Sabroe CMO/TCMO/HPO Installation Operation and Maintenance Guide

CMO/TCMO 20-30 and HPO 24-26-28 (including ATEX)

Reciprocating compressor units

Engineering manual (including installation and service)

en

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Manual for CMO/TCMO 20-30 and HPO 24-26-28

Compressor type

CMO 24 CMO 26 CMO 28 TCMO 28

CMO 34 CMO 36 CMO 38 TCMO 38

HPO 24 HPO 26 HPO 28

Compressor no.

Refrigerant R717 R22 R134a

R404A R507 R744 Other _____

Control UniSAB III None Other

Compressor

cooling

Thermopump

Water-cooled top and side covers

Air-cooled top and side covers

Air-cooled top covers and water-cooled side covers

Air-cooled top and side covers + oil cooling (refrigerant-cooled)

Drive type Fixed speed Variable speed (VSD)

Ex-execution

(ATEX) T3 T4 Other ________

Additional suction filter

Oil return on parallel systems

Oil separator Sabroe OVUR Sabroe OHUR

Intermediate

cooling system

With internal intermediate cooling system

With external intermediate cooling system

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Safety valve:

Data for calculation of

downstream line accord-

ing to EN 13136

Vessel data

Type External surface

[m2]

Design pressure

[bar]

Condenser

Evaporator

Liquid separator

Oil separator

Oil cooler

Economiser

Desuperheater

Subcooler

Other

Pressure loss, if any, from safety valve to customer connection

(based on design pressure) [bar] _____________

Safety valve type:

Back-pressure dependent

Back-pressure independent

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Contents

1. Introduction ................................................................................... 14

1.1 Main users.............................................................................. 14

1.2 Models covered...................................................................... 14

1.3 Amendments to the manual.................................................. 15

1.4 Manufacturer's information .................................................. 15

1.5 Safety precaution definitions used in this manual ............... 16

1.6 Requirements for competent persons .................................. 16

2. Signs and warnings....................................................................... 17

2.1 Main users.............................................................................. 17

2.2 Identification of equipment................................................... 17

2.3 Unit/pipe system name plate ................................................ 18

2.4 Compressor name plates ...................................................... 20

2.5 Labelling of explosion-proof equipment ............................... 22

2.6 Vessel name plate.................................................................. 23

2.7 Signs ..................................................................................... 24

3. Safety precautions ........................................................................ 25

3.1 Areas of application ............................................................... 25

3.1.1 Application...................................................................... 25

3.1.2 Application of combustion engines ................................ 25

3.2 Safety precautions ................................................................ 26

3.2.1 Emergency stop.............................................................. 26

3.2.2 General precautions ....................................................... 26

3.2.3 Work area safety ............................................................ 27

3.2.4 During operation ............................................................ 27

3.2.5 Transmission safety........................................................ 28

3.2.6 Cooling water system..................................................... 28

3.2.7 Safety during maintenance and service ........................ 28

3.2.8 Electrical installations .................................................... 29

3.2.9 Power supply .................................................................. 30

3.2.10 Lubricating oils ............................................................... 30

3.2.11 Refrigerants.................................................................... 30

3.2.12 Purging a refrigeration plant .......................................... 30

3.2.13 F-gas regulation (fluorinated greenhouse

gases) ............................................................................. 31

3.2.14 First aid for accidents with ammonia ............................. 33

3.2.15 First aid for accidents with HFC/HCFC ........................... 34

3.2.16 First aid for accidents with carbon dioxide

(CO2)............................................................................... 35

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3.2.17 Protecting the operator as well as the

environment ................................................................... 36

3.2.18 Noise data....................................................................... 39

3.2.19 Noise data for CMO, TCMO and HPO

compressors ................................................................... 39

4. Technical description ................................................................... 42

4.1 Compressor data ................................................................... 42

4.1.1 Description of CMO/TCMO and HPO

compressors ................................................................... 42

4.1.2 Cylinder lining with suction valve .................................. 44

4.1.3 Discharge valve .............................................................. 44

4.1.4 Connecting rod ............................................................... 44

4.1.5 Suction filter ................................................................... 45

4.1.6 Extra suction filter (non-standard)................................ 45

4.1.7 Relief valve ..................................................................... 45

4.1.8 Crankshaft ...................................................................... 46

4.1.9 Bearings for crankshaft.................................................. 46

4.1.10 Oil pump ......................................................................... 46

4.1.11 Oil pressure regulating valve ......................................... 46

4.1.12 Oil filter ........................................................................... 46

4.1.13 Shaft seal........................................................................ 46

4.1.14 Heating element ............................................................. 47

4.1.15 Oil charging and drain valve........................................... 47

4.1.16 Evacuating valve ............................................................ 48

4.1.17 Stop valves ..................................................................... 48

4.1.18 Cooling of compressor and oil ........................................ 48

4.1.19 Oil consumption.............................................................. 48

4.1.20 Oil separation and oil return on CMO/TCMO and

HPO ................................................................................. 49

4.1.21 Oil return in connection with parallel operation ............ 53

4.1.22 System A......................................................................... 53

4.1.23 System C......................................................................... 56

4.2 Capacity regulation of compressor ....................................... 58

4.2.1 Standard capacity regulation......................................... 58

4.2.2 Capacity regulation and unloaded start ........................ 59

4.2.3 Function .......................................................................... 60

4.2.4 Extended unloading ....................................................... 61

4.2.5 VSD unloading ................................................................ 62

4.2.6 TCMO compressor .......................................................... 63

4.2.7 TCMO with capacity regulation ...................................... 63

4.2.8 Capacity regulation ........................................................ 64

4.2.9 TCMO without capacity regulation................................. 64

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4.3 Hot-gas-controlled capacity regulation, HPO only............... 64

4.3.1 Solenoid valve for hot-gas-controlled capacity

regulation ....................................................................... 64

4.3.2 Hot gas capacity regulation in compressors using

refrigerant R744 (CO2), HPO only.................................. 66

4.3.3 Variable speed drive (VSD) ............................................ 67

4.3.4 Compressor unit ............................................................. 68

4.4 Instrumentation .................................................................... 68

4.4.1 UniSAB III reading, safety and capacity regulating

system ............................................................................ 68

4.5 Cooling systems for compressor........................................... 70

4.5.1 Refrigerant-cooled oil cooler for CMO and HPO

compressors ................................................................... 70

4.5.2 Cooling of intermediate gas on TCMO ........................... 72

4.5.3 Intermediate cooling system with intermediate

cooler type VMA, R717 ................................................... 72

4.5.4 Intermediate cooling system with liquid injection in-

to the intermediate discharge gas, HFC/HCFC and

R717................................................................................ 74

4.5.5 Water-cooling of the reciprocating compressor ............ 78

4.6 Selecting lubricating oil for Sabroe recip.

compressors .......................................................................... 83

4.6.1 Oil charge........................................................................ 83

4.7 Compressor accessories........................................................ 83

4.7.1 Thermopump cooling of R717 reciprocating

compressor..................................................................... 83

5. Physical and connection data ..................................................... 85

5.1 Safety precautions ................................................................ 85

5.2 Physical data.......................................................................... 85

5.3 Connections on CMO/HPO 24-26-28 .................................... 86

5.4 Connections on TCMO 28/38................................................. 87

5.5 Electrical connections............................................................ 88

5.6 Control of the unit.................................................................. 89

5.7 Pressure transmitters marked PT1, PT2 and PT3................. 89

5.8 Temperature sensors............................................................. 90

5.9 Heating element for oil heating............................................. 91

5.10 Coils for solenoid valves ........................................................ 91

6. Technical data ................................................................................ 92

6.1 Compressor data for reciprocating compressors CMO/

TCMO/HPO ............................................................................. 92

6.2 Dimension sketches of compressor block............................. 93

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6.3 Planning the machine room .................................................. 94

6.4 Requirements for ambient temperatures and

humidity................................................................................. 94

6.5 Operating limits ..................................................................... 96

6.5.1 Operating limits diagrams.............................................. 96

6.5.2 List of operating limits diagrams.................................. 100

6.5.3 R717 Single-stage compressor CMO and SMC............ 100

6.5.4 R717 Two-stage compressor TCMO and TSMC ........... 101

6.5.5 R717 Single-stage compressor HPO............................ 102

6.5.6 R22 Single-stage compressor CMO and SMC.............. 103

6.5.7 R22 Two-stage compressor TCMO and TSMC.............. 104

6.5.8 R23 Single-stage compressor CMO and SMC.............. 105

6.5.9 R134a Single-stage compressor CMO ......................... 106

6.5.10 R134a Two-stage compressor TCMO and TSMC 100

S-L................................................................................. 107

6.5.11 R290 Single-stage compressor CMO and SMC............ 108

6.5.12 R290 Two-stage compressor TCMO and TSMC ........... 109

6.5.13 R404A Single-stage compressor CMO and

SMC............................................................................... 110

6.5.14 R404A Two-stage compressor TCMO and

TSMC............................................................................. 111

6.5.15 R407C Single-stage compressor CMO......................... 112

6.5.16 R407C Two-stage compressor TCMO and

TSMC............................................................................. 113

6.5.17 R507 Single-stage compressor CMO and SMC............ 114

6.5.18 R507 Two-stage compressor TCMO and TSMC ........... 115

6.5.19 R600 Single-stage compressor CMO and SMC............ 116

6.5.20 R600 Two-stage compressor TCMO and TSMC ........... 117

6.5.21 R600a Single-stage compressor CMO and

SMC............................................................................... 118

6.5.22 R600a Two-stage compressor TCMO and

TSMC............................................................................. 119

6.5.23 R744 Single-stage compressor HPO............................ 120

6.5.24 R1270 Single-stage compressor CMO and

SMC............................................................................... 121

6.5.25 R1270 Two-stage compressor TCMO and

TSMC............................................................................. 122

6.5.26 LPG Single-stage compressor CMO and SMC .............. 123

6.5.27 LPG Two-stage compressor TCMO and TSMC.............. 124

6.6 Motor.................................................................................... 125

6.6.1 Direction of rotation ..................................................... 125

6.6.2 Choice of electric motor ............................................... 126

6.6.3 Starting torque of the compressor............................... 127

6.6.4 Moment of inertia ......................................................... 127

6.6.5 Handling of compressor and unit ................................. 128

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6.6.6 Compressor shaft ......................................................... 129

6.6.7 Coupling........................................................................ 129

6.7 Noise and vibration.............................................................. 131

6.7.1 Vibration data for compressors - all compressor

types ............................................................................. 131

6.7.2 Unbalanced forces and moments ................................ 132

6.7.3 Noise data..................................................................... 135

6.7.4 Noise data for CMO, TCMO and HPO

compressors ................................................................. 136

6.8 Materials and pressure levels.............................................. 139

6.8.1 Specification of compressor materials ........................ 139

6.8.2 Test pressure levels for standard compressors and

components.................................................................. 140

7. Installation instructions............................................................ 141

7.1 Safety precautions .............................................................. 141

7.2 Installation data .................................................................. 141

7.3 Installation and first start-up procedure ............................ 141

7.4 Installation drawings........................................................... 141

7.5 Personnel requirements ...................................................... 141

7.6 Tools and accessories .......................................................... 142

7.7 Safety equipment ................................................................ 142

7.8 Preparing the mounting site................................................ 142

7.9 Laying the unit foundation .................................................. 143

7.10 Mounting directly on the foundation................................... 145

7.11 Damping using vibration dampers...................................... 146

7.12 Mass damping between unit and building .......................... 148

7.13 Marine installation ............................................................... 149

7.14 VSD equipment.................................................................... 149

7.15 Installation instructions ...................................................... 150

7.16 Alignment ............................................................................ 150

7.16.1 Alignment of unit against foundation .......................... 150

7.16.2 Mounting directly on foundation .................................. 150

7.16.3 Alignment of compressor on base frame..................... 151

7.16.4 Alignment of motor on base frame .............................. 151

7.16.5 Fitting and alignment of coupling ................................ 152

7.16.6 Preliminary installation of coupling ............................. 153

7.16.7 Inspection of coupling .................................................. 155

7.16.8 Storage of rubber elements ......................................... 156

7.16.9 Alignment of coupling .................................................. 157

7.16.10 Achieving correct centre height ................................... 157

7.16.11 Achieving parallel shafts in vertical plane ................... 158

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7.16.12 Final installation of coupling ........................................ 158

7.17 Piping connections............................................................... 159

7.18 Connecting electricity supply .............................................. 159

7.19 Pressure testing................................................................... 161

7.19.1 Final installation check ................................................. 163

8. Components ................................................................................. 164

8.1 CMO/TCMO/HPO components ............................................ 164

8.1.1 Motors ........................................................................... 165

8.1.2 Transmission systems .................................................. 165

8.1.3 Direct drive ................................................................... 165

8.1.4 Oil separators ............................................................... 165

8.1.5 Oil coolers ..................................................................... 165

8.2 Control and monitoring system .......................................... 166

8.2.1 UniSAB III..................................................................... 166

9. Settings ......................................................................................... 167

10. Operating instructions ............................................................... 169

11. Maintenance instructions.......................................................... 170

11.1 Maintenance ........................................................................ 170

11.1.1 Safety precautions ....................................................... 170

11.1.2 Maintenance of compressor unit.................................. 170

11.1.3 Stopping routine........................................................... 172

11.1.4 Service intervals........................................................... 173

11.1.5 Service interval diagrams ............................................ 173

11.1.6 Annual service .............................................................. 176

11.1.7 Regular service schedule - refrigeration plant ............ 177

11.1.8 Regular service schedule ............................................. 178

11.1.9 Visual inspection........................................................... 179

11.1.10 Measures to be taken ................................................... 179

11.1.11 General rules for use of lubricating oil in refrigera-

tion compressors.......................................................... 181

11.1.12 Assessing the oil ........................................................... 181

11.1.13 Analytical evaluation .................................................... 181

11.1.14 Charging the compressor with lubricating oil.............. 182

11.1.15 Oil charge - Oil level ..................................................... 182

11.1.16 Oil charge...................................................................... 183

11.1.17 Compressor prelubrication .......................................... 183

11.1.18 Oil charging and drain valve......................................... 185

11.1.19 Hand-operated oil pump .............................................. 185

11.1.20 Shaft seal...................................................................... 186

11.1.21 Motor lubrication .......................................................... 186

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12. Faultfinding instructions ........................................................... 187

12.1 How to carry out faultfinding............................................... 187

12.2 Remedying malfunctions..................................................... 190

13. Service instructions.................................................................... 196

13.1 Introduction......................................................................... 196

13.2 General preparations before service .................................. 196

13.3 Servicing the compressor and refrigeration plant.............. 197

13.3.1 Pressure drop test ........................................................ 197

13.3.2 Removing refrigerant from the compressor................ 198

13.3.3 Checking the refrigeration plant .................................. 198

13.3.4 General guidelines........................................................ 199

13.4 Maintenance of reciprocating compressor ......................... 201

13.4.1 Preparation for maintenance ....................................... 201

13.4.2 If the compressor is operational .................................. 201

13.4.3 If the compressor is inoperative .................................. 201

13.5 Dismantling and assembly .................................................. 202

13.5.1 Water covers................................................................. 202

13.5.2 Top covers..................................................................... 202

13.5.3 Mounting of top cover................................................... 202

13.5.4 Discharge valve ............................................................ 203

13.5.5 Discharge valve types .................................................. 204

13.5.6 Suction valve types ...................................................... 204

13.5.7 Service life of discharge and suction valves ................ 204

13.5.8 Cylinder lining with suction valve ................................ 205

13.5.9 Extracting cylinder lining ............................................. 205

13.5.10 Dismantling suction valve ............................................ 205

13.5.11 Mounting suction valve ................................................ 206

13.5.12 Inserting cylinder lining ............................................... 206

13.5.13 Connecting rod ............................................................. 206

13.5.14 How to remove piston and connection rod .................. 207

13.5.15 Fitting connecting rod .................................................. 207

13.5.16 Piston ............................................................................ 208

13.5.17 Procedure for removing piston and connection

rod................................................................................. 208

13.5.18 Dismantling of unloading cylinder ............................... 208

13.5.19 Disassembly of unloading cylinder .............................. 209

13.5.20 Assembly of unloading cylinder ................................... 209

13.5.21 Mounting of unloading cylinder in the

compressor................................................................... 209

13.5.22 Shaft seal...................................................................... 210

13.5.23 Assembling and mounting shaft seal........................... 212

13.5.24 Crankshaft .................................................................... 213

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13.5.25 Dismantling crankshaft ................................................ 214

13.5.26 Inspection..................................................................... 214

13.5.27 Refitting crankshaft...................................................... 214

13.5.28 Main bearings ............................................................... 215

13.6 Lubricating system .............................................................. 215

13.6.1 Compressor lubricating system ................................... 215

13.6.2 Oil pump ....................................................................... 216

13.6.3 Dismantling of oil pump ............................................... 217

13.6.4 Mounting of oil pump.................................................... 217

13.6.5 Oil pressure regulating valve ....................................... 217

13.6.6 Oil filter ......................................................................... 219

13.6.7 Changing oil filter cartridge ......................................... 219

13.7 Relief valve .......................................................................... 220

13.7.1 Description of relief valve............................................. 220

13.8 Hot-gas-controlled capacity regulation.............................. 221

13.8.1 Dismantling and assembly of solenoid valves............. 222

13.9 Coupling............................................................................... 222

13.10 Refrigeration plant............................................................... 222

13.10.1 Refrigeration plant maintenance ................................. 222

13.10.2 Pumping down refrigeration plant ............................... 222

13.11 Dismantling plant ................................................................ 223

13.12 Tightness testing and pump down of refrigeration

plant ..................................................................................... 223

13.13 Spare parts .......................................................................... 223

13.13.1 How to order spare parts.............................................. 223

14. Transport instructions ............................................................... 225

14.1 Transport data ..................................................................... 225

14.2 Personnel requirements ...................................................... 225

14.3 Loading instructions ............................................................ 225

14.4 Transport instructions ......................................................... 226

14.5 Unloading instructions ........................................................ 227

14.6 Storage ................................................................................ 227

15. Commissioning instructions ..................................................... 228

15.1 Safety precautions .............................................................. 228

15.2 Preparations for commissioning ......................................... 228

15.3 Preparing the installation site ............................................. 229

15.4 Commissioning instructions................................................ 229

15.5 Commissioning checklist..................................................... 231

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16. Spare parts list............................................................................. 232

16.1 Please see separate Spare parts manual............................ 232

17. Spare parts drawings ................................................................. 233

17.1 Please see separate Spare parts manual............................ 233

18. Final disposal ............................................................................... 234

18.1 Safety precautions .............................................................. 234

18.2 Waste disposal ..................................................................... 234

19. Appendices ................................................................................... 235

19.1 Sundry clearances and check dimensions.......................... 235

19.2 Torque for screws and bolts ................................................ 236

19.3 Connecting rod .................................................................... 236

19.4 General torque..................................................................... 237

19.5 Coupling data....................................................................... 239

19.6 Capacity diagrams for CMO, TCMO and HPO

compressors ........................................................................ 240

Index.............................................................................................. 244

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Introduction

1. Introduction

The Sabroe reciprocating compressor and unit can be configured with various types of equipment

depending on its function and requirements. Some of the equipment may be described in this

manual even though it is not featured on your particular unit.

This all-in-one manual provides all compressor information needed for sales, installation, mainte-

nance and service. Operating instructions and spare parts data are not included, but can be found

in the operating and spare parts manuals respectively.

The manual includes:

• Description of all component parts

• Description of all important technical functions to ensure a thorough understanding of the

product functionality

• Refrigerant safety

• Connecting data

• Installation, maintenance, service instructions

• and much more.

1.1 Main users

This manual is primarily intended for sales, service and contracting purposes.

All compressor intervention within the warranty period must be performed by competent person-

nel only. If not, the warranty no longer applies.

1.2 Models covered

• CMO 20-30

• TCMO 20-30

• HPO 24 -26 -28

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Introduction

1.3 Amendments to the manual

2021.04 Version 6

• Oil charging instructions changed, see section 11.1.16 Oil charge and Table 46.

• Principle diagram showing two compressors in parallel operation, section 4.1.22 System

A, has been updated.

• Various minor changes/corrections.

2020.05 Version 5

• Section 6.4 Requirements for ambient temperatures and humidity has been updated in

accordance with the latest WHC (Water Heating and Cooling system) updates.

• Fig. 33 has been corrected for CMO/HPO 28–38.

• Various minor changes/corrections.

2019.09 Version 4

• The section ‘Water-cooling of the reciprocating compressor’ has been updated.

• Two tables showing ‘Unbalanced forces and moments’ have been added.

• Various minor changes/corrections.

2018.06 Version 3

• Noise data for 1800 rpm have been added.

• The ‘Storage’ section in the ‘Transport instructions’ chapter has been revised.

• Operating limits and more for R410A have been removed as the refrigerant has been

phased out.

• Cooling of side covers: the max. permissible cooling water pressure changed from 8 to

10 bar.

2018.03 Version 2

• Added information about ATEX, for example table with temperature classes.

• Name plates with EurAsian Conformity mark (EAC) have been added.

• A ‘Requirements for competent persons’ section has been added.

• The ‘F-gas regulation’ section has been updated.

• Declaration of conformity has been removed. It can be found in the operating manuals.

1.4 Manufacturer's information

This manual is produced by:

Johnson Controls Denmark ApS

Christian X's Vej 201

8270 Højbjerg, Denmark

Phone +45 87 36 70 00

CVR No 19 05 61 71

www.sabroe.com

This manual must not be copied without the written permission of Johnson Controls Denmark and

the contents must not be imparted to a third party nor be used for any unauthorised purposes.

Contravention will be prosecuted.

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Introduction

1.5 Safety precaution definitions used in this manual

Danger!

Indicates an imminently hazardous situation which, if not avoided, will result in death or serious

injury.

Warning!

Indicates a potentially hazardous situation or practice which, if not avoided, will result in death or

serious injury.

Caution!

Indicates a potentially hazardous situation or practice which, if not avoided, will result in damage

to equipment and/or minor injury.

Note: Indicates an operating procedure, practice, or portion thereof, which is essential to

highlight.

1.6 Requirements for competent persons

• Personnel working on the unit must be competent in accordance with national safety rules

and regulations relating to flammable refrigerants or according to EN 13313.

• Maintenance work must be performed according to EN 378 or ISO 5149 supported by evi-

dence of appropriate training.

• Assign only competent personnel instructed in safety and all machine functions to operate

or service the compressor/unit according to EN 13313.

• Operators and maintenance personnel must carefully read, understand and fully comply

with all alarms and instructions.

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Signs and warnings

2. Signs and warnings

This chapter describes:

• how to identify equipment from Johnson Controls Denmark

• all warning signs used on equipment delivered by Johnson Controls Denmark

• how information important to safety of personnel and equipment is presented in instruc-

tions belonging to equipment delivered by Johnson Controls Denmark

2.1 Main users

Information concerning Signs and warnings is intended for all users.

The following describes the importance of the individual signs attached to the Johnson Controls

Denmark products.

Before a compressor/unit is put into operation, it must be fitted with the warning signs belonging

to the type of compressor/unit in accordance with the rules and regulations in force.

2.2 Identification of equipment

All Johnson Controls Denmark equipment can be identified by one or several name plates as illus-

trated in the following:

Fig. 1: Identification of name plates

Unit pipe system name plate

Vessel name plateCompressor name plate

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Signs and warnings

2.3 Unit/pipe system name plate

Scope

Design code

Approval No

Refrigerant

Supply voltage

Test pressure

Allowable pressure

Sabroe CMO/TCMO/HPO Installation Operation and Maintenance Guide

Sabroe CMO/TCMO/HPO Installation Operation and Maintenance Guide

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