Service guide SMC and TSMC 100 Mk1, 2, 3 and 4

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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 3 4 8 8 9 9 12 12 13 15 16 18 21 24 25 26 27 30

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Service intervals
The service interval for a reciprocating compressor should be determined in the following way: 1. Choose the appropriate diagram corresponding to refrigerant and compressor type.
Condensing temperature

Fig. 1.3

R717 - TSMC 100 S-L E-type: Multiply by 0.75

TC F C 14060 12250 10440 86 30 68 20 50 10 32 0 12,000 --60 --50 --40 --30 --20 --10 0 C TE --76 --58 --40 --22 --4 14 32 F
Evaporating temperature

Service interval diagrams Fig. 1.1 R717 - SMC 100 S-L E-type: Multiply by 0.75
TC
F 140 122 104 C 60 50 40 30 20 10 0 12,000 13,000 11,000 5,000 6,000 8,000 10,000

5,000 6,000 8,000 10,000 11,000

Condensing temperature

86 68 50 32

T0113098_0

Fig. 1.4
TC C

HCFC/HFC/R290 - TSMC 100 S-L

01 introduction.fm

14 --10 --4 --20

F

140 60
0 32 10 50 20 68 30 40 C F

--22 --30 --60 --50 --40 --30 --20 --10 --76 --58 --40 --22
T0113097_0

--4

14

86 104

TE

Condensing temperature

122 50 104 40 86 30 68 20 50 10 32 0 12,000

5,000 6,000 8,000 10,000 11,000

Evaporating temperature

Fig. 1.2
F TC C 70 60 50 40 30 20 10 0

HCFC/HFC/R290 - SMC 100 S-L

158 140

--60 --50 --40 --30 --20 --10 0 --76 --58 --40 --22 --4 14 32
Evaporating temperature

C F

TE

5,000 6,000 8,000 10,000

Condensing temperature

122 104 86 68 50 32

T0113100_0

2.

Read the service interval from the curves in the diagram.

11,000 12,000

14 --10 --4 --20 --22 --30 13,000

If the compressor operates at another speed than 1460 rpm, correct the service interval according to table.

--60 --50 --40 --30 --20 --10 T0113099_0 --76 --58 --40 --22 --4 14

0 32

10 50

20 68

30

40 C

86 104 F

TE

Evaporating temperature

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Table 1.1
Rpm Correction factor 970 1.5 1,170 1.25 1,460 1.00 1,760 0.83

Note: The oil filter must always be replaced when changing oil or if indicated by control lamp or UNISAB II. The scope of the overhaul must follow the scheme below: 1 x service interval: Use service set A 2 x service interval: Use service set B 3 x service interval: Use service set A 4 x service interval: Use service set C

Correction may also be calculated according to the formula below: Correction =

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.

The service sets include parts which must always be replaced regardless of appearance when compressor is opened. The above cycle is repeated as long as the compressor is in operation. The content of the individual service set is shown in the annex. After the first 200 hours of operation, use the commissioning set supplied with the compressor. Inspection parts Besides the predetermined replacement according to above service sets, an inspection of certain parts is prescribed. Parts for inspection are shown in the annex. Criteria for replacement of inspected parts are shown in separate instruction. Nice-to-have-parts A list of recommended parts supporting the parts inspection is available. The list contains all parts necessary if the inspected parts must be replaced. In other words, these lists tell the service technician what to bring to the inspection.

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

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Table 1.2
Service A Service B Service C

Oil filter Ring plates Valve springs Lock nut for discharge valve Piston rings O-rings for shaft seal (+ needed gaskets)

Oil filter Ring plates Valve springs Lock nut for discharge valve Piston rings Half section bearings Bolt for connecting rod / lock nut Parts for unloading frame Shaft seal (+ needed gaskets)

Oil filter Ring plates Valve springs Lock nut for discharge valve Piston rings Half section bearings Bolt for connecting rod / lock nut Parts for unloading frame Shaft seal Piston pin Small end bearings Main bearings

01 introduction.fm

Discharge valve seat / bolt

(+ needed gaskets) TSMC 100 Needle bearing + piston pin HP TSMC 100 Needle bearing + piston pin HP TSMC 100 Needle bearing + piston pin HP

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Table 1.3

Additional nice to have parts

Additional / Nice to have

Change: V-belts

Change: V-belts Rocker for unloading

Change: V-belts Rocker for unloading Oil pump

(Change based on inspection)

(Change based on inspection)

(Change based on inspection)

Half section bearings Lock nut conrod screws Discharge valve seat / bolt Oil analysis kit Shaft seal Coils solenoid valves Control equipment:

Discharge valve seat / bolt Oil analysis kit Coils solenoid valves Control equipment:

Piston complete Cylinder liner Discharge valve complete Suction valve retaining plate Coils solenoid valves Oil analysis kit Control equipment:

pressostat thermostat transducers

Heating element Coupling parts Oil return system parts Valve seats Safety springs Stop valve gaskets Cylinder liners Pistons Piston pins Piston pin bushings

pressostat thermostat transducers

Heating element Coupling parts Oil return system parts Valve seats Safety springs Bearing half sections Stop valve gaskets

pressostat thermostat transducers

Heating element Coupling parts Oil return system parts Valve seats Safety springs

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If the service interval exceeds one year, an annual service and inspection is recommended. Oil and gas suction filters should be changed, one top cover should be dismantled and the discharge valve and cylinder liner should be inspected. Further a side cover must be removed and one connection rod bearing half should be removed to Table 1.4
Recommended annual service Oil filter Gas suction filter Bolt and nut for one connecting rod Gaskets for two top covers

inspect crankshaft journal and the big end of the connection rods. While service sets A, B and C are intended for actual service, the recommended annual service is intended to ensure that the compressor is inspected each year.

Additional / nice to have: (Change based on inspection)

01 introduction.fm

Gaskets for shaft seal Oil analysis kit

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Inspection of thermostats
Depending on temperature range, thermostats are checked as follows: Low temperature range, by means of ice water ( +/-0C ). High temperature range, by means of boiling water ( +100C ). Actual temperature setting is checked by slowly increasing or decreasing the setting while monitoring temperature cut off. 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:

After checking, reset to actual condition.

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.

Clean the filter pos. 80 and possibly the nozzles pos. 98M. Check the function of the non-return valves pos. 98K and 98Z by blowing compressed air opposite the normal flow direction. Check the level sensors and the control box according to instructions in the Service manual.

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Inspection of shaft seal

During operation a small amount of oil leaks from the shaft seal. The oil forms a lubricating film between the rotating and the static face and thus performs the sealing effect. Due to the differential pressure, a certain flow out of the shaft seal cannot be avoided. Usually the amount of leaked oil is fairly small but even when there is no mechanical fault, the shaft seal leak rate may vary considerably. This may be the result of different operating conditions as well as the actual vibration condition and also the state of the oil as temperature, viscosity, purity and refrigerant content will influence the sealing effect. The leak may be somewhat more extensive at the initial start-up of the compressor as the sliding surfaces have to a adapt to each other. 01 introduction.fm The actual leak rate must be checked according to the compressor logbook by comparing it with the table below. If a shaft seal for any reason has been dismantled, always replace O-rings before assembling. Check that the sealing faces are clean, smooth and free of scratches and wear marks.

Inspection of safety controls

If equipped with mechanical controls 1. Low suction pressure cut out, KP1(A) or KP15(A): a. b. c. d. e. 2. Check the correct setting of the pressure cut out Service manual, section 4. Slowly close the suction stop valve while monitoring the suction pressure gauge. Note the pressure where compressor cuts off. If necessary, adjust setting and repeat above process. Open suction stop valve and - check automatic reset on low pressure cut out.

Litres per 24 hours Good Worn Defect below 0.2 0.2 0.6 above 0.6

High discharge pressure cut out, KP5(A) or KP15(A) or KP7(A)BS: a. b. Check the correct setting of the pressure cut out Service manual, section 4. Slowly close the discharge stop valve while monitoring the discharge pressure gauge. Note the pressure where compressor cuts off NB! KP7(A)BS dual high pressure control. If necessary adjust setting and repeat above process. Open discharge stop valve and check manual reset (pressure diff. 4 bar.) on high pressure cut out.

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.

c.

d. e.

3.

Oil pressure cut out, MP55(A):

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a. b.

Check the correct setting of the pressure cut out Service manual section 4. Slowly and stepwise open the oil pressure regulating valve while monitoring the oil pressure. Allow reaction time of 60 seconds for each step. Note the oil pressure where compressor cuts off and check manual reset (after 2 min.). If necessary, adjust setting and repeat above process. Adjust oil pressure (on regulating valve) to 4.5 bar. 3.

a.

Check the correct setting of the high discharge pressure warning/alarm UNISAB manual section 5. Slowly and stepwise close the discharge stop valve while monitoring the discharge pressure. Allow reaction time of 5 seconds for each step. Note the discharge pressure where warning/alarm appears and compressor cuts off. If necessary, adjust setting and repeat above process. Open discharge stop valve and check manual reset on high pressure alarm.

b.

c. d.

c. d.

e. f. 4.

e. f.

Oil and discharge pipe thermostat, KP98: a. b. c. Check the correct setting of the thermostat Service manual, section 4. Slowly decrease temperature settings while monitoring temperatures cut off. Adjust actual settings and check manual reset (temp. diff. oil/HT = 14/25 K). b. a.

Oil pressure warning/alarm: Check the correct setting of the low oil pressure warning/alarm UNISAB manual section 5. Slowly and stepwise open the oil pressure regulating valve while monitoring the oil pressure. Allow reaction time of 60 seconds for each step. Note the oil pressure where warning/alarm appears and compressor cuts off and check manual reset. If necessary, adjust setting and repeat above process. Adjust oil pressure (on regulating valve) to 4.5 bar.

If equipped with UNISAB control 1. Low suction pressure warning/alarm. a. Check the correct setting of the low suction pressure warning/alarm UNISAB manual section 5. Slowly close the suction stop valve while monitoring the suction pressure. Note the pressure where warning/alarm appears and compressor cuts off. If necessary, adjust setting and repeat above process. Open suction stop valve and check automatic reset on low pressure alarm. 4.

c. d.

b. c. d. e. 2.

e. f.

Temperature warnings/alarms discharge gas, oil, suction superheat and discharge superheat. a. Check the correct settings of above warnings/alarms UNISAB manual section 5.

High discharge pressure warning/alarm:

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b.

Slowly increase/decrease temperature settings while monitoring warnings/alarms. Adjust actual settings and check manual reset.

c. 5.

If equipped with UNISAB control and high pressure safety cut out, KP 7(A)BS 1. First, do the test procedures for the mechanical safety cut out as described above. Set the UNISAB high discharge pressure alarm a little higher than the mechanical cut off. 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. Note: Local rules and standards are mandatory and overrule the above recommendations if in conflict.

Emergency stop: a. Activate the emergency stop by a light pressure when compressor is in operation. Before restarting, reset the alarm and release the emergency stop by turning it clockwise.

b.

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Inspection of heating rod

When the compressor is stopped, the heating rod must be activated and the oil temperature during standstill must be clearly ( 10K or more ) above ambient temperature. Check if the power supply is switched on and check the resistance of the heating cartridge by using a multi-meter. If the heating circuit is cut off, the resistance is infinitely great.

Inspection of compressor stop valves

Check the tightness of the gland at the valve spindle by appropriate leak detection while turning the valve spindle. In case of leak, the packing gland pos. 25M and the gasket for bonnet pos. 25J must be changed. Check the tightness of the valve seat by appropriate leak detection inside the compressor. In case of leak, the sealing ring pos. 25H and the gasket for bonnet pos. 25J must be changed. When changing sealing rings and gaskets, the sealing surfaces have to be clean and free from scratches and wear marks.

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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). Fig. 1.5

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Fig. 1.6

Apply lever bar to load joints

No cracks allowed between rubber and steel bushes.

For coupling of rubber type, check if vulcanization between rubber and steel bush is intact. Apply a lever bar to load joint. Apply lever bar to load joints.

Check and adjust coupling alignment as described in manual.

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Inspection of crank main bearings

1. 2. Make sure the journals are not seized up (picture). The diameter of the crankshaft journals should not be less than 79.81 mm. 3. The diameter of the intermediate bearing journals on long blocks (112 and 116) should not be less than 79.87 mm.

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Inspection of connecting rod bearings

1. Check the connecting rod bearings with your fingertips and make sure that you feel no scratches. The bearing surfaces between the individual stages must be even.

Fig. 1.7

Scratches are not acceptable. Transitions between bearing surfaces must be even.

2.

The diameter on the journals should not be less than 79.89 mm.
CMO Mk1 & 2 (T)SMC 100 4-10 cyl. 0.40 0.64

3.

Check the axial clearance of the crank.

(T)SMC 100 12-16 cyl. 0.75 1.0

minimum maximum

0.30 0.55

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4.

Check appearance of thrust bearing.

Fig. 1.8

01 introduction.fm

Scratches and material displacement are unacceptable.

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How to determine usability of cylinder liners

See if there are any visible lengthwise scratches on the running face:

Fig. 1.9

Visible lengthwise scratches that you can feel with your fingertips are not acceptable.

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See if the suction valve seats are damaged.

Fig. 1.10

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See if valve seats are worn, i.e. has rounded shoulders:

Fig. 1.11

Edges of valve seat surfaces should be sharp and not rounded

Measure the inside diameter of the cylinder liner at the top and bottom of the running face.

2.

Perform the measurement with a micrometer gauge. The diameter should not exceed 100.25 mm anywhere. If a measuring gauge is not at hand, wear may be measured indirectly by a piston ring and a feeler gauge (oil must be wiped away before measuring): 1. Insert a piston ring (preferably a new one) in the lower non-worn part of the cylinder sleeve. Measure the gab between the ends of the ring with a feeler gauge.

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. Finally, move piston ring to the lower part of the worn area, approximately 10 mm above the transition between worn and non-worn area. Measure the gab. Compare the measurements. The maximum difference between measurements in non-worn and worn area (running face) should not exceed 0.6 mm.

3.

4.

If a cylinder sleeve shows any of the above defects, it must be replaced.

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Inspection of connecting rod

1. Small end: Must be free from distinct scratches (material displacement) on the bearing surface. Shiny areas are acceptable.

Fig. 1.12

01 introduction.fm

Distinct scratches and material displacement are not acceptable

The picture shows a useless connecting rod bushing with scratches. 2. The bushing diameter must not exceed 40.08 mm. Can be measured with a good digital slide gauge.

If the connecting rod and the piston are not separated a check can be made as follows:

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Fig. 1.13

Press small end towards one side of the piston.

3.

Hold the piston steady against a level surface. Press the small end of the connecting rod towards one side of the piston.

Try to move the big end of the connecting rod sideways. The big end should not move more than 1 mm sideways.

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Fig. 1.14

Shiny areas are acceptable - material displacement is not.

01 introduction.fm The picture shows a bushing after normal operation.

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Inspection of safety springs

The safety springs on the discharge valves must be intact and have the following minimum heights in unloaded condition: Table 1.5
(T)SMC Mk2&3 9.0 mm wire Minimum height 62 mm 58 mm 73 mm 69 mm (T)SMC Mk2&3 9.5 mm wire (T)SMC Mk4 S&L 12 mm wire (T)SMC Mk4 E 10.5 mm wire

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Inspection of piston pin

1. At normal workshop temperature, you should be able to just slightly rotate and move sideways the piston pin with your fingers. The hotter the piston gets, the more the fitting will loosen. There should be no clearance in the fitting.

Fig. 1.15

01 introduction.fm 2.

The diameter of the piston pin should not be less than 39.96 mm.

3.

Feel the bearing surfaces on the piston pin with your fingertips and make sure that they are even.

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Inspection of pistons
1. Make sure there are no deep scratches in the piston skirt. 2. The width of a worn area must not exceed 30 mm.

Fig. 1.16

Worn area. Scratches are visible and you can feel them with your fingertips.

max. 30 mm

The picture shows a useless piston. In order for a piston to be reused, it must be in a considerably better condition than this one. 3. 4. The diameter of the piston should not be less than 99.7 mm. Check that the piston rings can be turned freely in the piston groove. 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.

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Inspection of valve seats

The valve seats must not be damaged... Fig. 1.17

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or corroded... Fig. 1.18

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or have rounded shoulders. Fig. 1.19

The valve seat edges must not be rounded. 01 introduction.fm

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Inspection of unloading mechanism

Make sure that wear has not made oval holes in the spring eye fittings. Connect the prelubrication pump to each unloading cylinder. Press the pump handle with a constant pressure of approx. 20 kp. The handle must not sink more than 5 cm in 60 seconds. Observe that the unloading frame moves between extreme positions when the pressure is activated and removed. Check for broken springs and wear on rocker arms and the bushing in the unloading system.

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