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CMO 20-30 and TCMO 20-30Reciprocating compressor unit

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Manual for CMO 20-30 and TCMO 20-30

Compressor type CMO24 CMO26 CMO28 TCMO28

CMO34 CMO36 CMO38 TCMO38

Compressor no.

Refrigerant R717 R22 R134a R404A

R507 Other ________

Control Unisab III None Other

Compressorcooling

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 Direct drive

Explosion-proof electrical design

Additional suction filter

Oil return on parallel systems

Sabroe OVUR oil separator

Intermediatecooling system

With internal intermediate cooling system

With external intermediate cooling system

Operating manual - CMO 20-30/TCMO 20-30001849 en 2014.09 1/49

Safety valve:Data for calculation ofdownstream line accord-ing to EN 13136

Vessel data

TypeExternal surface

[m2]Design pressure

[bar]

Condenser

Evaporator

Liquid separator

Oil separator

Oil cooler

Economizer

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

Contents 1. Introduction 5

1.1.1 Safety precaution definitions used in this manual 6 2. Safety 7

2.1. Areas of application 7

2.1.1 Application 7

2.1.2 Application of combustion engines 7

2.2. Identification 8

2.2.1 Identification of equipment 8

2.2.2 Unit/pipe system name plate 9

2.2.3 Compressor name plate 11

2.2.4 Vessel name plate 12

2.3. Safety precautions 13

2.3.1 Signs 13

2.3.2 Emergency stop 14

2.3.3 Maintenance safety/safety at servicing 14

2.3.4 General precautions 15

2.3.5 During operation 16

2.3.6 Cooling water system 16

2.3.7 Lubricating oils 17

2.3.8 Refrigerants 18

2.3.9 Purging a refrigeration plant 18

2.3.10 F-gas regulation (fluorinated greenhouse gases) 18

2.3.11 Transmission safety 20

2.3.12 Compressor noise data 20

2.3.13 Noise data specifications 21 3. Operating instructions 22

3.1.1 Safety precautions 22

3.1.2 Ventilation 22

3.1.3 Pressure 22

3.1.4 Hot and cold surfaces 22

3.1.5 Qualification requirements 23

3.1.6 Compressor control and alarm functions 23

3.1.7 Alarms and warnings 23

3.1.8 Unisab reading, safety and capacity regulating system 24

3.1.9 Valves for operation of compressor 25

3.1.10 Installation and first start-up procedure 26


3.1.11 Preparations for starting 27

3.1.12 Pressure and temperature settings 28

3.1.13 Monitoring of operation 29

3.1.14 Example of an operation log 29

3.1.15 Stopping routine 30

3.1.16 Brief stop 30

3.1.17 Shutting down for a long standstill period 30

3.1.18 Problems 30

3.1.19 Troubleshooting 30 4. Maintenance instructions 31

4.1.1 Compressor maintenance/service 31

4.1.2 Safety precautions 31

4.1.3 Safety measures 31

4.1.4 Basis for maintenance 31

4.1.5 Service intervals 32

4.1.6 Service interval diagrams 32

4.1.7 Annual service 35

4.1.8 Regular service schedule - refrigeration plant 36

4.1.9 Regular service schedule 37

4.1.10 Visual inspection 38

4.1.11 Charging compressor with lubricating oil 38

4.1.12 Oil charge - Oil level 39

4.1.13 Oil charge 40

4.1.14 Compressor prelubrication 41

4.1.15 Oil charging and drain valve 42

4.1.16 Hand-operated oil pump 42

4.1.17 Shaft seal 43

4.1.18 Motor lubrication 43 5. Final disposal 44 6. Appendices 45

6.1.1 Declaration of conformity 45

Index 48

4/49Operating manual - CMO 20-30/TCMO 20-30

001849 en 2014.09

1. Introduction

The reciprocating compressor may be fitted with different equipment, depending on its func-tions and requirements. Part of this equipment is described in this manual although it may notbe fitted on your particular unit.

This manual describes:

• dangers resulting from failure to comply with safety precautions when operating theequipment and performing maintenance tasks

• how to start, operate and stop the equipment safely

• how to act when problems occur during operation

• scheduled maintenance tasks for the equipment and when/how to carry them outsafely

This manual is primarily intended for operators and service engineers.

• It is important that the operating personnel familiarise themselves with the contentsof this manual in order to ensure proper and efficient operation. Johnson ControlsDenmark is not liable for damage occurring during the warranty period where this isattributable to incorrect operation.

• All compressor intervention within the warranty period must be performed by author-ised personnel only. If not, the warranty no longer applies.

This manual does not describe:

• Control systems. A specific operating manual is delivered with the compressor.

• Safety when handling refrigerants and oils.

• Installation.

• Service and repair including spare parts lists.

For further information, see www.sabroe.com

This manual is produced by:

Johnson Controls Denmark ApSChristian X's Vej 2018270 Højbjerg, DenmarkPhone +45 87 36 70 00Fax +45 87 36 70 05CVR No 19 05 61 71www.sabroe.com

Copyright © Johnson Controls Denmark

This manual must not be copied without the written permission of Johnson Controls Denmarkand the contents must not be imparted to a third party nor be used for any unauthorised pur-poses. Contravention will be prosecuted.

The original version of this manual is the English language version. If there are any discrepan-cies or conflicts between the English and any other version that has been translated into an-other language, the English version will prevail.

Introduction


1.1.1 Safety precaution definitions used in this manual

Danger!

Indicates an imminently hazardous situation which, if not avoided, will result in death or seri-ous injury.

Warning!

Indicates a potentially hazardous situation or practice which, if not avoided, will result indeath 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, etc. or portion thereof which is essential tohighlight.

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2. Safety

2.1. Areas of application

2.1.1 ApplicationTo prevent unintentional application of the compressor which could injure personnel or dam-age equipment, the following must be observed:

• The compressor must only be used as a refrigeration compressor with the number ofrevolutions per minute and within the operating limits specified in the manuals or in awritten agreement with Johnson Controls Denmark.

• The compressor must only be used with the following refrigerant: See relevant oper-ating limits diagrams in the Engineering manual.

• Johnson Controls Denmark further accept no liability of any kind for damage to com-pressor unit and plant parts caused by torsional oscillation or the like which is attrib-utable to built-in VSD solutions initiated by the customer after delivery.

• CMO and TCMO compressors may be used at a maximum discharge pressure of 28bar.

• The compressors are approved for application in potentially explosive atmospheres,provided they have been fitted with explosion-proof equipment. This can be seen fromthe Ex name plates fixed on each unit.

Please note that specially made tools which do not cause any sparks must be used for allmaintenance work on the compressor.

The compressor must NOT be used:

• to evacuate the refrigeration plant of air and moisture

• to put the refrigeration plant under air pressure in view of a pressure testing

• as an air compressor.

Warning!

Johnson Controls Denmark is not liable for injuries to personnel or damage to equipment re-sulting from using the equipment for other purposes than the ones stated above.

2.1.2 Application of combustion enginesIf combustion engines are installed in rooms containing refrigeration machinery or rooms withpipes and components containing refrigerant, make sure that in case of leakage the air intakefor the engine comes from an area without refrigerant gas.

Failure to do so involves a risk of lubricating oil from the combustion engine mixing with re-frigerant. At worst, this may lead to corrosion and damage the engine.

Safety


2.2. Identification

2.2.1 Identification of equipmentAll Johnson Controls Denmark equipment can be identified by one or several name platespositioned as illustrated in the following drawing:

Unit pipe system name plate

Vessel name plate Compressor name plate

Fig. 1: Identification of name plates

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2.2.2 Unit/pipe system name plate

BY JOHNSONCONTROLS

Scope

Design code

Approval No

Refrigerant

Supply voltage

Refrigerant charge

Pressure systemCategoryAllowable pressure

Test pressure

Allowable temp.

Refrigeration unit

Fluid

Type

No

Group

Control

Year

Max.

LP side HP side

V/Hz

kg

bar g

°Cbar g

2516-342

Min/Max.

The unit name plate is positioned on the frame and contains the following information:

Refrigeration unit No. Identification no. (serial no.)Year Year of manufacturing.Type Manufacturer's type designation.Scope For EC - PED approval: “Unit & Piping” means that the CE mark

covers the complete unit including the piping system.“Piping “ means that the CE mark covers the piping system onlyand it is the sole responsibility of the owner to ensure and de-clare that the complete unit is in conformity with the provisionsof all relevant directives.(See the CE Declaration of conformity).

Design code Design code used for the unit and piping system.Approval no. If the unit/manufacture has been approved by a 3rd party/noti-

fied body.Refrigerant - Fluid Refrigerant of the unit.

Refrigerant designation (Rxxx) according to ISO 817.Refrigerant - Group For EC - PED approval:

Fluid group 1 or 2 according to PED directive.Supply voltage - Control Supply voltage and frequency of the control system.Refrigerant charge Weight of refrigerant charge of the unit.

Only stated if the unit includes an evaporator and/or a con-denser.

Pressure system Low pressure side of the unit piping is referred to as LP-side.High pressure side of the unit piping is referred to as HP-side.

Safety


Category For EC - PED approval:The maximum category of the piping system (CAT 1, 2 or 3.) orof the assembly unit and piping (CAT 3 or 4).

Allowable pressure, max. The max. pressure (pressure relative to atmospheric pressure)for which the unit/piping system has been designed in terms ofpressure strength design. Maximum practical operation pres-sure is lower than “maximum allowable pressure” depending onoperating conditions and the safety equipment settings.

Test pressure The test pressure with which the unit/piping system has beenstrength tested.

Allowable temperature,min./max.

Minimum and maximum temperatures for which the unit/pipingsystem has been designed for at the indicated maximum allow-able pressures.

CE xxxx The CE mark appears on the name plate for EC - PED approvalonly. The four digits compose the registration no. of the notifiedbody/3rd party in charge.

Ex An Ex mark appears on the name plate if the unit has been de-signed according to the EC – ATEX directive.

Note: Main supply voltage can be found on the motor and/or electrical panel name plate.

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2.2.3 Compressor name plate

The compressor name plate is positioned on the compressor and contains the following infor-mation:

Compressor no. Identification no. (serial no).Year Year of manufacturing.Type Manufacturer's type designation.Refrigerant Allowable refrigerant or refrigerants for the compressor.

(The actual refrigerant for the unit is stated on the unit nameplate).

Speed Specific rotational speed. Specific rotational speed is used forcalculating swept volume. For the actual allowed operatingspeed, please refer to operating limits and Matchmaster's cal-culation on the actual operating condition.

Swept volume Swept volume of compressor at nominal speed.Pressure system Low pressure side of the compressor is referred to as LP-side.

High pressure side of the compressor is referred to as HP-side.Allowable pressure, max. The max. pressure (pressure relative to atmospheric pressure)

for which the compressor has been designed in terms of pres-sure strength design.Maximum practical operating pressure is lower than maximumallowable pressure depending on the operating conditions andsettings of the safety equipment.

Test pressure The test pressure the compressor has been strength testedwith.

CE and Ex A CE and Ex mark appears on the name plate if the compres-sor has been designed according to the EC – ATEX direc-tive.

Safety


2.2.4 Vessel name plate

The pressure vessel name plate is positioned on the shell of the vessel and contains the fol-lowing information:

Vessel no. Identification no. (serial no.)Year Year of manufacturing.Type Manufacturer's type designation.Design code Design code used for the pressure vessel.Approval no./CAT The approval no. of the vessel issued by the relevant 3rd party/

notified body.For EC - PED approval: CAT (Category 1, 2, 3 or 4) according toPED directives.

Side For heat exchangers only.Refers to the columns "Shell" side and "Tube" side of the heatexchanger.

Fluid Designation of the primary refrigerant(s) and the secondary re-frigerant(s).For EC - PED approval: Designation of the refrigerant(s) and/orthe highest fluid group (Group 1 or 2) according to PED direc-tive.

Allowable pressure, PS Min. and max. pressure (pressure relative to atmospheric pres-sure) for which the vessel or vessel part has been designed.

Allowable temperature,TS

Min. and max. temperatures for which the vessel or vessel parthas been designed.

Volume Volume of the vessel or vessel part.CE xxxx The CE mark appears on the name plate for EC - PED approval.

The four digits compose the registration no. of the notifiedbody/3rd party in charge.

Note: Depending on the supplier of the pressure vessel/heat exchanger the layout and con-tent of the name plate may differ from the Sabroe name plate above.

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2.3. Safety precautions

2.3.1 SignsAll signs which may be found on your equipment are shown below. The number of signs, how-ever, may vary from one product to another.

Risk of electrical shockHigh voltage/High pressure

High surfacetemperature(about 70°C)

The compressor may betop-heavy

Internal overpressure Hazardous substance Cold surfacesDangerous noise level,use hearing protectors

Do not step on surface No open flame Flammable gasThe unit IS filled with

refrigerant R290

Internal protection Pacemaker users keep out

Påfyldt beskytte lsesgasCharged with inert gasEnthält SchutzgasChargé du gaz prote cteu rContiene gas protector

N20,5 bar7.3 PSI

1534-169

Compressor blocks and units areusually delivered without refrigerantand oil. To protect the compressorsagainst internal corrosion, they aredelivered evacuated of all atmos-pheric air and charged with dryNitrogen (N2) to an overpressure of0.5 bar [7.3 PSI].In such cases a yellow sign is affixedto a visible spot on the compressor.

The magnetic field on the rotormay affect pacemakers.The motor rotor contains a powerfulmagnetic field. This field may affectdigital devices such as watches,mobile phones etc.Assembly or maintenance of therotor must not be carried out bypeople with pacemakers or any otherimplanted medical electronic device.

The VSD contains capacitors capableof storing electrical energy, ie thereis a risk of electrical shock within15 minutes after the drive has beenturned off.

Safety


2.3.2 Emergency stop

Emergency stop button

Fig. 2: Emergency stop button on the reciprocating compressor unit with Unisab III control system

The compressor control system must be equipped with an emergency device.

If the compressor is delivered with a Unisab control system, the emergency device is integra-ted in the control system.

The emergency device must be made in such a way that it remains in its stopped position af-ter a stop command and until it is deliberately set back. The emergency device must not beable to block without releasing a stop command.

It should only be possible to set back the emergency stop by a deliberate act and this mustnot start the compressor. It should only make it possible to restart it.

Additional requirements for the emergency device:

• It must be operated by means of an easily recognisable and visible manual handlewith easy access.

• It must be able to stop any dangerous situation as quickly as possible without thiscausing any additional danger.

2.3.3 Maintenance safety/safety at servicing• Personnel must be qualified according to national safety rules and regulations and

perform the maintenance work according to EN 378.

• Read the chapter Safety precautions in this manual before opening the compressorand other parts of the refrigeration plant.

• It is recommended to remove all main fuses. Switch off all electric components on thecompressor/unit before starting the dismantling/servicing process and lock the mainswitch.

• Make sure that the motor cannot start up inadvertently.

• Make sure that there is no over-pressure and no refrigerant in the part to be disman-tled. Close all necessary stop valves.

• Use the prescribed tools and check that they are properly maintained and in goodworking condition. In explosion-proof areas, use tools suited for this specific purpose.

• Use only Johnson Controls Denmark original spare parts; other parts may impair thesafety of the compressor/unit.

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• When performing maintenance, the main switch must be locked.

• Use gloves and protective goggles and make sure to have a gas mask close at hand.Also use electrical protection equipment and tools suited for electrical operation pur-poses.

• When dismantling the top covers, pay attention to the considerable spring force be-neath the covers. When the screws are loosened, the cover must lift itself from theframe.

SpringsTop cover

Fig. 3: Springs and top cover

• Before dismantling the side covers, empty the crankcase of its oil content.

• Check that the heating rod in the crankcase is de-energised.

2.3.4 General precautionsThese precautions should be used as a supplement to the safety precautions and warnings in-cluded in:

• All other manuals pertaining to the compressor/unit

• Local, plant and shop safety rules and codes

• National safety rules and regulations

Read and understand all safety instructions before setting up, operating or servicing/perform-ing maintenance on the compressor/unit. Assign only qualified personnel instructed in safetyand all machine functions to operate or service the compressor/unit.

Operators and maintenance personnel must carefully read, understand and fully comply withall alarm and instruction plates mounted on the compressor/unit.

• Observe the safety warnings.

• Use ear protection when operating the compressor/unit.

• Use safety equipment. Wear appropriate gloves as well as eye and face protectionwhen working with parts containing refrigerant and/or lubricating oil.

• Use proper electrical safety protection.

Note: These instructions only provide general information. The owner of the refrigerationplant is responsible for ensuring that all codes, regulations and industry standards are com-plied with.

Safety


2.3.5 During operation

Warning!

All safety features, disengagement and interlocks must be in place and function correctly be-fore the equipment is put into operation. Never by-pass or wire around any safety device.

Ventilation

Before operating the unit always check, where relevant, the function of the ventilation systemand refrigerant detectors used in the area where the compressor/unit is located (machineroom).

Rotating parts

Warning!

Safety guards, shields, barriers, covers and protective devices must not be removed while thecompressor/unit is operating.

Vibration and noise

During operation, pay attention to the compressor unit process. Excessive vibration, unusualsounds etc. may indicate problems requiring your immediate attention.

Pressure

Danger!

A compressor/unit comprises a pressurised system. Never loosen threaded joints while thesystem is under pressure and never open pressurised system parts.

Note: Whenever a relief valve/safety valve has been activated, we recommend recalibratingit. This must be carried out by authorised personnel only. See also EN 378 and existing na-tional legislation.

2.3.6 Cooling water system

Warning!

The recirculation water system may contain chemicals or biological contaminants, including le-gionella, which can be harmful if inhaled or ingested. Water systems should only be operatedwith an effective biological treatment programme.

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2.3.7 Lubricating oilsCompressor oils include the following oil types:

Code design Oil typesM Mineral oil, naphtenic baseA Synthetic oils based on alkylated aromatics (alkyl-benzene)AP Synthetic oils blended from alkyl-benzene and poly-alfa-olefin base stocksS Semi synthetic oils (hydro-treated mineral oil on paraffinic base)

PAO Synthetic oils based on poly-alfa-olefinPOE Synthetic oils based on polyol estersPAG Synthetic oils based on polyalkylene glycols

See Sabroe oil recommendation for recommended type of oil.

Warning!

When charging oil, follow the safety instructions given by the oil supplier (MSDS: MaterialSafety Data Sheet). Always avoid direct contact with the oil as this may cause skin allergies.Always use protective equipment - goggles and gloves - when charging oil.

When changing oil on the compressor or draining oil from the vessel of the refrigeration plant,always collect the used oil in containers marked “waste oil,” and send them to an approvedincineration plant. It is not recommended to reuse oil.

Safety


2.3.8 RefrigerantsBe very careful when dealing with refrigerants. For safe handling please refer to the safety/data sheets etc. delivered by the refrigerant supplier.

Warning!

Be aware that large amounts of escaping (or released) refrigerant entail a risk of suffocation.If in direct contact with leaking liquid refrigerant there is a high risk of injuries caused by in-tense cold.

2.3.9 Purging a refrigeration plantPurging of air or other non-condensable gases is required in order to keep high system per-formance and avoid corrosion of the equipment which could endanger the safety of personsand equipment.

When purging a refrigeration system, make sure to observe the following:

• Refrigerants must not be released into the atmosphere except CO2, which can be re-leased slowly into the atmosphere.

• When purging an R717 system, use an approved air purger. The purged air must passthrough an open container or water for any remaining R717 to be absorbed. The wa-ter mixture must be sent to an authorised incineration plant.

• Halocarbon refrigerants (CFC, HCFC and HFC) cannot be absorbed by water. An ap-proved air purger must be fitted to the system. This must be checked regularly by useof a leak detector. All precautionary measures practicable must be taken to preventand minimise leakage of refrigerant from refrigeration and air conditioning systems tothe atmosphere.

Note: The occurrence of air is usually an indication of poor maintenance or lack of thorough-ness at installation.

Note: R717 systems should be purged on a regular basis to avoid atmospheric air and othernon-condensable gases.

2.3.10 F-gas regulation (fluorinated greenhouse gases)Based on the Kyoto protocol regarding reduction of harmful gases in the atmosphere, the Eu-ropean Parliament (EU) has established guidelines for the regulation of certain greenhousegases in a directive named “F-gas regulation”. The following is an extract from the guidelineswhich is relevant for end users and operators.

Fluorinated refrigerants are included in the category of greenhouse gases and therefore fallunder the F-gas regulation directive. The table below lists the relevant refrigerants and theirrespective GWP (Global Warming Potential) according to the F-gas regulation.

Refrigerant GWP (Global Warming Potential)R134a 1300R407C 1650R404A 3785R507 3850R410A 1975

Requirements of the F-gas regulation include:

• Labelling

• Leakage test

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• Recovery of refrigerant

• Certification of personnel

• Log book.

Labelling: The unit must be fitted with a label (name plate). Refrigerant type and charge inkg must be stated on the plate.

Leakage test: It is the operator’s responsibility to ensure that the unit is checked for leak-ages by a certified person. For units charged with fluorinated greenhouse gases, the followingconditions apply depending on type of plant and amount of charge:

• Applications containing 3 kg or more of fluorinated greenhouse gases must bechecked for leakage at least once every 12 months.



The applications must be checked for leakage within one month after a leak has been repairedto ensure that the repair has been effective.

For units containing 300 kg or more of fluorinated greenhouse gases leakage detecting sys-tems must be checked at least once every 12 months.

Recovery of refrigerant: Operators must be responsible for putting in place arrangementsfor the proper recovery of fluorinated greenhouse gases by certified personnel to ensure theirrecycling, reclamation or destruction.

Certification of personnel: Since July 2008 it has been mandatory for the member states toestablish certification and training programs for personnel involved in leakage inspections andthe recovery, recycling, reclamation and destruction of fluorinated gases.

Logbook: For all units containing more than 3 kg fluorinated greenhouse gases a logbookmust be kept indicating the quantity and type of product, quantities added for recharges andthe quantity recovered during servicing, maintenance and final disposal. Other relevant infor-mation is also requested, such as identification of the servicing company or technician as wellas dates and results of the checks.

For further information please see the F-gas regulation in full.

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2.3.11 Transmission safety

Coupling

The coupling guard for directly driven compressors is not designed to resist unintended load.Therefore, do not step on it or load it in any way during operation. The guard is marked witha sign.

Warning!

When mounting the coupling guard, make sure that it is not in contact with any rotatingparts. After 20 hours check to see if tightening-up is required. Check the coupling guard forcorrect tightening, cracks or other defects every 5000 hours.

Warning!

Do not start the compressor until the coupling guard is mounted correctly. Before performingany kind of work on the coupling, make sure that the compressor motor cannot start up inad-vertently. When performing service where the motor is dismantled from the base frame, fol-low the instructions for coupling alignment in the Installation Instructions section.

Note: These instructions only provide general information. The owner of the refrigerationplant is responsible for ensuring that all codes, regulations and industry standards are com-plied with.

2.3.12 Compressor noise dataIn the following tables the noise data of the compressors is stated in:

- A-weighted sound power level Lw(Sound Power Level)

- A-weighted sound pressure level Lp(Sound Pressure level).

The values for Lw constitute an average of a large number of measurements on various units.The measurements are carried out in accordance with ISO 9614-2.

The values are also stated as average sound pressure in a free field above a reflecting planeat a distance of 1 meter from a fictional frame around the unit.

Normally, the immediate sound pressure lies between the Lw and Lp values and can be calcu-lated, provided that the acoustic data of the machine room is known.

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2.3.13 Noise data specifications

Single-stage

Lw and Lp values are measured at the following conditions:

Evaporating temperature TE -15°C [5°F]Condensing temperature TC +35°C [95°F]Refrigerant R22/R717Number of revolutions 1450 rpm

Compressor block Lw LpCMO 24CMO 26CMO 28

848687

697172

CMO 34CMO 36CMO 38

858788

707273

Table 1

Two-stage

Evaporating temperature TE -35°C [-31°F]Condensing temperature TC +35°C [95°F]Refrigerant R22/R717Number of revolutions 1450 rpm

Compressor block Lw LpTCMO 28TCMO 38

8182

6667

Table 2

Sound pressure values higher than the stated average value may be found locally, e.g. closeto the air inlet or outlet grid for the drive motor or air discharge on top of the noise cabinet.Higher noise levels may appear if the noise cabinet is not mounted correctly.

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3. Operating instructions

3.1.1 Safety precautions

Danger!

A number of safety precautions which must be read before operating the unit are presented inthe following. General safety instructions/regulations must be studied carefully. Failure to doso may result in personal injury or even death. Moreover, equipment may be damaged or de-stroyed.

3.1.2 VentilationBefore operating the unit, always check the function of the ventilation system used in thearea where the compressor unit is located (machine room).

Danger!

Pay close attention to the fact that large amounts of escaping (or released) refrigerant entailrisk of suffocation. Safety sheets explaining the risks associated with the relevant refrigerantshould be supplied by the supplier of the plant.

Danger!

Body contact with leaking liquid refrigerant entails high risk of injuries caused by intense cold.The safety sheets supplied by the supplier of the plant also explain the risks generally associ-ated with refrigerants.

3.1.3 Pressure

Danger!

A compressor unit comprises a pressurised system. Never loosen threaded joints (such as aunion nut) while the system is under pressure and never open pressurised system parts.

Note: Whenever a by-pass valve/safety valve has been activated we recommend recalibrat-ing it. This must be carried out by authorised personnel only. See also EN 378 and existingnational legislation.

3.1.4 Hot and cold surfaces

Warning!

A compressor unit contains both hot and cold system parts. Always wear and use appropriatesafety equipment.

Never use your hands or other parts of your body to search for leaks.

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3.1.5 Qualification requirementsBefore carrying out the measures set forth in this manual, all personnel must have carefullystudied the instructions issued for the compressor unit.

Personnel must also fulfil all national requirements for authorisation.

3.1.6 Compressor control and alarm functionsStandard reciprocating compressors can be equipped with either an analogue reading andregulating system or a Unisab reading, safety and regulating system.

3.1.7 Alarms and warnings

Analogue system

Analogue reading and regulating systems always require an external control board for theregulation of capacity. The board can be equipped with alarms.

The safety system consists of the following components:

KP1: Low pressure cut-out

Stops the compressor at too low pressure in the refrigeration system.

KP 5: Intermediate pressure cut-out

(TSMC compressors only)Stops the compressor at too high intermediate pressure.

KP7 ABS High pressure cut-out

As standard equipped with a high pressure cut-out adjusted to stop the compressor if the dis-charge pressure rises to a pressure higher than 0.9 x the compressor design pressure (PS) or2 bar below the setting pressure of the by-pass valve, whichever is the lower value.

MP 55: Oil differential cut-out

Stops the compressor at too low oil pressure in the lubricating system.

KP 98: Discharge pipe thermostat

Stops the compressor at too high discharge gas temperature.

KP 98: Oil thermostat

Stops the compressor at too high oil temperature.

The safety equipment stops the compressor if the maximum or minimum values are excee-ded. If this happens, correct the error before restarting the plant. To prevent accidents theplant cannot be started before the function of the safety cut-out has been activated. Cut-outsand thermostats are not factory set on delivery but must be set during the initial phase. In-sert the set values in Table 5: Pressure and temperature settings for compressor type CMO/TCMO. Always check the set values before starting the plant.

Note: Set values should be changed by authorised personnel only.



3.1.8 Unisab reading, safety and capacity regulating systemThe Unisab III control system is described in a separate manual and will be delivered with allunits equipped with Unisab III.

Warning!

At delivery, the compressor is fitted with a fine-meshed filter bag in the suction filters. The fil-ter bag filters off any small rust particles, which may penetrate the suction filters, and thuseffectively ensures that no impurities are mixed with the oil. The filter bag must not be usedmore than 50 hours after the first compressor start-up. This also applies to situations wheremodifications which may cause impurities in the suction gas are carried out on the plant. After50 hours, the filter bag and the insert must be removed and discarded. Disposal of used filterbags must be carried out according to the existing environmental legislation, please readchapter Final disposal.



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3.1.9 Valves for operation of compressor

Fig. 4: Valves on the CMO compressor

Fig. 5: Valves on the TCMO compressor

Pos. Description CMO TCMO1 Suction stop valve X X2 Discharge stop valve X XB Oil purge/drain valve X X7 Control equipment X X

Table 3: Descriptions of valves



3.1.10 Installation and first start-up procedureInstallation in terms of mechanical work (refrigeration system and piping), electrical work andinstallation of safety equipment must be performed in accordance with local codes/rulesand/or according to EN 378-3 and EN 378-4 as a minimum requirement.

The pressure loss in the downstream line from the safety valve must meet the values statedin EN 13136 to which EN 378 is referring. The data necessary to dimension the line in accord-ance with this standard is stated in the data sheet for the specific unit on the first page of thismanual.

Make sure that all necessary documents are available including declarations, certificates,identification plates, manuals, machine card, log books etc. and/or other documentation re-quired according to local rules and/or EN 378.



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3.1.11 Preparations for startingCheck the following before starting the compressor for the first time after installation:

• That the oil level is at the middle of the sight glass. If this is not the case, rechargewith oil. See section 4.1.14. Compressor prelubrication.

• That the safety equipment is set correctly. All safety functions are factory set. This isthe case for both analogue control and Unisab control.

• That the heating element in the crankcase has been energised 6-8 hours before start-ing up the compressor.

• That the pilot voltage is switched on. Check that the emergency stop button is in ON-position (the button must be in its outermost position). If the plant does not start,check that the fuses are intact.

• That the valves are open according to Table 4.

• That direction of rotation is correct. Check this by starting the motor and turning it offagain immediately.At fixed speed, check the direction of rotation before mounting the coupling inter-mediate part. At VSD operation, make the check with the entire coupling mounted,but run the motor for maximum 1 second. It is a good idea to have someone else helpobserve the direction of rotation.

Pos.no.

Qty. Designation Position duringoperation

Remarks

1 1 Suction stop valve OpenOpen by a couple ofturns only

2 1 Discharge stop valve Open 3 1 Air purge valve Closed

4 1 Oil charge valve ClosedMarked “B” on the com-pressor

5 1Stop valve- after oil separator

Open

6 1 Stop valve - receiver Open 7 1 Stop valve - liquid line Open Open after start-up

Table 4: Position during operation

31 To condenser2

5From condenser6

7

4

To evaporator

OpenClosed

Fig. 6: Principle drawing - position during operation

Note: There may be more valves. See dimensions and piping diagram.



3.1.12 Pressure and temperature settings

For compressor CMO/TCMO

Analogue control and safety system

Refrigerant

Min

.se

ttin

g

Max

.se

ttin

g

R22

R13

4

R40

4A

R50

7

R71

7

Saf

ety

equi

pmen

t

Safety valve on compres-sor

HPX X X X X 24 bar (standard) X X X X X 22 bar (special)

IP X X X X X 12 bar

High and intermediatepressure cut-out

KP7ABS(KP15)

X X X X X

Set to stop the compres-sor at a pressure 2 barlower than the safetyvalve setting.

Low pressure cut-outKP1(KP15)

X X X X X

Set to a pressure with sat-uration temp. 5°K lowerthan the lowest evaporat-ing temperature.

Oil pressure cut-out MP55 X X X X X 3.5 bar

Discharge pipe thermostat KP98X X X X * 120°C X * 150°C

Oil thermostat KP98 X X X X X 80°C

Con

trol

equ

ipm

ent

Thermostat for oil cooling KP77 X X X X X 55°C

Thermo valve for oil cool-ing

T(E)XT(E)NT(E)S

X X X X Normally set at 4°C super-heatChange to min. 10°C su-perheat

TEA X

Injection valve for inter-mediate cooling

TX X X

Set at min. 10°C super-heat

X Set at min. 10°C super-heat

TEA XSet at min. 10°C super-heat

Oil pressure regulatingvalve

X X X X X 4.5 bar

* Factory setting - can be adjusted, if required, to a breaking point 20°C higher than the higest normal dis-charge pipe temperatureTable 5: Pressure and temperature settings for compressor type CMO/TCMO



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3.1.13 Monitoring of operationTo ensure satisfactory operation, it is recommended to enter the following routines in a log-book. The service engineer will need this information in connection with e.g. error reports.Apart from the data mentioned in Table 6 all other activities of service, maintenance or repairwork must be entered into the logbook as required by EN 378 and national laws.

3.1.14 Example of an operation log

Machine room or system designation Data

ChecklistUsual level Data registered at

From To 04.00 08.00 12.00 16.00 20.00 24.00

Suction pressure Suction temperature Superheating, suction gas Discharge pressure Discharge temperature Oil pressure, compressor Oil pressure, filter Oil temperature Oil temperature,separator

Oil collection from shaftseal

Oil level Charged oil, ltr. Operation time (hours) Motor 1/1-load amp. Capacity load (%) Noise level Table 6: Proposal for operation log



3.1.15 Stopping routine

3.1.16 Brief stopBefore stopping the compressor, reduce the capacity to the lowest capacity level for a coupleof minutes. It is not necessary to shut the suction and discharge stop valve when it is only abrief stop. If the compressor is water-cooled, the water flow must always be stopped whenthe compressor is not in operation. The heating element must be or remain energised.

3.1.17 Shutting down for a long standstill periodIf the plant is stopped for a long period, ie 2-3 months or more, follow this procedure:

• Close the main shut-off valve after the receiver.

• Pump down evaporators. It might be necessary to adjust low pressure cut-out to alower suction pressure during pump down. Continue pump down until the suctionpressure has been reduced to a little above atmospheric pressure.

• Close the suction and discharge stop valves and the stop valve in the oil return line.

• Follow the plant instructions which indicate how to stop and close down the plant cor-rectly.

• Shut off the main and control power supply.

• Remember to write down all actions in the logbook.

3.1.18 ProblemsSome frequently encountered errors that can be remedied by the operator are described be-low.

In more complex situations, please call in skilled personnel who have access to the appropri-ate documentation.

3.1.19 TroubleshootingCompressor does not start.

• No demand for chilling (refrigeration). Wait until the temperature rises whereupon thecompressor will start automatically.

• Incorrect set point setting. Check the set point and, if necessary, make a change.

• One of the following digital entries has not been activated:

- External start permission/Immediate stop

- External start/Normal stop.

• Restarting delay (Unisab).

• Emergency stop activated.

If an alarm caused by a tripped monitor occurs, call in skilled personnel who have access toFaultfinding Instructions (Troubleshooting).



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4. Maintenance instructions

4.1.1 Compressor maintenance/serviceBefore performing any kind of service on the compressor, it is important to make sure thatthe motor cannot start up inadvertently. Please read chapter 2. Safety before servicing thecompressor in any way.


Danger!

Risk of injury to personnel and damage to equipment! In addition to the safety precautions inthis manual, always read the safety precautions belonging to the equipment before start. Fail-ure to comply with safety precautions may cause injury to personnel or death. Furthermore,equipment may be damaged or destroyed.

4.1.3 Safety measures

Danger!

The following sections present some important safety considerations regarding this type ofcompressor unit. Before carrying out any maintenance, please study carefully the generalsafety instructions/regulations that apply to this series of compressor units. Failure to followthese instructions/regulations may cause personal injury or death. Furthermore, equipmentmay be damaged or destroyed.

4.1.4 Basis for maintenanceRegular maintenance and inspections carried out by competent service personnel is of utmostimportance to ensure smooth and reliable operation.

Benefits of regular maintenance:

• Economical operation

• Prolonged equipment life

• Possibility to schedule stops due to maintenance

• Reduction of non-scheduled repair costs.

Carrying out the prescribed service and maintenance during the warranty period documentedby service certificates signed by competent personnel is considered a prerequisite for JohnsonControls Denmark to accept any warranty claim. Generally, we recommend that service andmaintenance work is carried out by competent personnel. Furthermore, it is advisable to entera service contract. The correct number of operating hours between maintenance activities de-pends on the specific operating conditions.

Maintenance instructions


4.1.5 Service intervalsDetermine the service intervals for a reciprocating compressor as follows:

1. Choose the appropriate diagram corresponding to refrigerant and compressor type.

2. Read the operating hours/service interval from the curves in the diagram.

The service intervals should be considered guidelines only as operation at non-specified condi-tions and/or the presence of water, acid, solid particles in the lubricating oil or refrigerant,forced starts and stops, part load, use of wrong oil type or lack of surveillance of the oil condi-tion, etc. all contribute to increased wear.

The service interval diagrams, which specify the number of maximum operating hours be-tween scheduled maintenance, are based on refrigerant type, standard rpm, operating hoursas well as pressure level and difference over the compressor. They do not, on the other hand,take into account unspecified conditions such as the ones mentioned above.

4.1.6 Service interval diagrams

HCFC/HFC/R290 - SMC/CMO R717 - SMC/CMOE-type: Multiply by 0.75

T0113099_1--40 --22 --4 14 32 50 68 86 104

--60 --50

--30

--20

--10

0

10

20

--22

--4

14

50

68

32

--76 --58

13,000

--40 --30 --20 --10 0

11,000

12,000

10 20 30 40TE

30

40

50

60

70

86

104

122

140

158

TC

5,000

6,000

8,00010,000

° C

° F

° C° F

Evaporating temperature

Con

dens

ing

tem

pera

ture

--76 --58T0113097_1

--40 --22 --4 14 32 50 68 86 104

--60 --50

--30

--20

--10

10

20

0

--22

--4

14

32

50

68

13,000

--40 --30 --20 --10 0 10 20 30 40

10,000

11,000

12,000

TE

30

40

50

60

86

104

122

140

TC

5,000

6,000

8,000

° C

° C° F

° F


Con

dens

ing

tem

pera

ture

HCFC/HFC/R290 - TSMC/TCMO R717 - TSMC/TCMO

E-type: Multiply by 0.75

10

20

0--60--76

50

68

32

T0113100_1

--50 --40 --30 --20--58 --22--40 --4

12,000

11,000

--1014

032

TE

40

50

30

60

86

104

122

140

TC

10,000

8,0006,000

5,000

° C° F

° C

° FEvaporating temperature

Con

dens

ing

tem

pera

ture

T0113098_1

--600

10

20

30

40

50

60

32

50

68

86

104

122

140

--76--50 --40 --30 --20

--40--58 --22 --4--1014

032 TE

TC

12,000

10,000

11,000

8,000

6,000

5,000

° C° F

° C

° F


Con

dens

ing

tem

pera

ure



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R717 - HPC/HPO R410A - HPC/HPO

10

20

30

40

50

--40 --30

--40 --22

50

68

86

104

122

T0113101_0

10,000

--20 --10 0 10 20

14--4 32 50 68

30 40 50

86 104 122TE

6,000

5,000

8,000

60

70

80

140

158

176

TC

4,000

° C

° F

° F

° C


Con

dens

ing

tem

pera

ture

--40

--30

--20

--10

--60 --50

--40

--22

--4

14

T0113102_0--76 --58

14,000

--40 --30 --20 --10 0

12,000

--40 --22 14--4 3210 20 30 4050 68 86 104

TE

0

10

20

30

40

50

32

50

68

86

104

122

8,000

10,000

6,000

5,000

4,00060140

TC

° C

° C

° F

° F

Evaporating temperatureC

onde

nsin

g te

mpe

ratu

re

R744 - HPC/HPO

T0113104_2

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

--58

0

--4

--22

--40

32

14

--50

--40

--30

--20

--10

--30--60 --50 --40

8,000

10,000

--20 --10 0

32TE

6,000

50

TC

10 4,000


Con

dens

ing

tem

pera

ture

HPO defrost



If the compressor operates at a different speed than 1,460 rpm, the service interval should becorrected according to the following table:

Rpm 970 1,170 1,460 1,760

Correction factor 1.5 1.25 1.00 0.83

Correction may also be calculated with the formula:

Correction = 1460rpm

Example

The service interval of a compressor is 10,000 hours according to the diagram.

If the compressor runs at 970 rpm, the service interval will be 1.5 x 10,000 = 15,000 h.

Note: Always replace the oil filter when changing oil, or when the control lamp or Unisab IIIindicates change of oil filter.

For reciprocating compressors, standard service inspections will be carried out in cycles con-sisting of 4 preventive maintenance service visits:

• 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”.

Furthermore, a yearly service visit, independent of the standard service visits, is carried out.After the first 200 operating hours, please use service set “0”.

Inspection of parts

In addition to the planned replacement of parts according to the service sets mentioned be-low, certain parts must be inspected. Inspections and replacement criteria for inspected partsare specified in a separate service guide.

Nice-to-have part sets

A list of recommended parts supporting the part inspection is available. The list contains allparts which may be replaced. In other words, the sets tell the service technician which partsto bring to the inspection.



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4.1.7 Annual serviceIf the time interval between two standard service visits exceeds one year, an annual serviceand inspection visit is carried out. The service visit includes the activities specified in Table 7and Table 8.

Prescribed serviceChange oil filterCheck leak rate of shaft sealCheck oil, and clean gas suction filterInspect one of the discharge valves and one of the cylinder linersCheck bolt and nut for one connecting rodCheck one of the connecting rod bearing shafts, one of the crankshaft journals and the largeend of the connecting rods. If any of these parts are worn, please replace the bearings.Change gaskets for covers which have been openedPerform functional test of safety devicesCheck for correct operation and working order of:- all safety controls

- all measuring devices

- all alarm systems

Check safety valves, bursting discs and fusible plugs for leaksPerform oil and refrigerant leak testAdjust refrigerant chargeCheck vibration dampers for cracks and adjustmentCheck for abnormal vibrations and noisesCheck coupling for any signs of cracks and/or other kinds of damageTable 7: Prescribed service

Recommended serviceAnalyse oilCheck when last instruction of the operating personnel was performedCheck that the logbook is available and updatedCheck if the machine card and piping layout diagram is availableCheck the safety devices on site: Switching devices, emergency signals, alarm systemsand external pressure relief devicesCheck personal protective equipment for emergency useTable 8: Recommended service



4.1.8 Regular service schedule - refrigeration plantEN 378-1:2000; section 4.5.2.1: Refrigeration systems must be maintained and repaired byqualified personnel only (see EN 13313).

Safety

Service to be carried outat each periodic

maintenanceand/or repair

minimum yearly

Check for correct operation and working order of: X - all safety controls X - all measuring devices X - all alarm systems X Check if machine card is available X Check if diagram of piping layout is available X Check on site:Safety switching devices, emergency signals andalarm systems

X

Perform leak test X Check and perform leak test of safety valves,bursting discs and fusible plugs

X

Perform functional test of safety devices X Perform “pressure drop test” RePerform refrigerant leak test on all components andsystems

Re

Check personal protective equipment X ReCheck if the operating personnel are properly in-structed and familiar with the contents of theOperating manual

X

FunctionPerform evacuation X Adjust refrigerant charge X Analyse oil ReCheck for corrosion X ReCheck for damaged insulation/vapour barrier X ReCheck composition of secondary cooling medium X ReCheck that the logbook is updated X Table 9: Service activities

Re = Check and replace, if necessaryX = Mandatory according to EN 378



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4.1.9 Regular service scheduleEN 378-1:2000; section 4.5.2.1: Refrigeration systems must be maintained and repaired byqualified personnel only (see EN 13313).

Compressor parts:

Internal parts according to partslists for yearly service,Service A, B and C

Yearlyservice

Planned maintenance activities(document service in logbook)

ServiceA

ServiceB

ServiceA

ServiceC

Ch/Re Ch/Re Ch/Re Ch/Re Ch/ReBuilt-on/external parts: Check for leaks in:Safety valves, bursting discsand fusible plugs

X X X X X

Check on site:Safety switching devices, emergencysignals and alarm systems

X X X X X

Check vibration dampers for cracks andcompression

Re Re Re Re Re

Check for abnormal noisesand/or vibrations

Re Re Re Re Re

Check crankcase heating Re Re Re Re ReCheck alignment and coupling condition Re Re Re Re ReCheck solenoid valves Re Re Re Re ReCheck compressor cooling Re Re Re Re ReCheck thermopump Re Re Re Re ReCheck oil return to compressor Re Re Re Re ReElectric motor:See manufacturer's instruction manualregarding lubrication and control

Re Re Re Re Re

Check for abnormal noisesand/or vibrations

Re Re Re Re Re

Table 10: Service activities (intervals according to service interval diagrams)

Ch = Change/replaceRe = Check and replace if necessaryX = Mandatory according to EN 378



Compressor parts:

Internal parts according to partslists for yearly service,Service A, B and C

Yearlyservice

Planned maintenance activities(document service in logbook)

ServiceA

ServiceB

ServiceA

ServiceC

Ch/Re Ch/Re Ch/Re Ch/Re Ch/ReSafety parts - built-on/external:Check for correct operation and workingorder of:

X X X X X

- all safety controls X X X X X- all measuring devices X X X X X- all alarm systems X X X X XPerform leak test X X X X XPerform evacuation X X X X XPerform adjustment of refrigerant charge X X X X XPerform functional test of safety devices X X X X XPerform “Pressure drop test” Re Re Re Re RePerform refrigerant leak test on allcomponents and system

X Re Re Re Re

Analyse oil Re Check that the logbook is updated Re Table 11: Service activities (intervals according to service interval diagrams)

4.1.10 Visual inspection

Oil pressure

Check that the oil pressure complies with the recommendations in Table 5: Pressure and tem-perature settings for compressor type CMO/TCMO.

Oil level

Check the oil level in the compressor. It is of vital importance for the service life of the com-pressor that an optimal lubrication is maintained. The oil level must always be visible in the oillevel glass. If the oil level is below the lowest part of the oil level glass, oil must be recharged.

Recharging of oil (“topping up”) can be carried out during operation either by means of ahand-operated oil pump or as described in 4.1.11. Charging compressor with lubricating oil.Use the recommended oil only.

Remember to write down drained or recharged amount of oil.

4.1.11 Charging compressor with lubricating oilAs all Johnson Controls Denmark reciprocating compressors are supplied with a special oilcharging valve on the crankcase, lubricating oil may be charged while the compressor is oper-ating.

For this purpose, use a hand-operated oil pump as mentioned earlier, or follow the procedurebelow.

See oil charge in Table 12 and oil level in Table 13.

Note: When charging for the first time, use the oil pump. Never start the compressor, if it isnot charged with oil.

• Reduce pressure in the crankcase, e.g. by throttling the suction stop valve until thesuction pressure gauge shows a pressure slightly below atmospheric.



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• Fill the pipe connected to the oil charging valve with lubricating oil, and place the freeend of the pipe in a receptacle containing fresh lubricating oil.

• Open the oil charging valve carefully. External air pressure will force oil into thecrankcase.

• Avoid air or other impurities being sucked into the compressor.

Note: In order to achieve pressure below atmospheric, it will sometimes be necessary to setthe low-pressure cut-out so that the compressor can operate down to this pressure. Remem-ber to reset the pressure cut-out to its normal setting after oil charging. During operation, thecompressor can be recharged with oil by means of the hand-operated oil pump.

Note: As halocarbon refrigerants are miscible with lubricating oils, there will always be a goodportion of oil blended with the refrigerant in the plant. Therefore, it is often necessary to re-charge with lubricating oil after starting up for the first time and after charging with fresh re-frigerant.

Watch the oil level in the compressor closely after start-up.

4.1.12 Oil charge - Oil level

Compressor Amount of oilin crankcase

Type Size Litre US gal.HPO 24 - 26 - 28 14 3.7

CMO24 - 26 - 28

16 4.234 - 36 - 38

TCMO 28 - 38 18 4.8Table 12: Oil charge

Compressor 10 mm difference in oillevel corresponds toType Size

HPO 24 - 26 - 28- 1litre of oil[0.3 US gal.]

CMO24 - 26 - 2834 - 36 - 38

TCMO 28 - 38Table 13: Oil level



4.1.13 Oil chargeUsually, the compressor is delivered without any oil in the crankcase. As a principal rule, theamount of oil indicated in Table 12: Oil charge should be charged to the compressor.

After a few hours of operation, the compressor must be recharged with oil as part of the oilhas been absorbed by the refrigerant. This particularly applies to HFC and HCFC refrigerants.

The amount of oil to be recharged depends on the size of the refrigeration plant and theamount of refrigerant. Oil is charged to the middle of the oil level glass, and the amount of oilneeded in order to increase the oil level 10 mm is indicated in Table 13: Oil level.

10 mm

Fig. 7: Oil level glass



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4.1.14 Compressor prelubrication

Warning!

Do not start the compressor without prelubricating bearings and shaft seal.

Before starting up the compressor for the first time after a standstill period of several months,the compressor must be prelubricated. This way the bearings will be lubricated and the oilsystem filled with oil before the compressor is started. Prelubrication is carried out by con-necting an oil pump to the prelubrication branch, which is connected to the cover, pos. 86H or87K, on CMO-TCMO-HPO compressors.

The Sabroe hand-operated oil pump, part no. 3141-155, is recommended as prelubricationpump. For prelubrication, use clean fresh refrigeration oil of the same type as the one in thecompressor and pump as follows:

Compressor type Pump strokes with Sabroehand-operated oil pump

Estimated amount of oilLitres

CMO, TCMO, HPO approx. 25 2.5Table 14

The heating rod in the crankcase must be switched on for at least 6-8 hours before compres-sor start-up to boil out any refrigerant from the compressor oil. At the same time, the suctionstop valve must be open.

Check the oil level in the crankcase. The oil level must always be visible in the oil sight glass.

A hand-operated oil pump connected to the oil charging valve pos. B can be used for thefirst as well as the following oil charges. See subsection 3.1.9. Valves for operation of com-pressor.

Cap

Gasket

Optional hand-operated oil pump

To compressor

B

Fig. 8: Hand-operated oil pump



4.1.15 Oil charging and drain valveThe compressor is fitted with a valve for charging and draining oil. A cover is placed over thespindle to avoid the valve from opening inadvertently.

Cover Oil charging valve

Fig. 9

4.1.16 Hand-operated oil pumpOil charging is also possible during operation.

Fig. 10

Connections to oil pump

1 threaded sleeve 1/2” RG1 threaded nipple 1/2” RG1 union nut 7/8” RG



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4.1.17 Shaft sealThe rotating sealing surface on the mechanical shaft seal is made of a soft material, which willtend to wear during operation. Therefore, the shaft seal must be checked regularly for tight-ness and wear in accordance with the service intervals applying to the compressor.

4.1.18 Motor lubricationIn connection with electric motors, it is absolutely essential to lubricate the bearings correctlyand use the appropriate type of grease.

Please refer to the motor manual and/or the motor name plate.

Major overhaul of the compressor

Contact Johnson Controls Denmark's service organisation.



5. Final disposal


Danger!

Before dismantling the plant, read the safety precautions carefully.

Dismantling a cooling unit to be scrapped must be carried out safely.

Authorised refrigeration personnel must participate in the first part of the dismantling processas fundamental knowledge of refrigeration systems and the risks involved is required.

Before dismantling the plant, refrigerant and oil must be drained into suitable containers. Dis-connect all electrical connections to the unit, and remove fuses in the main switchboard.

During the dismantling process, the individual machine parts and components must be sortedto ensure proper disposal. All waste must be transported to receiving stations which complywith the prevailing national rules and regulations.

Danger!

Be very careful when using cutting tools such as angle grinders or flame cutters during thedismantling process as pipes and the like contain oil residue, which may ignite. Refrigerantresidue also involves a great risk, as HFC and HCFC refrigerants develop toxic gasses whenheated. Make sure that there are no air traps, as heating results in a pressure rise.

5.1.2 Disposal of• Machine parts

When dismantling the plant, it is important to sort the parts to be disposed of. Com-pressor, frame, containers, etc. belonging to the category of iron and metal scrapmust be brought to an approved scrap dealer, who complies with the prevailing na-tional rules and regulations.

• Oil and refrigerantOil and refrigerant must be brought to a receiving station for hazardous waste for de-struction or regeneration. This also applies to used oil filters. The receiving stationmust comply with the prevailing rules and regulations of the individual country. Donot transport oil in open vessels in a closed car.

• Electrical componentsElectrical and electronic products, e.g. wiring, panels, hardware etc., must be broughtto a receiving station approved to handle electronic waste. The receiving station mustcomply with the prevailing rules and regulations of the individual country.

• BatteriesUsed batteries from e.g. the backup of the computer control must be brought to a re-ceiving station for destruction. The receiving station must comply with the prevailingrules and regulations of the individual country.

Final disposal


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6. Appendices

All relevant instructions for products supplied by sub-suppliers are collected here.

6.1.1 Declaration of conformityJohnson Controls Denmark declares on the signed declaration of conformity that the machineis manufactured and CE-marked in conformity with relevant directives and standards.

On the next two pages you can see a declaration of conformity, however not filled in with thespecific data. It may occur that the original signed declaration of conformity is sent separate-ly. If so, it will be based on a clear written agreement between the customer and JohnsonControls Denmark.

Appendices


Appendices


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Appendices


Index

AAnnual service 35

Appendices 45

BBatteries 44

CCompressor name plate 11

Compressor noise data 20

Cooling water system 16

DDisposal 44

EElectrical components 44

FF-gas regulation 18

Final disposal 44

first start-up 26

Ggreenhouse gases 18

IInstallation 26

Llubricating oil 38

Lubricating oils 17

MMaintenance safety/safety at servicing 14

maintenance/service 31

Motor lubrication 43

NNoise 21

OOil and refrigerant 44

Oil charge 39


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Oil level 39

Oil types 17

operation log 29

PPurging 18

RRefrigerants 18

SSafety precaution definitions 6

Safety precautions 44

Service intervals 32

service schedule 36

Signs 13

Stopping routine 30

TTransmission safety 20

Troubleshooting 30

UUnit/pipe system name plate 9

VVessel name plate 12


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