pin. Remove feeler gauge.
• Rotate coupling 180° and measure increase
in distance "z" from one millimetre by means
of feeler gauges.
• Then lift motor by placing shims of thickness
equal to half value of "z" under all four feet.
• After securing motor, repeat measurement
and compare result with table values in pos.
1 vertical, Fig. 7.2
1. Remember that the centre line of the motor
shaft must be at least 0.05 mm higher than
the centre line of the compressor, corre-
sponding to a minimum of 0.1 mm distance
less at the top position of the alignment
gauge.
Achieving Parallel Shafts in Vertical
Plane
The motor is now positioned at its correct height.
What now remains is to push and turn the motor
at the level on which it is already lined up.
224/288
• Turn coupling so that alignment gauge fac-
es out to one side horizontally.
• Guide both measuring pins towards cou-
pling with a 1.0 mm feeler gauge in be-
tween.
• Turn coupling 180° and measure deviations
from one millimetre at both pins by means of
feeler gauges.
• By moving and turning motor and by
repeating this measurement, align motor in
accordance with pos. 1 horizontal and pos.
2, Fig. 7.2.
2. Remember that the motor must be firmly se-
cured when measuring.
Final Installation
• Tighten foundation bolts on motor (see table
showing the torque for screws and bolts).
• Fit four bolts into motor coupling flange so
that thin shims are placed between flange
and lamellae with rounded side facing la-
mella. There are no thin shims on couplings
for CMO and HPO.
• Tighten bolts to torque specified in table.
• Readjust flange distance "C" so that lamel-
lae are aligned by moving motor flange on
shaft and securing motor flange.
• Check alignment of coupling in horizontal
and vertical planes for pos. 1 and pos. 2,
Fig. 7.2
• Dismantle alignment gauge and tighten
screw to prescribed torque.
• Fit coupling guard.
• Once normal operating temperature has
been achieved, double-check coupling
alignment.
0178-931 - ENG
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 compres-
sive stresses or tensile strains in the event of ex-
pansions or contractions due to temperature
changes. Steel pipes expand approx. 1 mm per
metre per 100°C.
We recommend that piping be laid as shown in ex-
ample 2 of the sketch, Fig. 7.5. Example 1 demon-
strates too rigid pipe laying.
Fig. 7.5
> 1.5 m
07 installation instructions.fm
1 2
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
5.1 Refrigerant Connection to Compres-
sor
The connecting pipe is to be welded onto a
connecting branch on a stop valve. In order
to protect the stop valve when welding, re-
move the insides of the valve. Do not put the
insides back into the valve until the weld has
cooled off - see the instructions from the
valve manufacturer in Section 21, Appendi-
ces.
The welding must be carried out according
to the specifications and standards applying
to the plant in question.
5.2 Refrigerant Connection to Oil Cooler
(OOKH og OSSI)
The connection to the oil cooler is indicated
on the compressor with V for water supply
and Q for return. See section 5, Physical
and Connection Data.
5.3 Connection to Water-Cooled Top
and Side Covers
The water cooling hoses are delivered sep-
arately and connected to top and side cov-
ers according to enclosed mounting instruc-
tions. Connect water supply to the inlet of
the water system and establish return to
drain or the like, e.g. cooling tower for reuse
of the water. Connection dimensions are in-
cluded in Section 5, Physical and Connec-
tion Data. The system is described in detail
in Section 4, Technical Description.
225/288
SMC /TSMC 100 Mk4 - Engineering Manual
7. Installation Instructions

6. Connecting Electricity Supply

Data for the electrical components of the unit and Remember! Check that the direction of rota-
their supply is included in Section 5, Physical and tion is correct - see Section 6, Technical Data -
Connection Data. Direction of Rotation of Electric motor.

WDanger! 6.2 Connecting UNISAB

Two manuals are delivered together with
Risk of injury to personnel and damage to equip- UNISAB II: - Starting-up Manual which is placed
ment! Always read the safety precautions belong- inside the UNISAB II cabinet on delivery.
ing to this equipment before start. Failure to com- - Instruction Manual delivered together with other
ply with safety precautions may cause death or in- documentation.
jury to personnel. It may also cause damage to or
Installation
destruction of the equipment.
UNISAB II is placed on a bracket on the unit, see
Before connecting, make sure that
dimension sketches in Dimensions and Piping Di-
– there is no power on the cables which agrams. To gain access to the terminals, open the
are to be connected, cabinet by loosening the screws which hold the
– the power cannot be connected acciden- operating panel. Lift up the panel as shown in
tally. This can be done by locking the Fig. 7.6 and take out the Starting-up Manual.
switches or placing a sign indicating that The Starting-up Manual includes key diagrams for
the connection in question must not be UNISAB II. These are included under the section
connected. Supplementary Instructions. In this Installation
Manual references are made to these key dia-
After being connected, all electrical con- grams.
nections should be checked by an elec- Fig. 7.6 Opening the Cabinet
trician.
6.1 Connecting the Motor
Installation and connection instructions for the
chosen motor type is order specific and delivered
together with the unit by YORK Refrigeration.
These data sheets include descriptions of how to
connect the motor. Where another motor type is
used, data sheets containing this information
must be obtained.
Motor data appear from the name plate on the mo-
tor.
Important!
Always follow the instructions from the manufac- Connecting Supply Voltage
turer concerning connection. The supply voltage 230 VAC, 115 VAC is led
through the screwed cable entry and connected to

226/288 0178-931 - ENG

Rev. 27.10.03
 SMC /TSMC 100 Mk4 - Engineering Manual
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 sup-
ply voltage used.
As standard UNISAB II is prepared to be supplied
by 230/115 VAC, but UNISAB II can also be sup-
plied by 24 VAC. If this is the case, another trans-
former must be used. Check that the correct trans-
former 24/24 VAC (YORK Refrigeration product
no. 1556.043) has been fitted. Check,
moreover, that the jumper for 220/115 VAC has
been removed and that components, e.g. sole-
noid valves, are designed for 24 VAC.
Connections to Motor
The control supply of the motor must be connect-
ed across terminals 118 and 119 on UNISAB II to
07 installation instructions.fm
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
former XXX/1 A AC, which reads the motor cur-
rent taken up. Terminals 35 and 36 must be
supplied with max. 1A - see page 013 in diagram
2347-003.
Other Connections
UNISAB II's alarm output is made in such a way
that under normal conditions there is a connection
between terminals 107 and 109 whereas in an
alarm situation there is a connection between ter-
minals 107 and 108. The alarm output is supplied
by applying max. 230 V to terminal 107 - see page
020 in diagram 2347-003.
UNISAB II is prepared for connection of thermo-
pump. The connection is shown on page 028 in di-
agram 2347-003.
6.3 Control without UNISAB II
Where the unit is to be controlled by a control sys-
tem which is not delivered by
YORK Refrigeration, the connection must be
made as described in the key diagrams pertaining
to the control system in question.
Section 21, Appendices includes data sheets for
the individual control components with more de-
tailed descriptions of how to carry out the connec-
tion.
227/288
SMC /TSMC 100 Mk4 - Engineering Manual
7. Installation Instructions
7. Pressure Testing
After installing the unit, it must be pressure tested
and pumped down.
7.1 Pressure Testing of the Refrigera-
tion Plant
Before charging the plant with refrigerant, it
must be pressure tested and pumped down.
Pressure test the plant with one of the fol-
lowing:
– dry air - pressurized cylinders contain-
ing dry atmospheric air may be used -
but never oxygen cylinders;
– air compressor for high pressure;
Important!
The plant compressors must not be used to
pressurize the plant.
Water and other fluids must not be used for
pressure testing.
If nitrogen is used, it is important to place a
reducing valve with a pressure gauge be-
tween the nitrogen cylinder and the plant.
During pressure testing, it is important to en-
sure that pressure transducers and
other control equipment are not exposed to
the testing pressure. The compressor stop
valves must also be closed during pressure
testing.
Plant safety valves must normally be
blanked off during pressure testing, as their
opening pressure is lower than the testing
pressure. Shut-off valve pos. 4K-1 must be
closed during pressure testing.
Important!
During this pressure testing no person
should be allowed to be present in rooms
housing plant parts or in the vicinity of the
plant outside the rooms.
228/288
• The entire plant must be pressure tested
in accordance with the local regulations
for pressure testing.
• The test pressure must never exceed
the pressure for which the unit was de-
signed.
• If it is required that the compressor
should be pressure tested together with
the unit or with the plant, the testing
pressure must not exceed:
– For reciprocating compressors:
- HT side 24 bar
- LT side 17.5 bar
• Please observe that manometers, pres-
sure controls, pressure transmitters and
other control equipment are not ex-
posed to testing pressure.
• Afterwards, reduce pressure to 10 bar
for a period of 24 hours - as an initial
tightness test - as a tightly sealed plant
will maintain this pressure throughout
the period.
During the tightness test, it is permitted to
enter the room and approach the plant.
• By way of a second tightness test, ex-
amine all welds, flange joints etc. for
leakage by applying soapy water while
maintaining the pressure of 10 bar.
When pressure testing, prepare a pressure
test report containing the following points:
• date of pressure testing,
• person carrying out the test,
• comments.
7.2 Pumping Down the Refrigeration Plant
Following pressure testing, the refrigeration
plant must be evacuated in order to elimi-
nate 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 sys-
tems with particular care.
The boiling point of a fluid is defined as the
temperature at which the steam pressure
equals atmospheric pressure. For water the
boiling point is 100°C. If the pressure is low-
ered, the boiling point of the water will also
be lowered.
The table sets out the boiling point of water
at very low pressures:
07 installation instructions.fm
Table 7.3
Boiling point At pressure
of water °C mm HG
bar
5 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 condens-
ing in the vacuum pump.
0178-931 - ENG
Rev. 27.10.03
Important!
Never use the refrigeration compressor to
evacuate the plant.
For an evacuation to be performed satisfac-
torily, the final pressure must be lower than
5 mm Hg. Please note that water left in the
refrigeration plant may freeze if ambient
temperatures are lower than 10°C. In such
cases it will be necessary to supply heat to
the component surroundings, as ice evapo-
rates with difficulty.
It is recommended to carry out evacuation
as follows:
• Evacuate to a pressure lower than 5 mm
Hg.
• Blow dry air or nitrogen into the system
to a pressure corresponding to atmos-
pheric pressure. Never use OXYGEN
cylinders.
• Repeat evacuation to reduce pressure
to less than 5 mm Hg.
• Shut off the vacuum pump from the
refrigeration plant and check that the
pressure does not rise for the next cou-
ple of hours. If the system still contains
water, this will evaporate and cause the
pressure to rise, thereby indicating un-
satisfactory evacuation, which means
that the above procedure must be re-
peated.
229/288
SMC /TSMC 100 Mk4 - Engineering Manual
7. Installation Instructions

8. Oil Charging accordance with the oil recommendation before

Since the compressor is usually delivered without start-up.
any oil in the crank case, oil must be charged in

230/288 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
WWarning!
It is of vital importance that all security systems
through the following check list.
and their functions are checked before start-up.
Failure to comply with safety precautions may
cause death, personal injury or damage to the
equipment.

Table 7.4
Check list for the installation OK

1 Level foundation Measure whether the foundation is level

2 Position of vibration dampers Measure flexion

3 Position of motor on foundation Check that the motor rests on all four supporting
surfaces

4 Position of compressor on foundation Check that the compressor rests on all four support-
07 installation instructions.fm

ing surfaces

5 Tightness of pipe connection Pressure testing: After putting the unit under pres-
sure, paint with soapy water around welds, thread
connections and union nuts.

6 Coupling between motor and compressor Check that the alignment is in order - must be
checked again after 5 hours of operation while the
coupling is warm.

7 Torque Check that all bolts are tightened to the torque indi-
cated.

8 Electrical connection Check all electrical connections e.g. by measuring.

9 Oil charging Check that the oil in the crankcase goes up to the
middle of the sight glass.

0178-931 - ENG 231/288

Rev. 27.10.03
SMC /TSMC 100 Mk4 - Engineering Manual
7. Installation Instructions

232/288 0178-931 - ENG

Rev. 27.10.03
 SMC /TSMC 100 Mk4 - Engineering Manual
8. Components

8. Components
The purpose of this document is to describe the • Variable speed drive (VSD) in connec-
components which form part of the product as well tion with computerized capacity regulat-
as the variety of accessories which can be mount- ing system.
ed.
This document is primarily intended for construct- Valves
ing engineers, service technicians, future custom- • Suction valve
ers, sales personnel and personnel in the process
• Discharge valve
of training.
• Oil charging valve
This document was produced by:
• Purge valve
YORK Refrigeration
Chr. X’s Vej 201 • Thermostatic expansion valve for inter-
DK-8270 Hoejbjerg mediate cooling (TSMC)
Denmark • Thermostatic expansion valve for oil
Copyright © 2003 YORK Refrigeration cooling

This document must not be copied without the • Solenoid valves for oil cooling and inter-
08 components.fm

written permission of YORK Refrigeration and the mediate cooling

contents hereof must not be imparted to a third • Solenoid valve block for capacity regula-
party nor be used for any unauthorised purpose. tion
Contravention will be prosecuted.
Equipment
General • Oil separator
SMC 100 and TSMC 100 compressor blocks and
• Oil cooler
units are available in different versions with differ-
ent components. • Float valve for oil return
• Intermediate cooler (TSMC)
Regulating Systems • Heat exchanger for intermediate cooling
• Electromechanical control (analogue (TSMC)
reading and safety system). • Heating element
• Computerized reading, safety and For further information regarding dimensions and
capacity regulating system. location, please see the binder Dimensions and
Piping Diagrams as well as Section 5, Physical
and Connection Data.

0178-931 - ENG 233/288

Rev. 27.10.03
SMC /TSMC 100 Mk4 - Engineering Manual
8. Components

Motors a belt pulley diameter of 400 mm. The required

The standard SMC 100 and TSMC 100 units are transmission of speed between motor and com-
available with motors in different sizes, with differ- pressor is achieved by choosing the right standard
ent enclosures, power and supply voltage. belt pulley for the motor.

• Makes: Schorch and Leroy-Somer
• Supply voltage: 3x380V 50 Hz or
3x440V 60 Hz
• Enclosure class: IP 22/23 or IP 54/55
• Size: IEC 160 - 355
The necessary motor power depends on the oper-
ating conditions of the unit. The motor size can be
determined on the basis of the calculations in the
calculation program COMP1.
See, moreover, Section 6, Technical Data where
both systems are described in detail.
Oil Separators
Section 6, Technical Data - Oil separators in-
cludes a complete list of application areas for the
individual oil separators.
The function and mode of operation of the oil sep-
arator are described in detail in Section 4, Techni-
cal Description.

Transmission Systems Oil Coolers

SMC 104-106-108 and TSMC 108 are available See Section 4, Technical Description - Cooling
either directly driven or belt driven. Systems for Compressors where the oil cooling
principles are described in detail.
Directly Driven The table below shows which oil cooler (depend-
The power transmission between motor and com- ing on the type of refrigerant) forms part of the
pressor takes place by means of a coupling. Type units.
of coupling AMR 312 is used for SMC Table 8.1 Refrigerant-Cooled Oil Cooler
104-106-108 and TSMC 108 and type AMR 350
Oil Cooler Model Refrigerant
for SMC 112-116 as well as TSMC 116. A cou-
pling hub with bushing is mounted on the com- OSSI R 717
pressor. A hub adjusted to the chosen motor size OOKH HFC/HCFC
is mounted on the motor. Moreover, the coupling
consists of an outer and inner screen and a cou- Table 8.2
pling intermediate piece. These parts are not Combinations
mounted when the compressor is delivered. They
Water-cooled top and side covers
are, however, included in the delivery. In cases
where the unit is delivered without motor, coupling Air-cooled top covers and
water-cooled side covers Chosen on the
hub for motor is also included. basis of
Air-cooled top and side operating
covers, refrigerant-cooled limits
Belt Driven oil cooler
The power transmission takes place by means of Thermo pump
V-belts. The compressor is always delivered with

234/288 0178-931 - ENG

Rev. 27.10.03
 SMC /TSMC 100 Mk4 - Engineering Manual
8. Components

Regulating Components

Electromechanical Control Moreover, the compressor is equipped with ma-

The following components form part of the electro- nometers for visual control of the pressure condi-
mechanical control: tions.

KP15 High and low pressure cut-out High pressure manometer:

KP5 Intermediate cut-out Indicating discharge pressure.

MP55 Oil difference cut-out High and intermediate pressure:

KP98 Discharge pipe thermostat Indicating discharge pressure for

HP and LP Stages (TSMC).
KP98 Oil thermostat
Low pressure and oil pressure:
KZD4/M3 Oil filter differential pressostat
Indicating suction pressure and oil pressure.
08 components.fm

0178-931 - ENG 235/288

Rev. 27.10.03
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 deliv-
ered with pressure transducers from Danfoss of
the type:
PT1: AKS32R and
PT2 and PT3: AKS2050 -
see data sheet in Section 21, Appendices.
For plants with another control the unit is delivered
with pressure transducers from Danfoss of the
type:
PT1: AKS3000 and
PT2 and PT3: AKS3050 -
see data sheet in Section 21, Appendices.
Temperature Sensors, marked TT5,
TT6 and TT7
As standard the unit is delivered with Pt100 tem-
perature sensors of the type: P2208 G¼"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 Sec-
tion 21, Appendices.
The regulating systems are described more close-
ly in Section 4, Technical Description - Instrumen-
tation.
Heating Element
The compressor is equipped with a heating ele-
ment in the crankcase for decocting of refrigerant
in the oil. See Section 4, Technical Data -
One-Stage Compressors and Section 5, Physical
and Connection Data which include descriptions
and data.
Accessories
If the compressor is to be installed in rooms where
explosive gases may occur, special explo-
sion-proof components can be delivered, see
Section 4, Technical Description - Compressor
Accessories.
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 infor- Safety Precautions

WDanger!
mation about the factory settings of the safety and
control equipment, how to change the settings
and the effect of a change.
Risk of injury to personnel and damage to equip-
This document is primarily intended for installation
ment! In addition to the safety precautions in this
and service engineers.
document, always read the safety precautions be-
This document was produced by: longing to this equipment before changing the set-
YORK Refrigeration tings. Failure to comply with safety precautions
Chr. X’s Vej 201 may cause death or injury to personnel. It may
DK-8270 Hoejbjerg also cause damage to or destruction of the equip-
Denmark ment.

Copyright © 2003 YORK Refrigeration

Qualification Requirements
This document must not be copied without a writ-
Changes in the factory settings must only be car-
ten permission from YORK Refrigeration and the
ried out by an authorised refrigeration company.
contents hereof must not be imparted to a third
Moreover, it is required that the personnel is able
party, nor be used for any unauthorised purpose.
09 settings.fm

to follow a detailed description in English.

Contravention will be prosecuted.
Factory settings for analogous control and safety
system appear from Table 9.1. In connection with
fault-finding in case of irregularities in the opera-
tion, the table should include own settings to make
it easier for the supervisor to identify the error in
question. The same applies to UNISAB II control.
Table 9.2 and Table 9.3 show the set values for
UNISAB II.

0178-931 - ENG 237/288

Rev. 27.10.03
SMC /TSMC 100 Mk4 - Engineering Manual
9. Settings

Table 9.1 Pressure and Temperature Settings for Compressor Type SMC/TSMC
Analogous control and safety Refrigerant
system Min. setting Max. set-

R 404A
R 134

R 507

R 717
(own setting) ting (own

R22
setting)
X X X X X 24 bar (standard)
Safety valve on HT
X X X X X 22 bar (special)
compressor
MT X X X X X 12 bar
SafetyEquipment

Set so that the compressor stops at a

High and intermedi- KP5
X X X X X pressure 2 bar lower than the safety
ate-pressure cut-out (KP15)
valve set- ting.
Set to a pressure with saturation
KP1
Low-pressure cut-out X X X X X temp. 5° K lower than the lowest
(KP15)
evaporating temperature.
Oil pressure cut-out MP55 X X X X X 3.5 bar

Discharge pipe ther- X X X * 120° C

KP98
mostat X * 150° C
Oil thermostat KP98 X X X X X 80° C
Thermostat for com- 55° C
KP77 X X X X X
pressor cooling
T (E) X
Thermo valve for com- Normally set at 4° C su- perheat
T (E) N X X X X
pressor cooling Change to min. 10° C superheat
T (E) S
ControlEquipment

X X X Factory setting 45° C. See NB

TEAT
Injection valve for in- X X Factory setting 75° C. See NB
termediate cooling X Set at min.10° C superheat
T (E) X
TEA X Set at min.10° C superheat
X X X -25° C
By-pass valve PMC+ CVC
X -15° C
Oil filter differential
KZD4/M3 X X X X X 2,0 bar
pressure
Oil pressure regulat- 4.5 bar
X X X X X
ing valve
* Factory setting - can be adjusted, if required, to a breaking point 20° C higher than the highest normal discharge pipe temperature.
** Adjust the TEAT valves so that the expected discharge pipe temperature (-5° C/+10° C) is achieved at 100% compressor capacity. Increase
the opening temperature 10° C by turning the spindle 5 turns clockwise. NB: Factory setting must always be increased by min. 10° C. Ad-
justment of the TEAT valve must be carried out with the thermopump out of operation. For detailed descriptions concerning setting and
adjustment of automatics, see Section 21, Appendices.

238/288 0178-931 - ENG

Rev. 27.10.03
 SMC /TSMC 100 Mk4 - Engineering Manual
9. Settings

UNISAB II Reading, Safety and Capacity Regulating System

Table 9.2 Measured and Calculated Pressure Levels
Mesuaring Min. Max. Factory Note
Setting
Suction pressure High alarm - - -
[bar] High warning 1,5 9,0 5,0 3+4+5
Low warning -1,0 6,0 2,5 3+4+5
Low alarm -1,0 6,0 1,5 3+4+5
Discharge pressure High alarm 4,0 24,0 16,0 1+6
[bar] High warning 3,0 22,0 15,0 1+6
Low warning - - -
Low alarm -1.0 -1.0 -1.0 1+5
Intermediate pressure High alarm 4,0 24,0 7,0 1+6
[bar] High warning 3,0 22,0 6,0 1+6
For two-stage Low warning -1,0 10,0 -1,0 1+6+16
compressors only Low alarm -1,0 10,0 -1,0 1+6+16
Oil pressure High alarm 5,0 7,0 6,0 2+5+16
[bar] High warning 5,0 7,0 5,5 2+5
Low warning 0,5 5,0 4,0 2+5+14
Calculated value Low alarm 0,5 5,0 3,5 2+5+14

Table 9.3 Measured and Calculated temp. - Reciprocating Compressors

09 settings.fm

Measuring Min. Max. Factory Note

Setting
Discharge temperature High alarm 60,0 155,0 125,0 1+6
[°C] High warning 50,0 155,0 120,0 1+6
Low warning -65,0 -65,0 -65,0
Low alarm - - -
Oil temperature High alarm 40,0 105,0 80,0 2
[°C] High warning 30,0 105,0 75,0 2
Low warning 0,0 50,0 30,0 2+7
Low alarm 0,0 40,0 25,0 2+7
Brine temperature High alarm -60,0 100,0 60,0 1+6
[°C] High warning -60,0 100,0 50,0 1+6
Low warning -100,0 100,0 4,0 1+6
Low alarm -100,0 100,0 2,0 1+6
Intermediate gas High alarm 50,0 155,0 100,0 2+7
temperature [°C] High warning 50,0 120,0 95,0 2+7
For two-stage Low warning -20,0 50,0 4,0 2+7
compressors only Low alarm -20,0 50,0 2,0 2+7
Suction gas superheat High alarm 6,0 120,0 110,0 2+7
[°C] High warning 5,0 120,0 100,0 2+7
Low warning 0,0 40,0 4,0 2+7+13
Calculated value Low alarm 0,0 40,0 2,0 2+7+13
Disch. gas superheat High alarm 5,0 40,0 10,0 2+7+10
[°C] High warning 0,0 40,0 0,0 2+7+10
Calculated value

0178-931 - ENG 239/288

Rev. 27.10.03
SMC /TSMC 100 Mk4 - Engineering Manual
9. Settings

4-20 mA Auxiliary input Signal

Measuring Min. Max. Factory Note

High alarm -999,9 999,9 0,0 3+18

Auxiliary input High warning -999,9 999,9 0,0 3+18

(4-20 mA) 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 un-
til the problem has been solved.
Note 2 The alarm can be switched off imme-
diately (RESET key).
Note 3 The alarm is switched off automati-
cally.
Note 4 The safety limits can be entered in
bar or °C/R at your choice.
Note 5 Alarm monitoring active when digital
output "compressor starting signal"
has been chosen.
Note 6 Alarm monitoring always active - ex-
cept when "BLOCKED" has been se-
lected in the picture COMPRESSOR
CTRL MODE.
Note 7 Alarm monitoring 300 sec delayed
after compressor start.
Note 8 Alarm monitoring 180 sec delayed
after compressor start.
Note 9 Alarm monitoring 45 sec delayed af-
ter compressor start.
Note 10 A setting of 0.0 impedes monitoring.
Note 11 Delay of 300 sec, regardless of when
the limits are exceeded.
Note 12 The compressor must have been
above 5% capacity. Below 5% ca-
pacity monitoring is impeded.
Note 13 Alarm monitoring 15 sec delayed af-
ter compressor start.
Note 14 Delay of 60 sec, regardless of when
the limits are exceeded.
Note 15 Only applies to HPO and HPC com-
pressors.
Note 16 Alarm monitoring 20 sec delayed af-
ter compressor start.
Note 17 For VMY Mk 2-2.5, calculate the fol-
lowing below: Oil pressure = Oil
pressure 3 (after oil filter) - Dis-
charge pressure 2. For all other
compressor types (except for SAB
80, see Note 20), calculate the fol-
lowing: Oil pressure = Oil pressure 3
(after oil filter) - Suction pressure 1 .
Note 18 The limits are not active until AUX.
INPUT SIGNAL has been selected in
the CALIBRATION 4-20 mA menu.
Note 19 For SAB 80 the differential pressure
across the oil filter is calculated as
follows below: Oil filter diff. pressure
= Discharge pressure 2 - Oil pres-
sure 4 (after oil filter).
The shown oil filter pressure will thus
be 0.1 to 0.7 bar higher than the ac-
tual pressure loss across the filter
due to the pressure loss across the
oil separator and the oil cooler.

240/288 0178-931 - ENG

Rev. 27.10.03
 SMC /TSMC 100 Mk4 - Engineering Manual
9. Settings

The maximum allowed pressure sure 3 (after pump) - Suction pres-

drop across the oil filter is 1.2 bar.
Consequently, the warning limit
should be set between 0.8 and 1.4
bar or lower. The alarm limit should
be set between 1.1 and 1.7 bar or
lower.
Note 20: Set points 1 and 2 are used for alarm
monitoring of the mechanical oil
pump. Cf. the description of the
alarm under "Oil pump error" in the
section Other Alarms. For SAB 80,
the oil pressure is calculated as fol-
lows below: Oil pressure = Oil pres-
sure 1 .
Note 21: The set points are used to control the
oil pump. When the pressure falls
below set point 1, the oil pump will
start. When the pressure exceeds
set point 2 for 60 seconds, the oil
pump will stop.
Note 22: The set points are used to control the
full flow pump. When the pressure
falls below set point 1, the full flow
pump will start. When the pressure
exceeds set point 2 for 60 seconds,
the full flow pump will stop.

Table 9.4 Oil Cooling

No. Regulator Type Min. Max. Factory Unit
Setting
09 settings.fm

Set point 1/ oil temp. +35 +75 +55

2 Difference 5(fixed) °C
Oil cooling

Set point 2/ oil temp. 0 +75 +35

Difference 5(fixed) °C
Oil heating

Set point 1/ discharge pipe -20 +150 +100

temp. Difference 5(fixed) °C
Water cooling

Set point 2/ discharge pipe -20 +150 +100

temp. Difference 5(fixed)
°C
Intermediate pressure
liquid injection

Change af factory settings, see Instruction Manu- Fig. 9.1 - Expected Discharge Gas Temperatures
al, UNISAB II Control. - shows the values recommended when setting
operational and safety functions.

0178-931 - ENG 241/288

Rev. 27.10.03
 HFC HCFC

Fig. 9.1

242/288
R134a R22 R404A/R507 R717 9. Settings
Evaporating temperature Evaporating temperature Evaporating temperature Evaporating temperature
or or or or
intermediate temperature intermediate temperature intermediate temperature intermediate temperature
C° C° C° C°

Condensing pressure bar

Condensing pressure bar
Condensing pressure bar

Condensing pressure bar

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

Suction gas superheat ° C

Condensing temp. ° C
20 5.7 38 41 43 48 55 8.2 37
8 48 61 76 91 11.0 40 42 46 53 62 7.6 53 71 91 110 131
25 6.6 44 45 48 52 59 9.5 47
9 57 69 84 101 12.5 44 47 51 58 67 9.1 65 83 102 121 142
30 7.7 49 50 53 58 11.1 55
66 11. 65 77 92 108 14.3 49 52 56 63 71 10.7 77 95 113 133 151
10 35 8.8 53 54 58 64 74 12.7 68 74 85 99 115 16.2 54 57 61 67 75 12.6 89 106 123 141 160
40 10.1 57 59 63 69 14.5 72
79 14 82 94 106 120 18.2 59 62 66 72 79 14.6 101 117 133 151 170
SMC /TSMC 100 Mk4 - Engineering Manual

45 11.5 61 63 67 74 82 16.5 81 90 100 112 126 20.5 65 67 71 77 83 16.9 110 126 143 161 -
Expected Discharge GasTemperatures

20 5.7 48 51 53 58 65 8.2 48
8 59 72 88 103 11.0 50 52 56 63 72 7.6 65 83 103 122 143
25 6.6 54 55 58 62 69 9.5 57
9 68 80 95 110 12.5 54 57 61 68 77 9.1 77 95 114 132 153

20 30 7.7 59 60 63 68 11.1 65
76 11 76 88 102 117 14.3 59 62 66 73 81 10.7 89 106 125 142 162
35 8.8 63 64 68 74 12.7 73
84 12 84 96 109 123 16.2 64 67 71 77 85 12.6 100 116 134 152 -
40 10.1 67 69 73 79 14.5 82
89 14 92 103 115 128 18.2 69 72 76 82 89 14.6 111 127 144 162 -
45 11.5 71 73 77 84 16.5 90
92 16 98 109 121 133 20.5 75 77 81 87 93 16.9 121 136 154 171 -
20 5.7 58 61 63 68 75 8.2 59
8 70 83 97 113 11.0 60 62 66 73 82 7.6 78 96 115 134 153
25 6.6 64 65 68 72 79 9.5 69
9 78 91 105 120 12.5 64 67 71 78 87 9.1 90 106 126 144 163
30 7.7 69 70 73 78 11.1 75
86 11 86 98 111 125 14.3 69 72 76 83 91 10.7 102 118 136 154 -
30
35 8.8 73 74 78 84 12.7 84
94 12 95 106 118 131 16.2 74 76 81 87 95 12.6 112 128 146 163 -
40 10.1 77 79 83 89 14.5 92 101 111 123 135 18.2 79
99 14 82 86 92 99 14.6 123 138 155 - -
45 11.5 81 83 87 16.5 99 108 117 128 139 20.5 85
94 102 16 87 91 97 103 16.9 132 148 165 - -
Discharge gas temp.° C Discharge gas temp.° C Discharge gas temp.° C Discharge gas temp.° C

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:
• Dangers resulting from failure to comply
with safety precautions when operating the
equipment.
• How to start, operate and stop this equip-
ment in a safe way.
• How to act when problems occur during op-
eration.
This document is primarily intended for operators
and service engineers.
This document was produced by:
YORK Refrigeration
Chr. X’s Vej 201
10 operating instructions.fm
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 equip-
ment! Always read the safety precautions belong-
ing to this equipment before start. Failure to com-
ply with safety precautions may cause death or in-
jury to personnel. It may also cause damage to or
destruction of the equipment.
0178-931 - ENG
Rev. 27.10.03
Safety Precautions
WDanger!
A number of safety considerations which must be
read before operating the unit in question are pre-
sented in the following. General safety instruc-
tions/regulations must be studied carefully. Fail-
ure to do so may result in personal injury or even
death. Moreover, the equipment may be damaged
or destroyed.
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 associat-
ed with using the refrigerant and oil. Pay close at-
tention to the fact that large amounts of escaping
(or released) refrigerant entail risk of suffocation.
The safety instructions also explain the risks gen-
erally associated with refrigerants. Body contact
with leaking liquid refrigerant entails high risk for
injuries caused by intense cold.
Pressure
A compressor unit comprises a pressurized sys-
tem. Never loosen threaded joints (such as a
union nut) while the system is under pressure and
never open pressurized parts of the system.
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 sys-
tem parts. Always wear and use the re-commend-
ed safety items.
Never use your hands or other parts of the body to
search for leaks.
Before carrying out the measures set forth in this
document, all personnel must have carefully stud-
ied the instructions issued for the compressor unit.
The personnel must also fulfil all national require-
ments for authorization.

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 sys-
tem or UNISAB II reading, safety and regulating
system.
Alarms and Warnings
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
10 operating instructions.fm
alarms.
The safety system consists of the following com-
ponents:
• KP 15: High and low pressure cut-out
Stops the compressor at too high or too low
pressure in the refrigeration system.
• KP 5: Intermediate pressure cut-out
(only on TSMC compressors)
Stops the compressor at too high intermedi-
ate pressure.
• MP 55: Oil differential cut-out
Stops the compressor at too low oil pres-
sure in the lubricating system.
• KZD4/M3 Oil differential cut out
Oil differential pressure across oil filter. A
warning is given if the pressure drop
through the external oil filter is too high.
• KP 98: Discharge pipe 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 temper-
ature.
The safety equipment stops the compressor if the
max. or min. values are exceeded. If this happens,
correct the error before restarting the plant. To
prevent accidents the plant cannot be started be-
fore the function of the safety cut-out has been ac-
tivated.
Cut-outs and thermostats are not factory set on
delivery. The set values are included in Section 9,
Settings - Analoque Control and Safety Function.
However, always check the set values before
starting the plant.
As regards adjustment and setting of the equip-
ment, see Section 21, Appendices, which in-
cludes instructions for the individual components.
UNISAB II Reading, Safety and
Capacity Regulating 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 temper-
ature sensors mounted on the compressor. It is
possible to connect UNISAB II to a superior mon-
itoring device- MULTISAB.
On delivery UNISAB II is preset with a number of
factory values, e.g. safety and alarm functions. A
battery backup makes sure that preset values are
not lost in case of power failure.
All control operations for the reciprocating com-
pressor unit are carried out from the operator's
panel and its keys. The following page in this doc-
ument gives a brief explanation of what the keys
on the operator's panel are used for.
245/288
SMC /TSMC 100 Mk4 - Engineering Manual
10. Operating Instructions

A detailed description of the control system, its Carefully read the Instruction Manual UNISAB II
functions and its use is included in the Instruction Control to get a thorough knowledge of how to op-
Manual for UNISAB II Control. erate the control system.

The following are for normal daily operation of the
reciprocating compressor unit.
1. The emergency stop button on the side of
the control cabinet can always be used to
stop the compressor unit quickly.
2. When voltage is applied to UNISAB II, the
following main picture will appear on the
display, and UNISAB II is ready for opera-
tion.
SUCT. PRESS. 0.0 BAR
DISCH. PRESS. 0.0 BAR
UNISAB II is operated exclusively by means of the
keys as shown in Fig. 10.2. Reading of operating
conditions as well as changing limit values and set
points is done via the display, which contains a
number of pictures.
The control panel is normally closed and locked
with a screw at each end of the panel.
By turning the screws half a turn the control panel
is loosened and can be lifted to an open position.
Here it is fastened to the cabinet as shown in
Fig. 10.1.
Fig. 10.1 Opening the Cabinet

MOTOR CURR. 0A

STOPPED 0% UNISAB II

Values for warning limits, alarm limits and set

points, etc. are programmed into UNISAB II.
This makes it possible to start the compressor
immediately. 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 illumina-
tion and displays 4 lines, each with
20 characters. The contrast has
been factory set, but can be adjusted
if required.
See subsection Contrast (display) in
the section Languages in the
UNISAB instruction manual.
In the display pressure levels, tem-
peratures as well as all set points,
warning and alarm limits can be
read.
Front Panel
10 operating instructions.fm
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 mo-
tor starter. At the same time the text
0178-931 - ENG
Rev. 27.10.03
"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 oper-
ation by pressing the key once.
Works only if yellow lamp pos. 3
is lit.
Pos. 6 B Compressor stop at manual oper-
ation by pressing the key once.
Works only if yellow lamp pos. 3
is lit.
Pos. 7 C A change between manual
(yellow lamp on) and automatic
(yellow lamp off) takes place by
pressing the key once.
Please note that if manual was se-
lected from the CONTROL menu, it
is not possible to change to automat-
ic. See section Control Mode in the
UNISAB instruction manual.
Pos. 8 D Key used to acknowledge alarms.
247/288
SMC /TSMC 100 Mk4 - Engineering Manual
10. Operating Instructions
Fig. 10.2 Front Panel of UNISAB II
10 9 8 7 3 4 2 5 6
I Suct.temp.
R O
Pos. 9 E Loading of capacity during
manual operation.
By pressing the E key once one
capacity level is loaded on a recipro-
cating compressor with fixed rpm.
On variable speed drive (VSD) com-
pressors, the capacity is increased
continuously by pressing the key.
Pos. 10 F Unloading of capacity during
manual operation.
By pressing the F key once one
capacity level is unloaded on a recip-
rocating compressor with fixed rpm.
On variable speed drive (VSD) com-
pressors, the capacity is decreased
continuously by pressing the key.
248/288
1 11 13 12 14 15
Dish.temp.
-25°C
38°C
Set
Oil press. 4,3 bar
Ready 0%
UNISAB II
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 car-
ried out by using the password shown
on page 1 in the UNISAB instruction
manual. As to the encoding of a pass-
word, see section Changing Set Values
in the UNISAB instruction manual.
Pos. 12 H Used for moving left in the menu
system. Used for selecting pictures
or a digit when changing a value.
Pos. 13 I Used for moving right in the menu
system. Used for selecting pictures
or a digit when changing a value.
0178-931 - ENG
Rev. 27.10.03
 SMC /TSMC 100 Mk4 - Engineering Manual
10. Operating Instructions
Pos. 14 J Used for moving upwards in a pic-
ture in order to point at a certain val-
ue, or when changing to a higher val-
ue.
Pos. 15 K Used for moving downwards in a
picture in order to point at a certain
value, or when changing to a lower
value.
10 operating instructions.fm
0178-931 - ENG
Rev. 27.10.03
Menu Structure
The UNISAB II features a number of different pic-
tures on compressor operation, set values,
configuration, etc. and these pictures are built up
in a menu system in which a certain picture can be
selected by means of the arrow keys. See Instruc-
tion Manual for UNISAB II
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.
1. Check that the oil goes up to the middle of 3.
the sight glass. If this is not the case, re-
charge with oil.
2. Check that the safety equipment is set cor- 4.
rectly. All safety functions are factory set.
This is the case for both analogue control
and UNISAB II control.
The heating element in the crankcase must
be energized 6-8 hours before starting-up
the compressor.
Check that the valves are open according to
Table 10.1.

Table 10.1 Position during Operation

Pos no Qty Designation In operation position Remarks

1 1 Suction stop valve Open Must be opened by only a

couple of turns.

2 1 Discharge stop valve Open

3 1 Air purge valve Closed

4 1 Oil charge valve Closed

5 1 Stop valve - after oil seperator Open

6 1 Stop valve - receiver Open

7 1 Stop valve - liquid line Open To be opened after start-up

Fig. 10.3 Principle Drawing - Position during Operation

1 2 To Conderser

5
4
From Condenser
Note!
Other valves may occur. See 6
Dimensions and Piping Diagram Open
Closed
Receiver
To Evaporator

5. Switch on the pilot voltage. Check that the most position). If the plant does not start,
emergency stop button, see Fig. 10.4, is in check that the fuses are intact. See
ON-position (the button must be in its outer- Fig. 10.5.

250/288 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 ca-
pacity. TSMC ia allowed to operate in a to-
tally unloaded position for a maximum of 5
Emergency
stop button
minutes. The operating temperature will oth-
erwise be too high.
• Start the compressor on the control board or
by means of A on UNISAB II (on compres-
sors with analogue/digital control the start
button is often mounted as an ON/OFF
service cut-out on the compressor).
• Check suction and oil pressure. For com-
Fig. 10.5 Drawing of Fuses and their Position pressors with variable speed drive (VSD),
the oil pressure has to be adjusted at min.
rpm and checked at max. rpm.
1 2 3
3 Amp • Check if the oil is foaming in the sight glass.
• Check that the time relay keeps the solenoid
10 operating instructions.fm

U N IS AB II
valve in the oil return line shut for 20-30 min-
utes after the compressor has been started.
Solenoid valve controlled oil return only.
• Open the suction stop valve slowly until it is
completely open.
• Open the main shut-off valve in the liquid
line.

Starting • The compressor is now operating. Gradual-

Before starting up the plant, carefully read the
section Preparations for Starting. Reset any
alarms.
When the plant is to be started for the first time, it
is recommended to choose a manual starting-up
procedure.
• Open the suction stop valve a couple of
turns. Open all other valves except from the
main shut-off valve in the liquid line.
• Start condenser cooling, brine pumps, ven-
tilators at air coolers and maybe compres-
sor cooling.
ly increase the capacity to 100%.
• Do not leave the plant unattended the first
15 minutes after start-up.
After start up, carry out the final regulation of the
plant and set the plant to automatic operation.
Operating Mode UNISAB II
The compressor can be adjusted to different
forms of operation. These are found in SETUP H
CONTROL I.

0178-931 - ENG 251/288

Rev. 27.10.03
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.
It is now possible to select the desired form of op-
eration with the keys J K.
The possibilities are:
• STOPPED
• MANUAL
• AUTO
• REMOTE
STOPPED means that the compressor is blocked
and thus cannot start.
MANUAL means that the compressor only oper-
ates manually, i.e. you cannot change to another
form on UNISAB II by means of the key C.
However, the compressor can be started with
A and stopped with the B key and capacity in-
creased/decreased with the keys E F.
AUTO means that the compressor runs in local
automatic operation according to the form of reg-
ulation chosen (suction pressure, brine, etc). It is
possible to change to MANUAL with the key C.
REMOTE means that the compressor runs in re-
mote regulation. It is chosen when a number of
compressors are working together in a common
MULTISAB regulating system.
Regulators
In UNISAB II it is possible to regulate the com-
pressor according to different pressures and
252/288
temperatures. These forms of regulation are
found in CONFIG CONTROL ON.
If you place the cursor on CONTROL ON and
press G until the cursor moves to the right side
of the picture, you can now select different types
of regulation with the keysJ K.
Among the following:
• SUCTION SIDE
• BRINE
• DISCH. SIDE
• HOT WATER
• EXT. COOL
• EXT. HEAT
These regulators have three set values in com-
mon: Set point (Sp), Neutral zone (Nz) and Pro-
portional band (Pb).
Set point Sp is the pressure or the temperature
desired in the plant.
Neutral zone Nz indicates how much the pres-
sure or the temperature is allowed to fluctuate in
relation to the Sp without the compressor chang-
ing its capacity. The set value of Nz positioned
symmetrically around the set point (Sp+/- ½ Nz).
Proportional band Pb indicates how powerful
the regulating signal to the compressor capacity
regulation is going to be, depending on the differ-
ence between the desired value (Sp) and the ac-
tual value.
In case the measured value is just outside the Nz,
the regulating impulses will be very brief, whereas
the regulating impulses will be very long if the
measured value is outside the P-band. The P-
band is positioned symmetrically around Sp out-
side the Nz.
0178-931 - ENG
Rev. 27.10.03
 SMC /TSMC 100 Mk4 - Engineering Manual
10. Operating Instructions

Fig. 10.6
2001.07.01 YORK Refrigeration Tel.: +45 8736 7000 "QUICK REFERENCE"
Chr. X’s Vej 201 Fax: +45 8736 7705 LEAFLET FOR
DK-8270 Hoejbjerg UNISAB II - One-stage
Denmark Reciprocating Compressor

1 MAIN PICTURE Factory-

setting SUCT.PRESS XXXX
Press H until the picture remains unchanged and this is your MAIN PICTURE. DISCH.PRES XXXX
MOTOR CURR XX
READY X

2 SELECT THE "CONFIGURATION" MENU

Main picture - I suction - K setup - I control - K config. - - - - - - - - - - - - - - - - - - i
Check whether UNISAB II is set correctly for the compressor. CONTROL ON XXXX
Press H until the Main picture appears. AUTO START YES XXX
AUTO STOP XX
COLD STORE XX
k
3 SELECT THE "TIMER SETUP" MENU
Main picture - I suction - K setup - I control
- Ktimers - I timers - K timer setup - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - i START START XXX
Check the set times in Timer setup STOP START XXX
10 operating instructions.fm

Press H until the Main picture appears in the display. START DELAY XXX
STOP DELAY XXX
k

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

Place cursor on suct. press or disch. pres and press "SET" (once).
5 SELECT THE MENU FOR SUCTION PRESSURE REGULATION
Main picture - I suction - I suct. press -
press "SET" for changing to °C/R - - - - - - - - - - - - - - - - - - i HIGH ALARM XXX SETPOINT 1 XXX
Press H until the Main picture appears. HIGH WARNING XXX SETPOINT 2 XXX
LOW WARNING XXX NEUTRAL ZONE XXX
LOW ALARM XXX PROP. BAND XXX
k
6 CHANGING THE SET VALUES
In order to be able to change a set value, a password must be encoded as described:
Press "SET" for 2 seconds [Standard code number 1234].
Find the right password in the instruction manual
With H I and J K the correct password is encoded
Press "SET" and the password is kept open for 60 mins.
7 SETTING OF VALUES, f. inst. SUCTION PRESSURE (LOW ALARM)
Main picture - I suction - I suct. press - I high alarm -- K low alarm
Encode password (see pt. 6) - JK and HI changing of set values - ”SET” for confirmation.
8 SELECT FUNCTION, f.inst. REGULATOR MODE
Main picture - I suction - K setup - I control - K config. - I type - K control on
Encode password (see pt. 6) - JK for selection of regulator - ”SET” for confirmation.
9 SELECT COMPRESSOR CONTROL MODE
Main picture - I suction - K setup - I control - I compressor control mode - "SET" (the cursor is now in line 2)
- JK for selection of control type (manual / auto / remote / stopped) - "SET" for confirmation.
10 CHANGING BETWEEN MANUAL- AND AUTOMATIC / REMOTE CONTROL MODE
Press -g to switch between manual - auto/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 253/288

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 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
UNISAB II - Menu Tree I PARAMETER SETTING
HIGH ALARM °C/R
One-stage Reciprocating HIGH WARN. °C/R
Suction LOW WARN. °C/R
Compressor SUCT.PRES. °C/R LOW ALARM °C/R
SUCT.TEMP. °C ACTUAL SP. °C/R
SUCT.SUPERH. °C SETPOINT 1 °C/R
RUNNING 100% SETPOINT 2 °C/R
NEUTRALZONE °C/R
PROP.BAND °C/R

Discharge
DISCH.PRES. °C/R
DISCH.TEMP. °C
DISC.SUPERH. °C
RUNNING 100%

Oil
Multisab state
SUCT.PRES. BAR
OIL PRES. BAR START NO.
OIL TEMP. °C SYSTEM NO.
RUNNING 100% SYS.CONTROLLER

Motor
MOTOR CURR A
All compressors
CAPACITY %
NOT USED % COMPR. # 01 MANUAL
Main picture Main menu RUNNING 100% SYSTEM # 01
START # 01 J
RUNNING 100%
SUCT.PRES. °C/R SUCTION BRINE
DISCH.PRES. °C/R DISCHARGE ALARM Brine
MOTOR CURR A OIL WARNING Timers
BRINE TEMP. °C
10 operating instructions.fm

RUNNING MOTOR SETUP

100% SUCT.PRES °C/R START START SEC
EXT.INPUT STOP START SEC
RUNNING 100% START DELAY SEC
STOP DELAY SEC
Alarms Control
NO ALARMS Service-timers
COMPR. CTRL. MODE
ON TIME HOUR
SINCE START
MANUAL

Warnings Multisab Date-time

NO WARNINGS MULTISAB HOUR
MIN
K
MULTISAB STATE SEC
ALL COMPRESSORS DAY
PARALLEL CONTR.
Dig. input
Setup Timers D.INPUT
D.INPUT
CONTROL CALIBRATE TIMERS D.INPUT
MULTISAB TIMERS D.INPUT
TIMERS CONFIG TIMER SETUP
DIAGNOSIS LANGUAGE SERVICE TIMERS Dig. output
D.OUTPUT
D.OUTPUT
Diagnosis D.OUTPUT
DIAGNOSIS D.OUTPUT
INSPECT OLD ALARMS Analog. input
MISC.FUNCTIONS
SOFTWARE VERSION PRES. INP 1
PT 100 INP 1
Calibrate EXT.
CALIBRATE
PRESS TRANSDUCER 4-20 MA input
BRINE TEMP. 4 MA
CAPACITY 20 MA

CAPACITY SETPOINT
Config.
TYPE Auxiliary output
REFRIGERANT
CONTROL ON AUXILIARY OUTPUT
VOLUME RATIO ACTIVE WHEN
AT MAX.CAP

Language
CONTRAST
LANGUAGE GB
H

0178-931 - ENG 255/288

Rev. 27.10.03
SMC /TSMC 100 Mk4 - Engineering Manual
10. Operating Instructions

Fig. 10.8
2001.07.01 YORK Refrigeration Tel.: +45 8736 7000 "QUICK REFERENCE"
Chr. X’s Vej 201 Fax: +45 8736 7705 LEAFLET FOR
DK-8270 Hoejbjerg UNISAB II - Two-stage
Denmark Reciprocating Compressor

1 MAIN PICTURE Factory-

setting SUCT.PRESS XXXX
Press H until the picture remains unchanged and this is your MAIN PICTURE. DISCH.PRES XXXX
MOTOR CURR XX
READY X

2 SELECT THE "CONFIGURATION" MENU

Main picture - I suction - K setup - I control - K config. - - - - - - - - - - - - - - - - - - i
Check whether UNISAB II is set correctly for the compressor. TYPE XXXX
Press H until the Main picture appears. REFRIGERANT XXX
CONTROL ON XX
VOLUME RATIO XX

k
3 SELECT THE "TIMER SETUP" MENU
Main picture - I suction - K setup - I control
- Ktimers - I timers - K timer setup - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - i START START XXX
Check the set times in Timer setup STOP START XXX
Press H until the Main picture appears in the display. START DELAY XXX
STOP DELAY XXX
k
4 READ SUCTION PRESSURE OR DISCHARGE PRESSURE IN BAR OR °C/R.
Place cursor on suct. press or disch. pres and press "SET" (once).
5 SELECT THE MENU FOR SUCTION PRESSURE REGULATION
Main picture - I suction - I suct. press -
press "SET" for changing to °C/R - - - - - - - - - - - - - - - - - - i HIGH ALARM XXX SETPOINT 1 XXX
Press H until the Main picture appears. HIGH WARNING XXX SETPOINT 2 XXX
LOW WARNING XXX NEUTRAL ZONE XXX
LOW ALARM XXX PROP. BAND XXX
k
6 CHANGING THE SET VALUES
In order to be able to change a set value, a password must be encoded as described:
Press "SET" for 2 seconds [Standard code number 1234].
Find the right password in the instruction manual
With H I and J K the correct password is encoded
Press "SET" and the password is kept open for 60 mins.
7 SETTING OF VALUES, f. inst. SUCTION PRESSURE (LOW ALARM)
Main picture - I suction - I suct. press - I high alarm -- K low alarm
Encode password (see pt. 6) - JK and HI changing of set values - ”SET” for confirmation.
8 SELECT FUNCTION, f.inst. REGULATOR MODE
Main picture - I suction side- K setup - I control - K config. - I type - K control on
Encode password (see pt. 6) - JK for selection of regulator - ”SET” for confirmation.
9 SELECT COMPRESSOR CONTROL MODE
Main picture - I suction - K setup - I control - I compressor control mode - "SET" (the cursor is now in line 2)
- JK for selection of control type (manual / auto / remote / stopped) - "SET" for confirmation.
10 CHANGING BETWEEN MANUAL- AND AUTOMATIC / REMOTE CONTROL MODE
Press - g to switch between manual - auto/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)
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.
10 operating instructions.fm

0178-931 - ENG 257/288

Rev. 27.10.03
SMC /TSMC 100 Mk4 - Engineering Manual
10. Operating Instructions

Fig. 10.9
UNISAB II - Menu Tree I PARAMETER SETTING
HIGH ALARM °C/R
Two-stage Reciprocating HIGH WARN. °C/R
Suction LOW WARN. °C/R
Compressor SUCT.PRES. °C/R LOW ALARM °C/R
SUCT.TEMP. °C ACTUAL SP. °C/R
SUCT.SUPERH. °C SETPOINT 1 °C/R
RUNNING 100% SETPOINT 2 °C/R
NEUTRALZONE °C/R
PROP.BAND °C/R

Discharge
DISCH.PRES. °C/R
DISCH.TEMP. °C
DISC.SUPERH. °C
RUNNING 100%

Oil
Multisab state
SUCT.PRES. BAR
OIL PRES. BAR START NO.
OIL TEMP. °C SYSTEM NO.
RUNNING 100% SYS.CONTROLLER

Motor
MOTOR CURR A
All compressors
CAPACITY %
NOT USED % COMPR. # 01 MANUAL
Main picture Main menu RUNNING 100% SYSTEM # 01
START # 01 J
RUNNING 100%
SUCT.PRES. °C/R SUCTION BRINE
DISCH.PRES. °C/R DISCHARGE ALARM Intermed.
MOTOR CURR A OIL WARNING Timers
RUNNING MOTOR SETUP INTERM.PRES °C/R
100% INTERM.TEMP °C/R START START SEC
EXT.INPUT STOP START SEC
RUNNING 100% START DELAY SEC
STOP DELAY SEC
Alarms Control
NO ALARMS Service-timers
COMPR. CTRL. MODE
ON TIME HOUR
SINCE START
MANUAL

Warnings Multisab Date-time

NO WARNINGS MULTISAB HOUR
MIN
K
MULTISAB STATE SEC
ALL COMPRESSORS DAY
PARALLEL CONTR.
Dig. input
Setup Timers D.INPUT
D.INPUT
CONTROL CALIBRATE TIMERS D.INPUT
MULTISAB TIMERS D.INPUT
TIMERS CONFIG TIMER SETUP
DIAGNOSIS LANGUAGE SERVICE TIMERS Dig. output
D.OUTPUT
D.OUTPUT
Diagnosis D.OUTPUT
DIAGNOSIS D.OUTPUT
INSPECT OLD ALARMS Analog. input
MISC.FUNCTIONS
SOFTWARE VERSION PRES. INP 1
PT 100 INP 1
Calibrate EXT.
CALIBRATE
PRESS TRANSDUCER 4-20 MA input
BRINE TEMP. 4 MA
CAPACITY 20 MA

SUCT.PRES
Config.
TYPE Auxiliary output
REFRIGERANT
CONTROL ON AUXILIARY OUTPUT
VOLUME RATIO ACTIVE WHEN
AT MAX.CAP

Language
CONTRAST
LANGUAGE GB
H

258/288 0178-931 - ENG

Rev. 27.10.03
 SMC /TSMC 100 Mk4 - Engineering Manual
10. Operating Instructions

Checks during Operation

When the plant has been set for normal operating
conditions, an inspection of the plant must be car-
ried out. Check for leaks and vibrations in the sys-
tem, noise from valves, etc. Particularly variable
speed drive (VSD) compressors must be checked
10 operating instructions.fm
for vibrations due to natural frequency. Rpm re-
sulting in vibrations must be locked out in the VSD
controller. Check that oil pressure, suction and
condensing pressure is within the permissible
working range for the compressor.

0178-931 - ENG 259/288

Rev. 27.10.03
SMC /TSMC 100 Mk4 - Engineering Manual
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 precau-
tions are not observed.
• How to assemble and transport this
equipment in a safe way.
This document is primarily intended for transport
supervisors, authorities and personnel who are in-
volved in loading, unloading and transporting the
equipment.
party nor be used for any unauthorised purpose.
Contravention will be prosecuted.
WDanger!
Risk of injury to personnel and damage to equip-
ment! Always read the safety precautions belong-
ing to this equipment before start. Failure to com-
ply with safety precautions may cause death or in-
jury to personnel. It may also cause damage to or
destruction of the equipment.

This document was produced by:

Safety Precautions
YORK Refrigeration
Chr. X’s Vej 201
DK-8270 Hoejbjerg
WDanger!
14 transport instructions.fm

Denmark Risk of injury to personnel and damage to equip-

ment! In addition to the safety precautions in this
Copyright © 2003 YORK Refrigeration
document, always read the safety precautions be-
This document must not be copied without the
longing to this equipment before transport. Failure
written permission of YORK Refrigeration and the
to comply with safety precautions may cause
contents hereof must not be imparted to a third
death or injury to personnel. It may also cause
damage to or destruction of the equipment.

0178-931 - ENG 261/288

Rev. 27.10.03
SMC /TSMC 100 Mk4 - Engineering Manual
14. Transport Instructions

Transport Data Table 14.1

Compressor Weight
Weight and Dimensions
Type Kg lb
SMC 104S-L 580 1279
When dispatched, the unit is placed on a wooden SMC 106S-L 675 1488
frame and covered by plastic film. The wooden
SMC 108S-L 740 1631
frame, which is adjusted to the size of the unit, is
SMC 112S-L 1250 2756
made so that the unit can be lifted with a forklift
SMC 116S-L 1350 2976
truck.
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 Weight of Compressor Units

Compressor Direct driven Belt driven Remarks
type
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 Leroy Somer
Sizes
IP 23 IP 54 PLS LS FLS
kg lb kg lb kg lb kg lb kg lb
IEC 160L 102 225 80 176 78 172 120 265
IEC 180M 190 419 173 381 98 216 100 220 135 298
IEC 180L 210 462 188 414 128 282 110 243 184 406
IEC 200M 240 529 165 364
IEC 200L 265 584 235 518 190 419 170 375 260 573
IEC 225S 309 681 205 452 290 639
IEC 225M 355 783 340 750 240 529 235 518 388 855
IEC 250S 455 1003 335 739
IEC 250M 480 1058 445 981 360 794 340 750 395 871
IEC 280S 625 1378 570 1257 460 1014 445 981 475 1047
IEC 280M 680 1499 630 1389 515 1135 490 1080 565 1246
IEC 315S 875 1929 900 1984 720 1587 850 1874
IEC 315M 945 2083 940 2072 730 1609 785 1731 1000 2205
IEC 315L 1050 2315 1200 2646 830 1830 1050 2315
IEC 355S 1500 3307
14 transport instructions.fm

IEC 355M 1790 3946 1600 3527 855 1885

IEC 355L 2095 4619 1750 3858 1510 3329
IEC 355L (LA)1900 (LA)1900 1550 3417
(LB)2150 (LB)2150

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 mini-
mum the lifting capacity of the truck must corre-
spond to the weight of the unit + the weight of the
electric motor + an extra 100 kg for packing.
If unpacked, the unit can be lifted with a crane.
The unit must be lifted in the lifting eyes on the
unit. Never lift in the lifting eyes of the compressor
or the motor separately. 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.

0178-931 - ENG 263/288

Rev. 27.10.03
SMC /TSMC 100 Mk4 - Engineering Manual
14. Transport Instructions
Preparations before Lifting
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.
Loading
Take great care when loading the unit so that it is
not damaged. Note in particular that the instru-
mentation of the unit is very vulnerable to impacts.
Transport Instructions
WDanger!
Risk of injury to personnel and damage to equip-
ment! YORK Refrigeration does not assume re-
sponsibility for injury to personnel or damage to
equipment caused by the use of transport meth-
ods which are not recommended in this document
or stated in a separate agreement between a
transport company and YORK Refrigeration.
Transport Regulations
It is the transport company's responsibility that all
regulations pertaining to the transport are ob-
served.
It is moreover the transport company's responsi-
bility that the unit or parts of the unit are properly
secured and that they do not shift during the trans-
port and thus get damaged.
264/288
Unloading Instructions
The same rules apply as when loading the unit.
See therefore Loading Instructions.
Unpacking and Inspecting the Unit
See Section 7, Installation Instructions.
Moving the Equipment to Mounting Site after
Unloading
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 com-
pressor. If the equipment is to be stored for a long
time, the compressor should be equipped with a
service manometer on the evacuation valve so
that the pressure can be checked. If the pressure
falls below 0.1 bar, recharge with nitrogen (N2).
Place the unit on a level foundation and cover it so
that it is protected against dust and dirt. The unit
must not be stored with other objects which give
off acidic vapours or the like as this can have a
corrosive effect on the unit. It is moreover required
that the store room is dry and frost-free.
When stored, the unit must be inspected at regu-
lar intervals. Every two weeks the compressor and
motor must be rotated 8-10 turns to prevent the oil
in the bearings from drying. As far as the motor is
concerned, check the lubricating nipples and lu-
bricate them if necessary.
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 pre-
cautions are not observed.
• How to start-up this equipment in a safe
way.
• How to prepare a safe and effective
start-up.
This document is primarily intended for inspectors
and supervisors.
This document was produced by:
YORK Refrigeration
Chr. X’s Vej 201
15 commissioning instructions.fm
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 equip-
ment! Always read the safety precautions belong-
ing to this equipment before start. Failure to com-
ply with safety precautions may cause death or in-
jury to personnel. It may also cause damage to or
destruction of the equipment.
Safety Precautions
WDanger!
Risk of injury to personnel and damage to equip-
ment! In addition to the safety precautions in this
document, always read the safety precautions be-
longing to this equipment before start. Failure to
comply with safety precautions may cause death
or injury to personnel. It may also cause damage
to or destruction of the equipment.
265/288
SMC /TSMC 100 Mk4 - Engineering Manual
15. Commissioning Instructions
Preparations for Commissioning
Final Check of Installation
Before the plant is put into operation, the installa-
tion must be checked one last time, see Section 7,
Installation Instructions - Final Check of the Instal-
lation.
Personnel Requirements
The personnel who are going to start up the plant
must be well-qualified and have a thorough know-
ledge of refrigeration technique. It is moreover
necessary that the personnel know the refrigera-
tion plant and its construction and mode of opera-
tion. The instructions in this manual must be read
before start-up.
YORK Refrigeration offers courses which deal
with operation of and service on the unit in ques-
tion. It is recommended that both the supervisor
and the operator take these courses.
Training
It must be made sure that all personnel have been
trained so that the requirements listed under Per-
sonnel Requirements above are complied with.
Documentation
Besides this manual the personnel should be in
possession of the following documentation mate-
rial before putting the plant into operation:
• Operating Manual
• Starting-up Manual and Instruction
Manual for UNISAB II
• Certificates regarding the reciprocating
compressor unit
• Installation drawings and functional descrip-
tions for the plant
266/288
Preparations on the Mounting Site
Final Check of the Plant
The check includes an examination of all parts
of the plant and all the connections to the
compressor.
Check in particular that
• the piping connections are made as indicat-
ed in the installation drawings.
• all electrical connections have been
checked.
• the unit and the plant have been pressure
tested.
• the coupling between motor and compres-
sor are set up as indicated in Section 7, In-
stallation Instructions.
• the insulation has been carried out correctly.
• the paint is in order, the screens have been
mounted correctly, etc.
Commissioning Instructions
Preparations before the First Start-up
Before start-up, go through the following points:
• Section 10, Operating Instructions -
Preparations for Starting.
• UNISAB II's Starting-up Manual - Before
Connecting the Voltage.
Go through the following point by point:
Press the Emergency Stop button and connect
voltage.
Carry out configuration and setting as well as set-
ting of alarms and warnings as described in Be-
fore Connecting Voltage in the Starting-up Manual
for UNISAB II. Check that set values and alarm
values correspond to the operating conditions of
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 cal-
ibrated at atmospheric pressure. The easiest way
to do this is to dismount the transducers.
WDanger!
Inadequate or erroneous setting of pressure
transducers may result in compressor breakdown
or personal injury.
Evacuation and Charging of
15 commissioning instructions.fm
Refrigerant
Check that the plant is evacuated to a pressure
lower than 5 mm Hg. Pressure testing and evacu-
ation of the plant is described in detail in Section
7, Installation Instructions.
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 be-
tween motor and compressor must be checked
again while the compressor is still warm.
If the compressor is belt driven, check the belt ten-
sion. Before letting the plant start to work, activate
the emergency stop and dismount the main fuses
to ensure that the motor does not start uninten-
tionally.
Important! Note the procedures for reducing the
evaporating pressure.
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: contents hereof must not be imparted to a third
• The norms and standards which this equip- party nor be used for any unauthorised purpose.
ment complies with. Contravention will be prosecuted.

• How this equipment complies with the

norms and standards.
Conformity with EU Regulations
According to current EU regulations, the manufac-
This document is primarily intended for commis-
turer is under an obligation to document that the
sioning engineers, inspecting bodies and authori-
product complies with the EU Directive for Ma-
ties.
chines. This is done by completing a Declaration
This document was produced by: of Manufacturer, which contains the principal in-
YORK Refrigeration formation about the product in question.
Chr. X’s Vej 201 The Directive for Machines does not apply to
DK-8270 Hoejbjerg countries outside the EU.
Denmark
Example of a Declaration of Manufacturer, see
16 compliance instructions.fm

Copyright © 2003 YORK Refrigeration Fig. 16.1.

This document must not be copied without the
written permission of YORK Refrigeration and the

0178-931 - ENG 269/288

Rev. 27.10.03
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 Machine safety - Fundamental concepts
DS/EN 294 Machine safety - Dangerous areas and safety distances
DS/EN 418 Machine safety - Emergency functions

Besides in case of machines with electric equipment:

EN 60 439-1 Low-voltage switch gear and control gear assemblies -
Type-tested and partially type-tested assemblies.
EN 60 204-1 Electrical equipment of industrial machines.

Operational instruction will be supplied.

Complete technical documentation has been prepared
Place and Date: ____________________________
Name and signature ____________________________

Agent/dealer stamp

270/288 0178-931 - ENG

Rev. 27.10.03
 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 com-
pressors.
This document is mainly intended for inspecting
bodies and authorities.
This document was produced by:
YORK Refrigeration
Chr. X’s 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.
17 certificate.fm
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
der. It will not be possible to make a separate cer-
tificate for the compressor at a later time.
Approvals
• Compressor Units
Are designed to comply with common legis-
lation in the EC-countries and former EFTA
member states.
• The technical design complies with the re-
quirements in the directives, most impor-
tantly the "Pressure Equipment Directive"
(PED).
Can also be delivered in a design according
with the rules of the following classification
societies:
Lloyd's Register of Shipping
Det Norske Veritas
Germanischer Lloyd
On request, compressor units can be de-
signed to fulfil the standards of other coun-
tries and classification societies than the
ones mentioned above
271/288
SMC /TSMC 100 Mk4 - Engineering Manual
17. Certificates

272/288 0178-931 - ENG

Rev. 27.10.03
 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. X’s 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.
20 final disposal.fm
General
Safety Precautions
WDanger!
Before dismantling the plant, read Section 3,
Safety Precautions carefully. Failure to do so may
result in personal injury or even death.
Dismantling of a cooling unit which is to be
scrapped must be carried out in a safe way.
Authorized refrigeration personnel must partici-
pate in the first part of the dismantling process as
fundamental knowledge of refrigerating systems
and the risks involved is required.
0178-931 - ENG
Rev. 27.10.03
Before dismantling the plant, refrigerant and oil
must be drained into containers intended for the
purpose. Disconnect all electrical connections to
the unit. Remove fuses in the main switchboard.
During the dismantling process, the individual ma-
chine parts and components must be sorted so
that disposal can take place in an efficient way.
WDanger!
Take great care if using cutting tools, e.g. angle
grinder or flame cutter, during the dismantling
process as pipes or the like will contain oil residue
which may ignite. Refrigerant residue does also
involve a great risk as HFC and HCFC refrigerants
will develop toxic gasses when heated. Make sure
that there are no air traps as heating will result in
a pressure rise.
Disposal of Machine Parts
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.
Disposal of Oil and Refrigerant
Oil and refrigerant must be delivered for destruc-
tion or regeneration at a receiving station for haz-
ardous waste, including used oil filters. The re-
ceiving station must comply with the prevailing
rules and regulations of the individual country.
273/288
SMC /TSMC 100 Mk4 - Engineering Manual
20. Final Disposal
Disposal of Electrical Components
Electrical and electronic products, e.g. wiring,
panels, hardware, etc., must be delivered to a re-
ceiving station approved to handle electronic
waste. The receiving station must comply with the
prevailing rules and regulations of the individual
country.
274/288
Disposal of Batteries
Used batteries from e.g. the backup of the compu-
ter control must be delivered for destruction at a
receiving station. The receiving station must com-
ply with the prevailing rules and regulations of the
individual country.
0178-931 - ENG
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
6. Danfoss automatic
Pressure cut-outs type KP, 4 pages
Pressure cut-outs type MP, 7 pages
Thermostats type KP, 5 pages
21 appendices.fm

Thermostatic expansion valves, 9 pages

Thermostatic injection valves, 5 pages

0178-931 - ENG 275/288

Rev. 27.10.03
SMC /TSMC 100 Mk4 - Engineering Manual

Fig. 21.1

1
Z
X 2

B A
F C

Table 21.1
Compressor AMR Nominal Torque moment Max. variation measured with a
type of Distance feeler gauge at a 180° turning of
coupling the coupling

C F A B D Pos. 1 Pos. 2

Horizon- Vertical
tal max. min./max. max.
mm mm Nm Nm Nm mm mm mm

HPC/SMC 312 S 103,5 25 147 55 44 0,2 0,1/0,3 0,2

104-108

SMC 350 S 114,5 27 147 128 44 0,2 0,1/0,3 0,2

112-116

276/288 0178-931 - ENG

Rev. 27.10.03
 SMC /TSMC 100 Mk4 - Engineering Manual

Torque Moments for Screws and Bolts

Metric thread (ISO 8.8)

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

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

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

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

Metric thread (ISO 12.9)

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

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

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

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

21 appendices.fm

Connecting rods with UNF thread

HPO/CMO HPC/SMC 100 SMC 180
UNF 5/16” 3/8” 5/8”
Kpm 2.1 4.4 17
ft.lbf.. 15 32 130
Nm 20 43 167

0178-931 - ENG 277/288

Rev. 27.10.03
SMC /TSMC 100 Mk4 - Engineering Manual

Sundry Clearances and Check Dimensions

Bearing clearance
CMO 1 CMO 2 SMC 65 SMC 100 SMC 100 SMC 180
CMP 1 TCMO 2 TSMC 65 TSMC 100 TSMC 100 TSMC 180
TCMO 1 4-10 cyl. 12-16 cyl.
CMO 4 HPO HPC Mk 1 & Mk 2

manufactured 0.08 0.08 0.08 0.08 0.08 0.14

Main bearings
max. 0.20 0.20 0.20 0.20 0.20 0.35

Connecting rod manufactured 0.08 0.08 0.08 0.10 0.10 0.14

bearings max. 0.15 0.15 0.15 0.20 0.20 0.30

Piston pin manufactured 0.04 0.04 0.04 0.04 0.04 0.09

bearings max. 0.10 0.10 0.10 0.10 0.10 0.20

Parallel to manufactured 0.18 0.18 0.20 0.20 0.20 0.25

piston pin max. - - - - - -
Piston

Al right angles manufactured 0.11 0.11 0.11 0.15 0.15 0.35

to piston pin max. 0.30 0.30 0.30 0.40 0.40 0.90

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.

Dimensions of crankshaft bearing journal

-0.06 -0.06 -0.06 -0.07 -0.07 -0.11
Main bearing journals 55 60 55 80 80 135
-0.09 -0.09 -0.09 -0.09 -0.09 -0.14
New

Connecting rod -0.025 -0.030 0 0 0 -0.015

50 55 55 80 80 135
bearing journals -0.040 -0.049 -0.02 -0.02 -0.02 -0.040

Intermediate journals -0.010

80
-0.029

-0.06 -0.06 -0.06 -0.07 -0.07 -0.11

Main bearing journals 54.5 59.5 54.5 79.5 79.5 134
-0.09 -0.09 -0.09 -0.09 -0.09 -0.14
Ground down

Connecting rod -0.025 -0.025 0 0 0 -0.015

49.5 54.5 54.5 79.5 79.5 134
bearing journals -0.040 -0.040 -0.02 -0.02 -0.02 -0.040

-0.010
Intermediate journals 79.5
-0.029

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

278/288 0178-931 - ENG

Rev. 27.10.03
 SMC /TSMC 100 Mk4 - Engineering Manual

Index

A 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

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

0178_931IX.fm

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

C 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 279/288

Rev. 27.10.03
SMC /TSMC 100 Mk4 - Engineering Manual

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

D 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

280/288 0178-931 - ENG

Rev. 27.10.03
 SMC /TSMC 100 Mk4 - Engineering Manual

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
0178_931IX.fm

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

0178-931 - ENG 281/288

Rev. 27.10.03
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

E 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

F 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

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

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

282/288 0178-931 - ENG

Rev. 27.10.03
 SMC /TSMC 100 Mk4 - Engineering Manual

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

I 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

K KP 15 ................................................................................................................... 245
KP 5 ..................................................................................................................... 245
0178_931IX.fm

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

L 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

M Machine Room
Planning ......................................................................................................... 124
Maintenance Safety ............................................................................................... 21
Manometers
Description
Manometers ............................................................................................... 74
Marine Installations .............................................................................................. 164
Max. Power Transmission ................................................................................... 155
Measured and Calculated temp. .......................................................................... 239
Menu Tree
SMC ............................................................................................................... 255
TSMC ............................................................................................................. 258

0178-931 - ENG 283/288

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

N Needle bearing
TSMC ...............................................................................................................44
Nitrogen charge .....................................................................................................71
Noise ...................................................................................................................166
Damping Acoustic Noise ................................................................................171
Reverberation Time .......................................................................................171
Normal set of tools .................................................................................................97
Nozzle size ............................................................................................................49

O 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

284/288 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

P 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
0178_931IX.fm

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

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

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

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

Safety Instructions

0178-931 - ENG 285/288

Rev. 27.10.03
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

286/288 0178-931 - ENG

Rev. 27.10.03
 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

T 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
0178_931IX.fm

Thermo Pump
Capacity Regulation ......................................................................................... 92
Thermo pump ........................................................................................................ 89
Description of the Pumping Cycle .................................................................... 92
Ensuring Liquid ................................................................................................ 94
Power Connection ............................................................................................ 95
Structure .......................................................................................................... 90
Thermodynamic Liquid Trap .................................................................................. 50
TLT Thermodynamic Liquid Trap .......................................................................... 50
Tool Safety ............................................................................................................ 20
Total Unloading ..................................................................................................... 63
Transport
Data ............................................................................................................... 262
Instructions ..................................................................................................... 261
TT5 ...................................................................................................................... 112
TT6 ...................................................................................................................... 112
TT7 ...................................................................................................................... 112
TWA-Werte ............................................................................................................ 25
Two-stage .............................................................................................................. 32
Two-stage Compressors
TSMC ............................................................................................................... 43
Type
E ....................................................................................................................... 31
L ....................................................................................................................... 31
S ....................................................................................................................... 31
Types of Spare Parts Set ...................................................................................... 98

0178-931 - ENG 287/288

Rev. 27.10.03
SMC /TSMC 100 Mk4 - Engineering Manual

U 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

V 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

W 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

288/288 0178-931 - ENG

Rev. 27.10.03