Sabroe SMC/TSMC/HPC/HPX Mk 4 LL and Mk 5 Installation Operation and Maintenance Guide

SMC/TSMC/HPC/HPX Mk 4 LL & Mk 5

Reciprocating compressor units

Engineering manual (including installation and service) EN

Engineering manual - SMC/TSMC/HPC 100 Mk 4 LL & Mk 5 and HPX 700 Mk 4 LL & Mk 5

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Manual for SMC/TSMC/HPC/HPX Mk 4 LL & Mk 5 compressors

Compressor

type

SMC TSMC HPC S L E

104 106 108 112 116

HPX 704 706 708 712 716

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 ________

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......................................................................................... 15

1.1 Introduction to manual................................................................ 15

1.1.1 Main users .........................................................................15

1.1.2 Models covered .................................................................. 15

1.1.3 Amendments to the manual ................................................. 15

1.1.4 Manufacturer's information .................................................. 18

1.1.5 Safety precaution definitions used in this manual................... 19

1.1.6 Requirements for competent persons ................................... 19

2. Signs and warnings............................................................................. 20

2.1 Main users ................................................................................20

2.2 Identification of equipment ..........................................................20

2.3 Unit/pipe system name plate.......................................................21

2.4 Compressor name plates............................................................ 23

2.5 Labelling of explosion-proof equipment........................................25

2.6 Vessel name plate...................................................................... 26

2.7 Signs .......................................................................................27

3. Safety precautions .............................................................................. 28

3.1 Areas of application.................................................................... 28

3.2 Application of combustion engines .............................................. 29

3.3 Safety precautions .....................................................................29

3.3.1 Emergency stop.................................................................. 29

3.3.2 General precautions............................................................ 30

3.3.3 Work area safety.................................................................30

3.3.4 During operation .................................................................30

3.3.5 Transmission safety ............................................................ 31

3.3.6 Cooling water system..........................................................31

3.3.7 Safety during maintenance and service ................................ 31

3.3.8 Electrical installations..........................................................33

3.3.9 Power supply...................................................................... 33

3.3.10 Lubricating oils ................................................................... 33

3.3.11 Refrigerants ....................................................................... 34

3.3.12 Purging a refrigeration plant................................................. 34

3.3.13 F-gas regulation (fluorinated greenhouse gases)................... 34

3.3.14 First aid for accidents with ammonia..................................... 37

3.3.15 First aid for accidents with HFC/HCFC .................................38

3.3.16 First aid for accidents with carbon dioxide (CO2).................... 39

3.3.17 Protecting the operator as well as the environment ................ 40

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4. Technical description .......................................................................... 43

4.1 Description of compressor ..........................................................43

4.1.1 Compressor types............................................................... 43

4.1.2 SMC-TSMC compressors.................................................... 43

4.1.3 HPC compressors............................................................... 44

4.1.4 HPX compressors............................................................... 45

4.1.5 Compressor type and version .............................................. 45

4.1.6 Marine application............................................................... 46

4.2 Single-stage compressor............................................................ 47

4.2.1 General.............................................................................. 47

4.2.2 Cylinder liners .................................................................... 47

4.2.3 Pistons............................................................................... 48

4.2.4 Suction valve...................................................................... 49

4.2.5 Discharge valve and safety spring........................................49

4.2.6 Connecting rod ................................................................... 50

4.2.7 Suction filter and filter bag ...................................................52

4.2.8 Relief valve ........................................................................52

4.2.9 Crankshaft .........................................................................55

4.2.10 Oil pump ............................................................................55

4.2.11 Oil pressure regulating valve................................................ 56

4.2.12 Oil suction strainer (internal oil filter)..................................... 56

4.2.13 External oil filter .................................................................. 57

4.2.14 Monitoring of external oil filter .............................................. 59

4.2.15 Shaft seal........................................................................... 61

4.2.16 Heating element .................................................................61

4.2.17 Oil draining valve ................................................................ 62

4.2.18 Oil level glass .....................................................................62

4.2.19 Evacuating valve ................................................................ 62

4.2.20 Stop valves ........................................................................63

4.2.21 Cooling of compressor and oil.............................................. 63

4.3 Two-stage compressors type TSMC 100...................................... 65

4.3.1 Description of two-stage compressor....................................65

4.3.2 Compressor block TSMC 100 .............................................. 65

4.3.3 Piston pin bearing TSMC 100 .............................................. 65

4.3.4 Suction filters, TSMC 100 .................................................... 67

4.4 Conversion of TSMC from two-stage to single-stage..................... 68

4.5 Oil consumption.........................................................................68

4.5.1 CVS - Crankcase Ventilation System....................................69

4.6 Oil separator.............................................................................. 73

4.6.1 Oil separator types OHUR/OVUR......................................... 73

4.6.2 One-stage horizontal type (coalescer) .................................74

4.6.3 Two-stage vertical type (demister and coalescer) ..................74

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4.7 Oil return to the compressor........................................................ 75

4.7.1 Solenoid valve controlled oil return ....................................... 75

4.7.2 Oil return in connection with parallel operation ......................76

4.8 Capacity regulation of the compressor, SMC/HPC 100..................80

4.8.1 Capacity regulation and unloading of the compressor ............ 80

4.8.2 Mechanism of capacity regulation system .............................80

4.8.3 Unloaded compressor start.................................................. 82

4.8.4 Solenoid valves for capacity regulation .................................82

4.8.5 "Standard unloading" capacity regulation.............................. 83

4.8.6 "Total unloading" capacity regulation ....................................85

4.8.7 "Extended unloading" capacity regulation .............................86

4.8.8 Variable speed drive (VSD).................................................. 89

4.9 Capacity regulation of the compressor, HPX 700 .......................... 91

4.9.1 Capacity regulation and unloading of the compressor ............ 91

4.9.2 Mechanism of capacity regulation system .............................91

4.9.3 Unloaded compressor start.................................................. 92

4.9.4 Solenoid valves for capacity regulation .................................92

4.9.5 “Standard unloading” capacity regulation .............................. 93

4.9.6 “Total unloading” capacity regulation ....................................94

4.9.7 Variable speed drive (VSD).................................................. 95

4.10 Compressor unit ........................................................................96

4.11 Instrumentation.......................................................................... 98

4.11.1 Analogue reading and safety system ....................................98

4.11.2 UniSAB III reading, safety and capacity regulating

system ............................................................................. 101

4.12 Cooling of the intermediate discharge gas on TSMC

compressors............................................................................ 102

4.12.1 Intermediate cooling system with intermediate cooler type

DVEA, R717..................................................................... 102

4.12.2 Intermediate cooling system with liquid injection into the in-

termediate discharge gas, R22 and R717 ........................... 103

4.12.3 Automatic regulation of intermediate pressure IP................. 104

4.12.4 Determining the intermediate pressure, IP .......................... 105

4.13 Cooling systems for compressors.............................................. 106

4.13.1 Air-cooled top and side covers with refrigerant-cooled oil

cooler R717 (1a)............................................................... 106

4.13.2 Water-cooled top and side covers - R717 (1b)..................... 109

4.13.3 Cooling with thermopump - R717 (1c)................................. 116

4.13.4 Air-cooled top and side covers - R22, R134a, R404A,

R507 (2a)......................................................................... 124

4.13.5 Air-cooled top covers and water-cooled side covers -

R717, R22, R134a, R404A, R507 (1d + 2b) ........................ 124

4.13.6 Air-cooled top and side covers and refrigerant-cooled oil

cooler

R22, R134a, R404A, R507 (2c).......................................... 125

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4.14 Selecting lubricating oil for Sabroe recip. compressors................ 125

4.14.1 Oil charge ........................................................................ 125

5. Physical and connection data ........................................................... 126

5.1 Safety precautions ................................................................... 126

5.2 Physical data ........................................................................... 126

5.3 Connection data ...................................................................... 126

5.4 Connections to the compressor................................................. 127

5.5 Connections on HPC-SMC-TSMC-HPX..................................... 129

5.6 Connections for HPC-SMC-TSMC-HPX .................................... 131

5.7 Electrical connections .............................................................. 133

5.8 Control of the unit..................................................................... 135

6. Technical data ................................................................................... 136

6.1 Technical data for SMC, TSMC, HPC and HPX .......................... 137

6.2 Planning the machine room ...................................................... 139

6.3 Requirements for ambient temperatures and humidity ................ 140

6.4 Operating limits........................................................................ 142

6.4.1 Operating limits diagrams .................................................. 142

6.4.2 List of operating limits diagrams ......................................... 146

6.4.3 R717 Single-stage compressor CMO and SMC................... 147

6.4.4 R717 Single-stage compressor SMC 100 E ........................ 148

6.4.5 R717 Single-stage compressor HPX 700............................ 149

6.4.6 R717 Two-stage compressor TCMO and TSMC.................. 150

6.4.7 R717 Single-stage compressor HPC .................................. 151

6.4.8 R22 Single-stage compressor CMO and SMC..................... 152

6.4.9 R22 Two-stage compressor TCMO and TSMC.................... 153

6.4.10 R23 Single-stage compressor CMO and SMC..................... 154

6.4.11 R134a Single-stage compressor SMC................................ 155

6.4.12 R134a Single-stage compressor CMO ............................... 156

6.4.13 R134a Two-stage compressor TCMO and TSMC 100 S-

L...................................................................................... 157

6.4.14 R290 Single-stage compressor CMO and SMC................... 158

6.4.15 R290 Two-stage compressor TCMO and TSMC.................. 159

6.4.16 R404A Single-stage compressor CMO and SMC ................ 160

6.4.17 R404A Two-stage compressor TCMO and TSMC................ 161

6.4.18 R407C Single-stage compressor SMC ............................... 162

6.4.19 R407C Two-stage compressor TCMO and TSMC ............... 163

6.4.20 R507 Single-stage compressor CMO and SMC................... 164

6.4.21 R507 Two-stage compressor TCMO and TSMC.................. 165

6.4.22 R600 Single-stage compressor SMC.................................. 166

6.4.23 R600 Two-stage compressor TCMO and TSMC.................. 167

6.4.24 R600a Single-stage compressor SMC................................ 168

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6.4.25 R600a Two-stage compressor TCMO and TSMC ................ 169

6.4.26 R1270 Single-stage compressor CMO and SMC................. 170

6.4.27 R1270 Two-stage compressor TCMO and TSMC ................ 171

6.4.28 R744 Single-stage compressor HPC .................................. 172

6.4.29 LPG Single-stage compressor CMO and SMC .................... 173

6.4.30 LPG Two-stage compressor TCMO and TSMC ................... 174

6.5 Motor ...................................................................................... 175

6.5.1 Direction of rotation of the compressor ............................... 175

6.5.2 Choice of electric motor..................................................... 176

6.5.3 Starting torque of the compressor ...................................... 178

6.5.4 Moment of inertia .............................................................. 181

6.5.5 Direction of rotation of electric motor .................................. 182

6.5.6 Handling of compressor and unit ........................................ 182

6.5.7 Compressor shaft ............................................................. 183

6.5.8 Coupling .......................................................................... 184

6.6 Noise and vibration .................................................................. 186

6.6.1 Vibration data for compressors - all compressor

types................................................................................ 186

6.6.2 Unbalanced forces and moments ....................................... 187

6.6.3 Noise data........................................................................ 190

6.6.4 Noise data specifications................................................... 190

6.7 Materials and pressure levels.................................................... 194

6.7.1 Specification of compressor materials ................................ 194

6.7.2 Test pressure levels for standard compressors and

components ..................................................................... 195

6.7.3 Tightness of Sabroe equipment.......................................... 195

7. Installation instructions..................................................................... 197

7.1.1 Safety precautions ............................................................ 197

7.1.2 Installation data ................................................................ 197

7.1.3 Installation and first start-up procedure ............................... 197

7.1.4 Installation drawings ......................................................... 197

7.1.5 Personnel requirements .................................................... 197

7.1.6 Tools and accessories....................................................... 197

7.1.7 Safety equipment.............................................................. 198

7.1.8 Preparing the mounting site ............................................... 198

7.1.9 Laying the unit foundation.................................................. 199

7.1.10 Mounting directly on the foundation .................................... 201

7.1.11 Damping using vibration dampers ...................................... 202

7.1.12 Mass damping between unit and building............................ 204

7.1.13 Marine installation............................................................. 205

7.1.14 VSD equipment ................................................................ 205

7.1.15 Installation instructions...................................................... 206

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7.2 Alignment................................................................................ 206

7.2.1 Alignment of unit against foundation ................................... 206

7.2.2 Mounting directly on foundation ......................................... 206

7.2.3 Alignment of compressor on base frame ............................. 207

7.2.4 Alignment of motor on base frame...................................... 207

7.2.5 Coupling alignment and fitting ............................................ 207

7.2.6 Preliminary installation of coupling ..................................... 209

7.2.7 Alignment......................................................................... 211

7.2.8 Achieving correct centre height .......................................... 212

7.2.9 Achieving parallel shafts in vertical plane ............................ 213

7.2.10 Final installation of coupling............................................... 213

7.3 Piping connections................................................................... 214

7.4 Connecting electricity supply..................................................... 214

7.5 Pressure testing....................................................................... 216

7.5.1 Final installation check ...................................................... 218

8. Components...................................................................................... 219

8.1 Motors .................................................................................... 220

8.2 Transmission systems.............................................................. 220

8.3 Direct driven ............................................................................ 220

8.4 Oil separators .......................................................................... 221

8.5 Oil coolers ............................................................................... 221

8.6 Electromechanical control......................................................... 221

8.7 UniSAB III ............................................................................... 222

9. Settings............................................................................................. 223

9.1 Extended discharge gas temperatures....................................... 225

10. Operating instructions ...................................................................... 227

11. Maintenance instructions .................................................................. 228

11.1 Safety precautions ................................................................... 228

11.2 Maintenance of compressor unit ............................................... 228

11.3 Stopping routine ...................................................................... 230

11.4 Service intervals ...................................................................... 231

11.5 Service interval diagrams for SMC-TSMC-HPC-HPX.................. 231

11.6 Annual service......................................................................... 236

11.7 Regular service schedule - refrigeration plant............................. 237

11.8 Regular service schedule - compressor unit ............................... 238

11.9 Visual inspection...................................................................... 238

11.10 Measures to be taken............................................................... 239

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11.11 General rules for use of lubricating oil in refrigeration

compressors............................................................................ 241

11.12 Assessing the oil...................................................................... 241

11.13 Analytical evaluation ................................................................ 241

11.14 Charging the compressor with lubricating oil .............................. 243

11.15 Oil charge................................................................................ 244

11.16 Compressor prelubrication........................................................ 245

11.17 Shaft seal................................................................................ 246

11.18 Motor lubrication ...................................................................... 246

12. Faultfinding instructions ................................................................... 247

12.1 How to carry out faultfinding...................................................... 247

12.2 Remedying malfunctions .......................................................... 250

13. Service instructions .......................................................................... 257

13.1 General preparations before service.......................................... 257

13.2 Servicing the compressor ......................................................... 258

13.2.1 Pressure drop test ............................................................ 259

13.2.2 Removing refrigerant from the compressor ......................... 260

13.3 Servicing the refrigeration plant................................................. 261

13.3.1 General guidelines............................................................ 261

13.4 Maintenance of the compressor ................................................ 263

13.4.1 Preparing for maintenance ................................................ 263

13.4.2 If the compressor is operational ......................................... 263

13.4.3 If the compressor is inoperative.......................................... 264

13.5 Service guide........................................................................... 264

13.5.1 Service parts for SMC, TSMC, HPC and HPX ..................... 264

13.5.2 Inspection of thermostats .................................................. 266

13.5.3 Inspection of thermopump ................................................. 266

13.5.4 Inspection of shaft seal...................................................... 267

13.5.5 Inspection of safety controls .............................................. 268

13.5.6 Inspection of heating rod ................................................... 271

13.5.7 Inspection of compressor stop valves ................................. 271

13.5.8 Inspection of coupling ....................................................... 272

13.5.9 Storage of rubber elements ............................................... 273

13.5.10 Inspection of crank main bearings ...................................... 274

13.5.11 Inspection of connecting rod bearings ................................ 274

13.5.12 How to determine the usability of cylinder liners................... 276

13.5.13 Inspection of connecting rod .............................................. 278

13.5.14 Inspection of safety springs ............................................... 280

13.5.15 Inspection of piston pin...................................................... 280

13.5.16 Inspection of pistons ......................................................... 281

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13.5.17 Inspection of valve seats ................................................... 282

13.5.18 Inspection of unloading mechanism.................................... 284

13.6 Dismantling and assembly ........................................................ 285

13.6.1 Water covers .................................................................... 285

13.6.2 Fitting water covers........................................................... 285

13.6.3 Top covers ....................................................................... 286

13.6.4 Fitting top cover ................................................................ 286

13.6.5 Mounting top and water covers .......................................... 287

13.6.6 Discharge valve................................................................ 288

13.6.7 Discharge valve types ....................................................... 288

13.6.8 Suction valve types ........................................................... 289

13.6.9 Service life of discharge and suction valves ........................ 289

13.6.10 Cylinder lining with suction valve ........................................ 290

13.6.11 Extracting cylinder lining.................................................... 290

13.6.12 Dismantling suction valve .................................................. 290

13.6.13 Mounting suction valve...................................................... 290

13.6.14 Inserting cylinder lining...................................................... 291

13.6.15 Monitoring cylinder lining insertion...................................... 291

13.6.16 Connecting rod ................................................................. 294

13.6.17 Procedure for removing piston and connecting rod .............. 294

13.6.18 Fitting bearings................................................................. 295

13.6.19 Fitting connecting rod ........................................................ 295

13.6.20 Piston .............................................................................. 296

13.6.21 Shaft seal......................................................................... 297

13.6.22 Assembling and mounting shaft seal .................................. 299

13.6.23 Coupling .......................................................................... 300

13.6.24 Crankshaft ....................................................................... 300

13.6.25 Dismantling crankshaft ...................................................... 301

13.6.26 Inspection ........................................................................ 301

13.6.27 Refitting crankshaft ........................................................... 301

13.6.28 Main bearings................................................................... 302

13.7 Lubricating system ................................................................... 303

13.7.1 Compressor lubricating system .......................................... 303

13.7.2 Oil pump .......................................................................... 304

13.7.3 Dismantling oil pump......................................................... 308

13.7.4 Oil pressure valve ............................................................. 308

13.7.5 Strainer............................................................................ 309

13.7.6 Oil filter ............................................................................ 309

13.8 Suction filter and relief valve ..................................................... 311

13.8.1 Suction filters.................................................................... 311

13.8.2 Relief valve, pos. 24.......................................................... 311

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13.9 Pressure gauges...................................................................... 312

13.9.1 Description....................................................................... 312

13.9.2 Adjustment to other temperature ranges ............................. 313

13.9.3 Cleaning and refilling glycerine-filled gauges....................... 313

13.10 Refrigeration plant ................................................................... 314

13.10.1 Refrigeration plant maintenance ........................................ 314

13.10.2 Dismantling plant .............................................................. 316

13.10.3 Tightness testing and pump down of refrigeration

plant ................................................................................ 316

13.11 Spare parts ............................................................................. 316

13.11.1 How to order spare parts ................................................... 316

14. Transport instructions....................................................................... 318

14.1 Transport data ......................................................................... 318

14.2 Personnel requirements ........................................................... 318

14.3 Loading instructions ................................................................. 318

14.4 Transport instructions............................................................... 319

14.5 Unloading instructions .............................................................. 320

14.6 Storage ................................................................................... 320

15. Commissioning instructions ............................................................. 321

15.1 Safety precautions ................................................................... 321

15.2 Preparations for commissioning ................................................ 321

15.3 Preparing the installation site .................................................... 322

15.4 Commissioning instructions ...................................................... 322

15.5 Checklist for commissioning...................................................... 324

16. Spare parts list .................................................................................. 326

16.1 Please see separate Spare parts manual................................... 326

17. Spare parts drawings ........................................................................ 327

17.1 Please see separate Spare parts manual................................... 327

18. Final disposal.................................................................................... 328

18.1 Safety precautions ................................................................... 328

18.2 Waste disposal ........................................................................ 328

19. Appendices ....................................................................................... 329

19.1 Torque for screws and bolts ...................................................... 329

19.2 Connecting rods ...................................................................... 330

19.3 General torque ........................................................................ 330

19.4 Coupling data .......................................................................... 333

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19.5 Sundry clearances and check dimensions ................................. 334

19.6 Capacity diagrams, SMC and TSMC compressors ..................... 336

19.7 Capacity diagrams, HPC compressors ...................................... 355

19.8 Capacity diagrams, HPX compressors....................................... 363

Index ................................................................................................. 371

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Introduction

1. Introduction

1.1 Introduction to manual

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

ment 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, main-

tenance 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.

1.1.1 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 per-

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

1.1.2 Models covered

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

• HPC 104 - 106 - 108 - 112 - 116

• HPX 704 - 706 - 708 -712 - 716.

1.1.3 Amendments to the manual

2023.06 Version 11

• Description of the oil separator types added.

See updated section 4.6.1 Oil separator types OHUR/OVUR and new section 4.6.3 Two-stage

vertical type (demister and coalescer).

2023.04 Version 10

• The compressor, vessel and unit pipe system name plates have been updated.

• Updated operating limits diagrams, see sections: 6.4.5 R717 Single-stage compressor HPX 700,6.4.22 R600 Single-

stage compressor SMC and 6.4.24 R600a Single-stage compressor SMC.

• Updated section: 4.13.2 Water-cooled top and side covers - R717 (1b).

• Various minor changes.

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Introduction

2021.12 Version 9

• Coupling data changes in Table 44 and Table 78.

• Subsection 6.7.3: Tightness of Sabroe equipment added.

• Subsection 15.5 Checklist for commissioning added - the list can be filled in electronically.

• Various minor changes.

2021.04 Version 8

• Oil charging instructions changed, see section 11.15 Oil charge,Table 57: Oil charge and Table 58: Oil level.

• Capacity diagrams for HPC 112 and HPC 116 have been added, section 19.7

• Principle diagram in section 4.7.2 Oil return in connection with parallel operation has been updated.

• Various minor changes.

2019.11 Version 7

• Section 6.3 Requirements for ambient temperatures and humidity has been updated in accordance with the latest

WHC (Water Heating and Cooling system) updates.

• Updated instructions in section 7.2.6 Preliminary installation of coupling.

• Min. rpm for TSMC compressors changed from 500 to 700 in all operating limits tables in section 6.4.2 List of operating

limits diagrams.

• Various minor corrections.

2019.06 Version 6

• Section about ‘Water-cooled top and side covers, R717’ has been updated.

• New section about the Crankcase Ventilation System (CVS).

• Various minor corrections.

2018.10 Version 5

• The regular service schedule, Table 56, and the ‘Annual service’ section have been updated.

• Lists of service parts have been updated.

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

• Various minor corrections.

2018.06 Version 4

• Drawings of SMC units have been updated – now showing single-beam units.

• Drawings of SMC compressors have been updated - now showing Mk 5 design.

• 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.

• Declarations of conformity (unit and ATEX) have been removed. They can be found in the operating manuals.

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Introduction

2018.01 Version 3

• The manual now covers version Mk 4 LL as well as Mk 5.

• HPC 112-116 and HPX 712-HPX 716 have been added.

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

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

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

• New operating limits diagram for R717 single-stage HPC compressor

• Compressor weights changed.

• Correction in connections table, pos. AC.

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

• Updated versions of declarations of conformity: Unit and ATEX.

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Introduction

1.1.4 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 purpo-

ses. Contravention will be prosecuted.

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Introduction

1.1.5 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 dam-

age to equipment and/or minor injury.

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

highlight.

1.1.6 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

evidence of appropriate training.

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

ate or service the compressor/unit according to EN 13313.

• Operators and maintenance personnel must carefully read, understand and fully com-

ply 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 Con-

trols Denmark products.

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

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

2.2 Identification of equipment

All equipment from Johnson Controls Denmark can be identified by one or several name plates

positioned as illustrated in Fig. 1.

Fig. 1: Position of name plates

Unit pipe system name plateVessel name plate Compressor name plate

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Sabroe SMC/TSMC/HPC/HPX Mk 4 LL and Mk 5 Installation Operation and Maintenance Guide

Sabroe SMC/TSMC/HPC/HPX Mk 4 LL and Mk 5 Installation Operation and Maintenance Guide

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