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SABROE Guia de Servicio SMC-100 TSMC-100 Mk1,2,3 y 4
SABROE Guia de Servicio SMC-100 TSMC-100 Mk1,2,3 y 4
SeviceGuide_0178_948TOC.fm
Contents
Contents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Service intervals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Inspection of thermostats . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Inspection of thermopump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Inspection of shaft seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Inspection of safety controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Inspection of heating rod . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Inspection of compressor stop valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Inspection of coupling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Inspection of crank main bearings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Inspection of connecting rod bearings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
How to determine usability of cylinder liners . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Inspection of connecting rod . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Inspection of safety springs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Inspection of piston pin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Inspection of pistons . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Inspection of valve seats . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Inspection of unloading mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
0178-948 - ENG
Rev. 04.04
1
3
4
8
8
9
9
12
12
13
15
16
18
21
24
25
26
27
30
1/30
2/30
0178-948 - ENG
Rev. 04.04
Service intervals
The service interval for a reciprocating compressor should be determined in the following way:
1.
Fig. 1.3
TC
qF qC
14060
12250
Condensing temperature
140
60
122
50
104
40
Condensing temperature
qC
86
30
68
20
50
10
32
5,000
6,000
10,000
14
10
20
30
40
qC
32
50
68
86 104
qF
Condensing temperature
--4
TE
Evaporating temperature
Fig. 1.2
TC
qC
140
60
122
50
104
40
86
30
68
20
50
10
32
32 0
12,000
--60 --50 --40 --30 --20 --10 0 qC
TE
--76 --58 --40 --22 --4 14 32
qF
Evaporating temperature
140 60
70
50 10
qF
13,000
T0113097_0
158
10,000
11,000
68 20
Fig. 1.4
12,000
qF
6,000
8,000
86 30
11,000
14 --10
--4 --20
5,000
10440
T0113098_0
8,000
--22 --30
Condensing temperature
01 introduction.fm
TC
qF
122 50
104 40
86 30
10,000
68 20
50 10
32
5,000
5,000
6,000
8,000
T0113100_0
11,000
12,000
--60 --50 --40 --30 --20 --10 0
qC
qF
--4
14 32
TE
Evaporating temperature
6,000
2.
8,000
10,000
11,000
12,000
14 --10
--4 --20
--22 --30 13,000
T0113099_0
10
20
30
32
50
68
86 104 qF
40 qC
TE
Evaporating temperature
0178-948 - ENG
Rev. 04.05
14
3/30
Table 1.1
Rpm
970
1,170
1,460
1,760
Correction
factor
1.5
1.25
1.00
0.83
1460
Rpm
Example
A compressor has a service interval of 10,000
hours according to the diagram.
If the compressor runs at 970 rpm, the service interval will be 1.5 x 10,000 = 15,000h.
Diagrams
The entire reciprocating compressor program will
be covered by 7 diagrams:
SMC-CMO/R717
SMC-CMO/R22-R134a-R404a
TCMO-TSMC/R717
TCMO-TSMC/R22-R134a-R404a
HPC-HPO/R410A
HPC-HPO/R744
HPC-HPO/R717
4/30
0178-948 - ENG
Rev. 04.05
Table 1.2
Service A
Service B
Service C
Oil filter
Oil filter
Oil filter
Ring plates
Ring plates
Ring plates
Valve springs
Valve springs
Valve springs
Piston rings
Piston rings
Piston rings
(+ needed gaskets)
Shaft seal
Shaft seal
(+ needed gaskets)
Piston pin
Small end bearings
01 introduction.fm
Main bearings
Discharge valve seat / bolt
(+ needed gaskets)
TSMC 100
TSMC 100
TSMC 100
0178-948 - ENG
Rev. 04.05
5/30
Table 1.3
Change:
Change:
Change:
V-belts
V-belts
V-belts
Piston complete
Cylinder liner
Control equipment:
Shaft seal
pressostat
thermostat
Control equipment:
pressostat
transducers
Heating element
Control equipment:
pressostat
thermostat
Coupling parts
thermostat
transducers
transducers
Heating element
Valve seats
Heating element
Coupling parts
Safety springs
Coupling parts
Valve seats
Cylinder liners
Valve seats
Safety springs
Pistons
Safety springs
Piston pins
6/30
0178-948 - ENG
Rev. 04.05
Table 1.4
Recommended annual service
Oil filter
Gas suction filter
Bolt and nut for one connecting rod
Gaskets for two top covers
01 introduction.fm
0178-948 - ENG
Rev. 04.05
7/30
Inspection of thermostats
Depending on temperature range, thermostats
are checked as follows:
Filling and evacuation of the pump vessel is controlled by the two level sensors pos. 98C. By
means of the control box, pos. 98B, the sensors
control the solenoid valves pos. 98G and pos.
98H. The solenoids open and close simultaneously open during filling of the pump vessel and
closed during emptying of the pump vessel.
Check the function of the thermostat pos. 98X.
The thermostat is factory set to start operation
once the discharge gas temperature is above
80C.
If the above inspection reveals malfunctioning:
Inspection of thermopump
Check the general function of the thermopump by
checking the pumping cycle monitored by the
light diodes inside the control box.
The pumping cycle of the thermopump, i.e. a filling
and an evacuation period, lasts between 4 and 8
minutes depending on the oil temperature, operating conditions and number of cylinders of the compressor. The filling period takes about 45 sec.
8/30
Clean the filter pos. 80 and possibly the nozzles pos. 98M.
0178-948 - ENG
Rev. 04.05
01 introduction.fm
2.
below 0.2
Worn
0.2 0.6
Defect
above 0.6
Good: leave the shaft seal as it is unless performing service B or C. At these services the
shaft seal must always be replaced.
Worn or Defect: replace the shaft seal. In
some cases the replacement of a Worn shaft
seal may be postponed to the next scheduled
service.
It is recommended to exercise great care with the
lapped slide surfaces as even the slightest scratch
or other damage to the slide surfaces will result in
leaks.
0178-948 - ENG
Rev. 04.05
3.
a.
b.
c.
d.
e.
Open suction stop valve and - check automatic reset on low pressure cut out.
b.
c.
d.
e.
9/30
Check the correct setting of the high discharge pressure warning/alarm UNISAB manual section 5.
b.
c.
d.
e.
f.
b.
Slowly and stepwise open the oil pressure regulating valve while monitoring
the oil pressure.
c.
d.
e.
f.
4.
a.
a.
b.
c.
3.
2.
b.
Slowly and stepwise open the oil pressure regulating valve while monitoring
the oil pressure.
c.
d.
Note the oil pressure where warning/alarm appears and compressor cuts
off and check manual reset.
a.
Check the correct setting of the low suction pressure warning/alarm UNISAB
manual section 5.
b.
e.
c.
f.
d.
e.
Open suction stop valve and check automatic reset on low pressure alarm.
10/30
4.
0178-948 - ENG
Rev. 04.05
5.
b.
c.
Emergency stop:
a.
b.
2.
Second, do the test procedures for the UNISAB control as described above.
Set the UNISAB high discharge pressure alarm a little lower than the mechanical cut off.
01 introduction.fm
0178-948 - ENG
Rev. 04.05
11/30
Check the tightness of the gland at the valve spindle by appropriate leak detection while turning the
valve spindle.
12/30
0178-948 - ENG
Rev. 04.05
Inspection of coupling
For coupling of the lamella type, see if there are
any signs of cracks in lamella (disc) package.
(To be inspected in-place).
01 introduction.fm
Fig. 1.5
0178-948 - ENG
Rev. 04.05
13/30
Fig. 1.6
No cracks allowed
between rubber and
steel bushes.
14/30
0178-948 - ENG
Rev. 04.05
2.
3.
01 introduction.fm
1.
0178-948 - ENG
Rev. 04.05
15/30
no scratches. The bearing surfaces between the individual stages must be even.
Fig. 1.7
2.
3.
(T)SMC 100
4-10 cyl.
(T)SMC 100
12-16 cyl.
minimum
0.30
0.40
0.75
maximum
0.55
0.64
1.0
16/30
0178-948 - ENG
Rev. 04.05
4.
Fig. 1.8
01 introduction.fm
0178-948 - ENG
Rev. 04.05
17/30
Fig. 1.9
Visible lengthwise
scratches that you can
feel with your fingertips
are not acceptable.
18/30
0178-948 - ENG
Rev. 04.05
01 introduction.fm
Fig. 1.10
0178-948 - ENG
Rev. 04.05
19/30
Fig. 1.11
20/30
2.
Secondly, move the piston ring to approximately 10 mm below the top of the sleeve.
Again, measure the gab between the ends
of the ring.
3.
4.
0178-948 - ENG
Rev. 04.05
01 introduction.fm
Fig. 1.12
If the connecting rod and the piston are not separated a check can be made as follows:
0178-948 - ENG
Rev. 04.05
21/30
Fig. 1.13
3.
Hold the piston steady against a level surface. Press the small end of the connecting
rod towards one side of the piston.
22/30
0178-948 - ENG
Rev. 04.05
Fig. 1.14
01 introduction.fm
0178-948 - ENG
Rev. 04.05
23/30
(T)SMC Mk2&3
(T)SMC Mk4 E
Mk2&3
9.5 mm wire
12 mm wire
10.5 mm wire
58 mm
73 mm
69 mm
9.0 mm wire
Minimum height
24/30
62 mm
0178-948 - ENG
Rev. 04.05
01 introduction.fm
Fig. 1.15
2.
0178-948 - ENG
Rev. 04.05
3.
25/30
Inspection of pistons
1.
2.
Fig. 1.16
max. 30 mm
4.
26/30
5.
Check the axial clearance between the piston and the ring using a feeler gauge. It must
not exceed 0.2 mm with a new piston ring.
0178-948 - ENG
Rev. 04.05
01 introduction.fm
Fig. 1.17
0178-948 - ENG
Rev. 04.05
27/30
or corroded...
Fig. 1.18
28/30
0178-948 - ENG
Rev. 04.05
01 introduction.fm
0178-948 - ENG
Rev. 04.05
29/30
30/30
0178-948 - ENG
Rev. 04.05