instruction manual for sab 110

01.10

0178-145-EN 1

Instruction manualforSAB 110

Screw compressor and unit may differ inequipment depending on their function andrequirements.

Some of these variants are treated in this

instruction manual although they may not befitted on your particular unit.

In the below table the x-mark indicates whichvariants are fitted on your unit with shop no.stated below.

Instrumentation

Oil cooling

Economizersystem(ECO-system)

Type of drive

Refrigerant

Shop no.

Capacityindicator

Instrument panel and manual regulation of Vi-slide

UNISAB II and manual regulating of Vi-slide

Water-cooled oil cooler OWSG/OWRG

Water-cooled oil cooler Type B

Refrigerant-cooled oil cooler OOSI

Refrigerant injection in the compressor HLI

Vessel type HESS

Closed system and vessel type EOSE

Open system and vessel type SVER

Compressor and unit are safeguarded

A Visual capacity indicator

B Capacity indicator with position transmitter

Ex-execution

Male drive Female drive

R717 R22 Other

SMLM

SFLF

0171-500-EN

00.07

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Preface

The aim of this instruction manual is toprovide the operators with a thoroughknowledge of the compressor and the unitand at the same time provide informationabout:

S the function and maintenance of theindividual components;

S service schedules;

S procedure for dismantling andreassembling of the compressor.

This instruction manual draws attention totypical errors which may occur during opera-tions. The manual states causes of error andexplains what should be done to rectify theerrors in question.

It is imperative that the operators familiarizethemselves thoroughly with the contents of

this instruction manual to ensure a safe,reliable and efficient operation of the productas YORK Refrigeration is unable to provide aguarantee against damage of the productoccurring during the warranty period as aresult of incorrect operation.

Dismantling and assembly of compressorsand components should only be carried outby authorized personnel to preventaccidents.

The contents of this instruction manual mustnot be copied or passed on to anyunauthorized person without YORKRefrigeration’s permission.

YORK Refrigeration’s General Conditions forthe Supply of Components and Spare Partswill apply.

In the space below you can enter the name and address of your local YORK RefrigerationRepresentative:

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Table of Contents

Instruction manual for SAB 110 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Preface 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Table of Contents 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .First Aid for accidents with Ammonia 6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .First aid for accidents with HFC/HCFC 8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Protecting the environment 9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Description of compressor SAB 110 12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Sound data for reciprocating and screw compressor units -- all types of compressors 14. .Vibration Data for Compressors - All Compressor Types 18. . . . . . . . . . . . . . . . . . . . . . . . . .Handling of the compressor, areas of application, safety equipment etc. 19. . . . . . . . . . . . .Technical data for compressor & unit SAB 110 22. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Compressor data SAB 110 23. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Operating limits, general 24. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Compressor and unit operation SAB 110 28. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1. Preparations before starting up 28. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2. Initial start-up 29. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3. Normal start-up 29. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4. Current control at normal operation 29. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5. Normal stop 30. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6. Emergency stop or incorrect setting 30. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7. Preparations before a lengthy stand-still period 30. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Pressure testing of the refrigeration plant 30. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Evacuation of refrigeration plant 31. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Operating log 32. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Service Schedules for screw compressors SAB 110, 128/163 Mk3, 202 & VMY 34. . . . . .Preparations before compressor inspection 34. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Cleansing of oil in the unit 35. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Checking the oil 36. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Assessing the oil 39. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Visual assessment 39. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Analytical evaluation 39. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Procedure 40. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Analysing the oil 40. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Limiting values 40. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Major Service Intervals SAB 110, SAB 128/163 Mk3, SAB 202 42. . . . . . . . . . . . . . . . . . . .Oil charges, Weights and Shipping Volumes SAB 110 43. . . . . . . . . . . . . . . . . . . . . . . . . . . .Temperature and Pressure Settings SAB 110 44. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Servicing the Refrigeration Plant 45. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Maintenance of compressor SAB 110 Dismantling and assembly 47. . . . . . . . . . . . . . . . . . .

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Tools 48. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Removal of refrigerant gas 48. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Removing compressor from oil separator 48. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1. Suction filter 49. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2. Suction pressure regulator and non-return valve 50. . . . . . . . . . . . . . . . . . . . . . . . . . . . .3. Safety valve 51. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4. Oil filter 52. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5. Float switch 52. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6. Regulating cylinder for capacity slide 54. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7. Capacity slide 54. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8. Shaft seal type 680 56. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9. Capacity indicator 59. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Magnetic coupling for capacity indication type A and B 59. . . . . . . . . . . . . . . . . . . . . . . . . .Position transmitter 60. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Position transmitter 60. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Limiting the minimum capacity of the screw compressor - SAB 110 S/L 62. . . . . . . . . . . .10. Bearing cover, rotors and bearings Dismantling and assembly 63. . . . . . . . . . . . . . . .11. Adjusting the rotors 68. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12. Slide stop for Vi-regulation 71. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13. Dismounting and assembly of motor and coupling 72. . . . . . . . . . . . . . . . . . . . . . . . . .Coupling type E128 74. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Coupling type 65 HEW 76. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Systems for regulation of compressor capacity and Vi-ratio of SAB 110 79. . . . . . . . . . . . . .1. Regulation of compressor capacity 79. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2. Manual regulating of Vi-slide 81. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Torque moments for screws and bolts 85. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Component description SAB 110 87. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Heating Rods, pos. 30, Element for Oil Heating 90. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Water-cooled oil cooler, type OWSG/OWRG for screw compressors types

SAB 110, SAB 128/163 Mk3, SAB 202 91. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Water-cooled oil cooler, type B SAB 110, SAB 128/163 Mk3, SAB 202 94. . . . . . . . . . . . . .Refrigerant-cooled oil cooler type OOSI SAB 110, SAB 128/163 Mk3 96. . . . . . . . . . . . . . .Oil temperature regulating system SAB 110, 128, 163, 202 and VMY 536 97. . . . . . . . . . . .Injection of refrigerant into compressor HLI (High-stage Liquid Injection) SAB 110 99. . . .Safety and monitoring devices SAB 110, SAB 128/163 Mk3, SAB 202, SAB 283L/283E 100Refrigeration Plant Maintenance 102. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Operational reliability 102. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Pumping down the refrigeration plant 102. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Dismantling plant 102. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Tightness testing and pump-down of refrigeration plant 103. . . . . . . . . . . . . . . . . . . . . . . . .

Troubleshooting on the Screw Compressor Plant 104. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Remedying Malfunctions 106. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Selecting Lubricating Oil for SABROE Compressors 113. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Data Sheet for Listed Sabroe Oils 119. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .List of Major Oil Companies 142. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Alignment of compressor unit SAB 110 143. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Key to Piping Diagrams/Component List 146. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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Ordering Spare Parts 150. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Spare Part Sets for Screw Compressor and Unit 151. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Tools for compressor SAB 110 0661-843. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .List of parts for SAB 110 0661-845. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Spare parts drawing 0661-844. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Spare parts survey for SAB 110 unit 0661-833. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Piping diagram order specific. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Wiring diagram order specific. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Dimensional sketch order specific. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Location of of vibration dampers order specific. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Instructions for control- and monitoring equipment order specific. . . . . . . . . . . . . . . . . . . . . . . .

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First Aid for accidents with Ammonia(Chemical formula: NH3 - refrigerant no.: R717)

GeneralAmmonia is not a cumulative poison. It has adistinctive, pungent odour that even at verylow, harmless concentrations is detectable bymost persons. Since ammonia is self-alarm-ing, it serves at its own warning agent, sothat no person will voluntarily remain in con-centrations which are hazardous. Since am-monia is lighter than air, adequate ventilationis the best means of preventing an accu-mulation.

Experience has shown that ammonia is ex-tremely hard to ignite and under normalconditions is a very stable compound. Underextremely high, though limited concentra-tions, ammonia can form ignitable mixtureswith air and oxygen, and should be treatedwith respect.

Basic rules for first aid1. Call a doctor immediately.

2. Be prepared: Keep an irrigation bottleavailable, containing a sterile isotonic(0.9%) NaCl-solution (salt water).

3. A shower bath or water tank should beavailable near all bulk installations withammonia.

4. When applying first aid, the persons as-sisting should be duly protected to avoidfurther injury.

Inhalation

1. Move affected personnel into fresh air im-mediately, and loosen clothing restrictingbreathing.

2. Call a doctor/ambulance with oxygenequipment immediately

3. Keep the patient still and warmly wrappedin blankets.

4. If mouth and throat are burnt (freeze oracid burn), let the conscious patient drinkwater, taking small mouthfuls.

5. If conscious and the mouth is not burnt,give hot, sweet tea or coffee (never feedan unconscious person).

6. Oxygen may be administered, but onlywhen authorized by a doctor.

7. If breathing fails, apply artificial respira-tion.

Eye injuries from liquid splashes orconcentrated vapour

1. Force the eyelids open and rinse eyes im-mediately for at least 30 minutes with thesalt water solution just mentioned

2. Call a doctor immediately.

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0178-145-EN 7

Skin burns from liquid splashes orconcentrated vapour1. Wash immediately with large quantities of

water and continue for at least 15 minutes,removing contaminated clothing carefullywhile washing.

2. Call a doctor immediately.

3. After washing, apply wet compresses(wetted with a sterile isotonic (0.9%)NaCl-solution (salt water)) to affectedareas until medical advice is available.

No plant can ever be said to be too safe.Safety is a way of life.

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First aid for accidents with HFC/HCFCRefrigerant no.: R134a -- R404A - R410A - R505A - R507 - R22, etc

General

HFC/HCFC form colourless and invisiblegasses which are heavier than air and smellfaintly of chloroform at high concentrationsonly. They are non-toxic, non-inflammable,non-explosive and non-corrosive under nor-mal operating conditions. When heated toabove approx. 300�C they break down intotoxic, acid gas components, which arestrongly irritating and aggessive to nose,eyes and skin and generally corrosive. Be-sides the obvious risk of unnoticeable, heavygases displacing the atmospheric oxygen,inhalation of larger concentrations may havean accumulating, anaesthetic effect whichmay not be immediately apparent. 24 hoursmedical observation is, therefore, recom-mended.

Basic rules for first aid

1. When moving affected persons from low-lying or poorly ventilated rooms wherehigh gas concentrations are suspected,the rescuer must be wearing a lifeline, andbe under continuous observation from anassistant outside the room.

2. Adrenalin or similar heart stimuli must notbe used.

Inhalation1. Move affected person into fresh air im-

mediately. Keep the patient still and warmand loosen clothing restricting breathing.

2. If unconscious, call a doctor/ambulancewith oxygen equipment immediately.

3. Give artificial respiration until a doctor au-thorizes other treatment.

Eye injuries1. Force eyelids open and rinse with a sterile

isotonic (0.9%) NaCl-solution (salt water)or pure running water continuously for 30minutes.

2. Contact a doctor, or get the patient to ahospital immediately for medical advice.

Skin injuries -- Freeze burns1. Wash immediately with large quantities of

luke warm water to reheat the skin.Continue for at least 15 minutes, removingcontaminated clothing carefully whilewashing.

2. Treat exactly like heat burns and seekmedical advice.

3. Avoid direct contact with contaminated oil/refrigerant mixtures from electrically burnt-out hermetic compressors.

No plant can ever be said to be too safe.Safety is a way of life.

0170-009-EN

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Protecting the environment

Increasing industrialisation threatens our en-vironment. It is therefore absolutely impera-tive that we protect nature against pollution.

To this end, many countries have passed le-gislation in an effort to reduce pollution andpreserve the environment. These laws applyto all fields of industry, including refrigeration,and must be complied with.

Be especially careful with the following sub-stances:

S refrigerants

S cooling media (brines etc)

S lubricating oils.

Refrigerants usually have a natural boilingpoint which lies a good deal below 0�C. Thismeans that liquid refrigerants can be extre-mely harmful if they come into contact withskin or eyes.

High concentrations of refrigerant vapoursare suffocating when they displace air; if high

concentrations of refrigerant vapours are in-haled they attack the human nerve system.

When halogenated gasses come into contactwith open flame or hot surfaces (over approx.300�C) they decompose to produce poiso-nous chemicals, which have a very pungentodour, warning you of their presence.

In high concentrations, R717 causes respira-tory problems, and when ammonia vapourand air mix 15 to 28 vol. %, the combinationis explosive and can be ignited by an electricspark or open flame.

Oil vapour in the ammonia vapour increasesthis risk significantly as the point of ignitionfalls below that of the mixture ratio stated.

Usually the strong smell of ammonia willgive ample warning of its presence beforeconcentrations become dangerous.

The following table shows the values for refri-gerant content in air, measured in volume %.Certain countries may, however, have an offi-cial limit which differs from those stated.

R717

vol.% 0,1 0,005

vol.% 0,2 0,002

R134a R404A R507 R22

0,10,10,1

R407C

0,1

HCFCHFC

R410A

0,1

Halogenated refrigerants Ammonia

Unit

Time weighted ave-

rage during a week

Warning smell

TWA

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Further comments on refrigerants:S If released to the atmosphere, haloge-

nated refrigerants of the type HCFC(e.g. R22) may cause a depletion of theozone layer in the stratosphere. Theozone layer protects the earth from theultraviolet rays of the sun. Refrigerants ofthe types HFC and HCFC are greenhousegases with contribute to an intensificationof the greenhouse effect. They must,therefore, never be released to the atmo-sphere. Use a separate compressor todraw the refrigerant into the plant con-denser/receiver or into separate refriger-ant cylinders.

S Most halogenated refrigerants are mis-cible with oil. Oil drained from a refrigera-tion plant will often contain significantamounts of refrigerant. Therefore, reducethe pressure in the vessel or compressoras much as possible before draining theoil.

S Ammonia is easily absorbed by water:At 15�C, 1 litre of water canabsorb approx. 0,5 kg liquidammonia (or approx. 700 litresammonia vapour).

S Even small amounts of ammonia in water(2-5 mg per litre) are enough to wreakhavoc with marine life if allowed to pollutewaterways and lakes.

S As ammonia is alkaline it will damageplant life if released to the atmosphere inlarge quantities.

Refrigerant evacuated from a refrigerantplant shall be charged into refrigerant cylin-ders intended for this specific refrigerant.

If the refrigerant is not to be reused, return itto the supplier or to an authorized incinerat-ing plant.

Halogenated refrigerants must never bemixed. Nor must R717 ever be mixed withhalogenated refrigerants.

Purging a refrigeration plantIf it is necessary to purge air from a refrige-ration plant, make sure you observe the follo-wing:

S Refrigerants must not be released to theatmosphere.

S When purging an R717 plant, use an ap-proved air purger. The purged air mustpass through an open container of waterso that any R717 refrigerant remainingcan be absorbed. The water mixture mustbe sent to an authorized incinerating plant.

S Halogenated refrigerants can not be ab-sorbed by water. An approved air purgermust be fitted to the plant. This must bechecked regularly using a leak detector.

Cooling mediaSalt solutions (brines) of calcium chloride(CaCl2) or sodium chloride (NaCl) are oftenused.

In recent years alcohol, glycol and halogena-ted compounds have been used in the brineproduction.

In general, all brines must be considered asharmful to nature and must be used withcaution. Be very careful when charging orpurging a refrigeration plant.

Never empty brines down a sewer or intothe environment.

The brine must be collected in suitable con-tainers, clearly marked with the contents, andsent to an approved incinerating plant.

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Lubricating oils

Refrigeration compressors are lubricated byone of the following oil types, depending onthe refrigerant, plant type and operating con-ditions.

-- mineral oil

-- semi-synthetic oil

-- alkyl benzene-based synthetic oil

-- polyalphaolefine-based synthetic oil

-- glycol-based synthetic oil.

When you change the oil in the compressoror drain oil from the refrigeration plant’s ves-sels, always collect the used oil in containersmarked “waste oil” and send them to an ap-proved incinerating plant.

Note

This instruction provides only general information. The owner of the refrigerationplant is responsible for ensuring that all by-laws are complied with.

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12 0178-145-EN

Description of compressor SAB 110

The SAB 110 is a screw compresor with oilinjection and capacity regulating, fromapprox. 25% to 100%.

Existing types of SAB 110:

SAB 110S 1.2 M

SAB 110L 1.5 M

SAB 110S 1.2 F

SAB 110L 1.5 F

L/D Form/typesof coupling

L/D indicates the ratio between the rotorlengths L and outer diameter D = 110 mm.

SAB 110 operates on either R717 or R22 re-frigerants within the following operational lim-its:

Max. operational pressure: 25 barMax. differential pressure: 20 barHighest condensation temperature:

R717 +53�CR22 +55�C

Highest evaporation temperature:R717 and R22 +15�C

Lowest evaporation temperature:R717 and R22 -55�C

S The electric motor is flanged directly tocompressor, thus ensuring alignment tothe compressor. The motor will not be partof the refrigerant circuit as with semiher-metic compressor types. In this way thecompressor can also be used for R717.

The electric motor is coupled to the rotorby means of a flexible coupling which canbe connected to either male rotor (coupl-

ing form M) or female rotor (couplingform F).

For each of the two types of couplingthere are two rotor sets:

Type S with L/D = 1.2 or type L withL/D = 1.5 respectively, corresponding to atotal of 4 rotor sets.

Using female drive the compressor yieldsa 50% higher capacity and requires a cor-respondingly higher motor power thanwhen using male drive.

S The rotors are designed with a so-calledD-profile acc. to SRM licence, and with aratio of 4+6. This means that the male ro-tor has 4 profile lobes and the female rotor6 ones.

At the suction end the rotors are providedwith roller bearings, while the bearings atthe discharge end consist of a combinedset of roller bearings which assimilate theradial load, and ball-bearings assimilatingthe axial road. The axial forces are partlyequalized by rotating balance pistonsmounted on the rotors.

S The compressor is equipped with a largebuilt-in suction filter, effectively preventingdirt from the plant being carried along withthe suction gas into the compressor. Fur-ther, the compressor has a combined suc-tion pressure regulator and a non-returnvalve ensuring that the compressor al-ways operates at a differential pressurebetween its discharge and suction side.Hereby an effective lubrication of the com-pressor is secured both on start-up andduring operation.

0178-145-EN 13

At the same time the suction pressure reg-ulator acts as non- return valve, prevent-ing the rotors from running in reversewhen current to the drive motor isswitched off.

S The rotor shaft, to which the motor is con-nected is equipped with a shaft seal of theslide ring type. It consists of a stationarysealing ring, made of special carbon, fittedin the end cover of the compressor andsealed against same by means of an O-ring.

Fastened to the rotor shaft and pressedagainst the carbon ring by a spring sys-tem. A rotating cast iron ring seals againstthe carbon ringThe shaft seal is of the bal-anced type, which means reduced slidesurface pressure and consequently pro-longed life.

S The compressor capacity is regulated bymeans of the regulating slide valve un-derneath the rotors.

When the regulating slide valve movesaway from its end stop in its 100% posi-tion, capacity is reduced steplessly, aspart of the suction gas, between rotors, isnot compressed.

The regulating slide valve is moved by apiston which via two solenoid valves is ac-tivated by the oil pressure in the unit.When in open position, one of the sole-noid valves, closed at dead coil, adds oilpressure to the piston, hereby moving theregulating the slide valve towards a highercapacity.

The other solenoid valve, open at deadcoil, carries, when open, oil from piston(cylinder) back to suction side of compres-sor. The result is that when the compres-sor is stopped and the two solenoid valvesare dead, the regulating slide valve ismoved to lowest capacity position bymeans of the built-in spring and the pres-sure behind the piston.

In this way the compressor is unloadedbefore next start-up.

S SAB 110 has a built-in regulating systemby which the compressor volume ratio Vican be adjusted manually. With theVi-system the compression ratio of thecompressor can be adjusted according tothe plant pressures, before and after thecompressor.

In this way over and under compression isavoided and the lowest possible energyconsumption achieved.

S Further, the SAB 110 compressor has abuilt-in combined oil filter which, bymeans of a filter cartridge retains all par-ticles bigger than 10 micron, and a mag-netic filter in which any small iron particlesare collected.

In connection with filter housing a floatvalve is built in, ensuring a constant oilflow the to compressor.

Likewise, a built-in safety valve safe-guards the compressor against unaccept-ably high differential pressures from dis-charge to suction side.

0170-114--EN

99.02

14 0178-145-EN

Sound data for reciprocating and screwcompressor units -- all types of compressors

In the following tables the noise data of thecompressors 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 alarge number of measurings on various units.The measurings have been carried out in ac-cordance with ISO 9614-2.

The values are further stated as averagesound pressure in a free field above a re-flecting plane at a distance of 1 meter froma fictional frame around the unit. See fig. 1.

Normally, the immediate sound pressurelies between the LW and LP values and canbe calculated provided that the acoustic dataof the machine room is known.

For screw compressors the average valuesare indicated in the tables for the followingcomponents.

S SAB 128, SAB 163, SAB 202, SV andFV:Compressor block + IP23 special motor +oil separator.

S SAB 110:Compressor block + IP23 standard motor+ oil separator

Dimensional tolerances are:

�3 dB for SAB, SV and FV screw com-pressors�5 dB for VMY screw compressors

As to the reciprocating compressors thevalues are stated for the compressor blockonly.

The dimensional values are stated for 100%capacity.

Fictional frame

Reflecting plane

Fig. 1

1 meter

Dimensional plane

1 meter

0178-145-EN 15

Note the following, however:

S at part load or if the compressor workswith a wrongly set Vi the sound level cansometimes be a little higher than the oneindicated in the tables.

S additional equipment such as heat ex-changers, pipes, valves etc. as well as thechoice of a different motor type can in-crease the noise level in the machineroom.

S as already mentioned, the stated soundpressures are only average values abovea fictional frame around the noise source.Thus, it is sometimes possible to measurehigher values in local areas than the onesstated -- for inst. near the compressor andmotor.

S the acoustics is another factor that canchange the sound level in a room. Pleasenote that the sound conditions of the sitehave not been included in the stateddimensional values.

S by contacting SABROE you can havesound data calculated for other operatingconditions.

The tables have been divided into reciprocat-ing and screw compressors, respectively.The reciprocating compressors are furtherdivided into one- and two-stage compressorsas well as in a heat pump. In each table theoperating conditions of the compressor dur-ing noise measuring have been stated, justas the refrigerant used has been mentioned.

16 0178-145-EN

RECIPROCATING COMPRESSORSOne-stageEvaporating temperature = --15�CCondensing temperature =+35�CRefrigerant = R22/R717Number of revolutions =1450 rpm.

Compressor block LW LP

CMO 24 84 69

CMO 26 86 71

CMO 28 87 72

SMC 104 S 95 79

SMC 106 S 96 80

SMC 108 S 97 81

SMC 112 S 99 82

SMC 116 S 100 83

SMC 104 L 96 80

SMC 106 L 97 81

SMC 108 L 98 82

SMC 112 L 100 83

SMC 116 L 101 84

SMC 104 E 96 80

SMC 106 E 97 81

SMC 108 E 98 82

SMC 112 E 100 83

SMC 116 E 101 84

Evaporating temperature = --15�CCondensing temperature = +35�CRefrigerant = R22/R717Number of revolutions = 900 rpm.


SMC 186 101 83

SMC 188 102 84

Two-stageEvaporating temperature = --35�CCondensing temperature = +35�CRefrigerant = R22/R717Number of revolutions =1450 rpm.

TCMO 28 81 66

TSMC 108 S 95 79

TSMC 116 S 97 81

TSMC 108 L 96 80

TSMC 116 L 98 82

TSMC 108 E 96 80

TSMC 116 E 98 82

LW LPCompressor block

Evaporating temperature = --35�CCondensing temperature = +35�CRefrigerant = R22/R717Number of revolutions = 900 rpm.


TSMC 188 100 82

Heat pumpEvaporating temperature = +20�CCondensing temperature = +70�CRefrigerant = R22/R717Number of revolutions =1450 rpm.

HPO 24 91 76

HPO 26 93 78

HPO 28 94 79

HPC 104 97 81

HPC 106 98 82

HPC 108 99 84


0178-145-EN 17

SCREW COMPRESSORSEvaporating temperature = --15�CCondensing temperature = +35�CRefrigerant = R22/R717Number of revolutions = 2950 rpm.*Number of revolutions = 6000 rpm.

SAB 110 SM 98 81SAB 110 SF 98 81SAB 110 LM 98 81SAB 110 LF 98 81

SAB 128 HM Mk2 102 84SAB 128 HF Mk2 106 88SAB 128 HM Mk3 101 84SAB 128 HF Mk3 104 86

SAB 163 HM Mk2 105 86SAB 163 HF Mk2 109 90SAB 163 HM Mk3 103 86SAB 163 HF Mk3 106 87

SAB 202 SM 104 85SAB 202 SF 105 86SAB 202 LM 104 85SAB 202 LF 105 86

SV 17 100 83SV 19 101 84

FV 19* 101 86SV 24 103 85

FV 24* 104 86SV 26 103 85

FV 26* 107 85

SAB 81 101 86SAB 83 102 85SAB 85 103 86SV 87 105 86SV 89 108 85


Evaporating temperature = --35�CCondensing temperature = --5�CRefrigerant = R22/R717Number of revolutions = 2950 rpm.

Compressor unit LW LP

SAB 163 BM 106 88

SAB 163 BF 110 92

Evaporating temperature = --15�CCondensing temperature =+35�CRefrigerant = R22/R717Number of revolutions = 2950 rpm.


VMY 347 H 97 82

VMY 447 H 100 85

VMY 536 H 104 88

Evaporating temperature = 0�CCondensing temperature =+35�CRefrigerant = R22/R717Number of revolutions = 2950 rpm.


VMY 347 M 99 84

VMY 447 M 101 86

VMY 536 M 105 89

0170-115-EN

01.01

18 0178-145-EN

Vibration Data for Compressors - All Compressor Types

Vibration data for YORK Refrigeration’sSabroe reciprocating compressors complieswith: the ISO 10816, standard, Part 6,Annex A, group 4, AB, which fixes max.permissible operating vibrations at 17.8mm/s.

Vibration for YORK Refrigeration’sSabroe screw compressors complies with:ISO 10816 standard, part 1, Annex B,Class III, C, which fixes max. permissibleoperating vibrations at 11.2 mm/s.

The measurements are made as illustrated inthe figure below (points A-D).

Pay attention to the following, however:

S Motors comply with EN 60034-14 (CEI/IEC 34-14) Class N.

S When placing the unit on the vibrationdampers delivered by YORK Refrigeration(additional), the vibrations against thefoundation are reduced by:

-- 85-95% for screw compressor units

-- 80% for recip. compressor units

S However, a higher vibration level may oc-cur if:

-- motor and compressor have not beenaligned as described in the InstructionManual.

-- the compressor runs at a wrong Vi ratio.This applies to screw compressors.

-- the piping connections have beenexecuted in a way that makes them forcepull or push powers on the compressorunit or transfer vibrations to the unitcaused by natural vibrations or con-nected machinery.

-- the vibration dampers have not beenfitted or loaded correctly as indicated inthe foundation drawing deliveredtogether with the order.

0170-120-EN

98.03

0178-145-EN 19

Handling of the compressor, areas of application,safety equipment etc.

Direction of rotation

In order to reduce the noise level from theelectric motors these are often made withspecially shaped fan wings, thus determininga particular direction of rotation.Consequently, it is essential that the motor isordered with the correct direction of rotationmade for the compressor.

The direction of rotation of the compressor isindicated by an arrow cast into the compres-sor cover as shown on the following sketch.Please, notice that male and female drivehave different directions of rotation.

Seen towards shaft ends

Female Male

Handling of compressor and unit

For lifting of the compressor it has beenequipped with a threaded hole for mountingof the lifting eye. As to the weight of the com-pressor, see table on compressor data.

Note:The compressor block alone may be liftedin the lifting eye. The same applies to themotor.

The unit is lifted by catching the lifting eyeswelded onto the unit frame. These have beenclearly marked with red paint. The weight ofthe unit is stated on the package as well as inthe shipping documents.

During transportation and handling careshould be taken not to damage any of thecomponents, pipe or wiring connections.

Areas of application of the screwcompressorsCompressor types:SAB 110 SM/SF, SAB 110 LM/LF,SAB 128 HM/HF,SAB 163 HM/HF,SAB 202 SM/SF, SAB 202 LM/LF,VMY 536 M/B

Application

In view of preventing an unintended applica-tion of the compressor, which could causeinjuries to the operating staff or lead to tech-nical damage, the compressors may only beapplied for the following purposes:

S As a refrigeration compressor with a num-ber of revolutions and with operating limitsas indicated in this manual or according toa written agreement with SABROE.

S With the following refrigerants:R717 -- R22 -- R134a -- R404A -- R507 --R600 -- R600A -- R290 -- LPGOther HFC refrigerants in accordance withSABROE’s instructions.All other types of gas may only be usedfollowing a written approval fromSABROE.

S In an explosion-prone environment, pro-vided the compressor is fitted with ap-proved explosion-proof equipment.

The compressor must NOT be used:

S For evacuating the refrigeration plant of airand moisture,

20 0178-145-EN

S For putting the refrigeration plant under airpressure in view of a pressure testing,

S As an air compressor.

Emergency device

The compressor control system must beequipped with an emergency device.

In case the compressor is delivered with aSABROE-control system this emergency de-vice is found as an integrated part of the con-trol.

The emergency device must be executed ina way to make it stay in its stopped position,following a stop instruction, until it is deliber-ately set back again.

It must not be possible to block the emergen-cy stop without a stop instruction being re-leased.

It should only be possible to set back theemergency device by a deliberate act, andthis set back must not cause the compressorto start operating. It should only make it pos-sible to restart it.

Other demands to the emergency device:

S It must be possible to operate it by meansof an easily recognizable and visiblemanual handle, to which there is free ac-cess.

S It must be able to stop any dangerous si-tuation, which may occur, as quickly aspossible without this leading to any furtherdanger.

Combustion motors

If combustion motors are installed in roomscontaining refrigeration machinery or roomswhere there are pipes and components con-taining refrigerant, you must make sure thatthe combustion air for the motor is derivedfrom an area in which there is no refrigerantgas, in case of leakage.

Failure to do so will involve a risk of the lubri-cating oil from the combustion motor mixingwith the refrigerant; at worst, this may giverise to corrosion and damage the motor.

Explosion-proof electricalexecution

If the compressor is delivered in an explo-sion-proof electrical execution, this is statedin the table on page 1 of this instructionmanual.

Likewise, the compressor will, besides theSABROE name plate, be equipped with anEx-name plate like the one illustrated below.

T2516273_0

0178-145-EN 21

The temperature of tangible surfaces

When a compressor is working, the surfacesthat are in contact with the warm dischargegas also get warm. However, the temperatu-re depends on which refrigerants and underwhich operating conditions the compressoris working. Often, it exceeds 70�C which formetal surfaces may cause your skin to beburnt even at a light touch.

Consequently, the compressors will be equip-ped with yellow warning signs informingyou that pipes, vessels and machine parts

close to the warning signs during operationare so hot that your skin may be burnt from 1second’s touch or longer.

22 0178-145-EN

Technical data for compressor & unit SAB 110

Compressor Refri- Oil cooling Max. dimensions Max.type gerant system1) Width Length Height weight net

mm2) mm mm3) Kg.4)

Without oil cooler

Dimensions and weight(without economizer)

SAB 110

R22

R717

400

410

415

490

410

490

HLI

B

OOSI

HLI

OOSI

520OWSG

800

750

750

800

950 1900

17001310

Length Width

Height

T4840097_0

1) HLI = High stage liquid injection in the compressor 2) Incl. motor IEC 200(High stage Liquid Injection) 3) Excl. vibration dampersB = Plate heat exchanger (water) 4) Excl. motor, oil cooling system,OOSI = Shell and tube exchanger (refrigerant) oil, water and refrigerantOWSG = Shell and tube exchanger (water)

0178-129-EN

98.04

0178-145-EN 23

Compressor data SAB 110

Block weightwithout motor

Kg

SAB 110 S

SAB 110 L

Compressor Rotor L/D Rotor Internal �P Motor at 2950 0/min Motor at 3550 0/mintype drive Dia. volume max. Male rotor suct. vol. Male rotor suct. vol.

1) ratio 2)

mm Vi bar 0/min m3/t 0/min m3/t

SAB 110 S-M M 2950 140 3550 168

SAB 110 S-F F 4425 209 5325 252

SAB 110 L-M M 2950 175 3550 210

SAB 110 L-F F 4425 262 5325 315

1) L/D =Rotor length divided by rotor diameter 2) Discharge pressure minus suction pressure

1.2

1.5

1101.8to4.5

20

150

See permissible operating limits, however, in the following Operating Limits Diagrams

SAB 110 S-M M 24.2 19.2 78.0

SAB 110 S-F F 36.5 29.9 121

SAB 110 L-M M 30.5 24.3 98.6

SAB 110 L-F F 46.2 37.9 153

Nominal capacity R717

Compressortype

L/DMotor at 2950 rpm

--40/--10�CkW 1)

--40/35�CkW 2)

--10/35�CkW 2)

1.2

1.5

Based upon: Suction gas overheating10 KLiquid undercooling:

1) 0 K for Booster operation2) 5 K for high pressure operation

SAB 110 S-M M 33.0 21.4 81.1

SAB 110 S-F F 50.0 33.5 126

SAB 110 L-M M 41.7 27.1 102

SAB 110 L-F F 63.2 42.3 159

Nominal capacity R22

Compressortype

Rotordrive

L/DMotor at 2950 rpm

--40/--10�CkW 1)

--40/35�CkW 2)

--10/35�CkW 2)

1.2

1.5

Above performance values apply for standard units

Rotordrive

24 0178-145-EN

Operating limits, general

The recommended operating limits for thecompressor when using R717, R22, R134a,R404A/R507and R407C are illustrated in thefollowing diagrams.

With respect to the graphs, please notethe following:

S The upper operating limits apply to Maleand Female Drive as appropriate (please

refer to page 1 for your particular com-pressor type) .

S Note extended operating limits if the com-pressor is provided with the following extraequipment:

-- HLI (High stage Liquid Injection)

-- HLI + economizer together

S Economizers can be used within the entireoperating area in which the compressor ispermitted to work.

0178-145-EN 25

Operatinglimits

R717

(T250839_0)

--30

--20

--10

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

0

10

--20 --10 0 10 20 C

20

30

40

50

60

C�

HLI + ECO

MALE DRIVE

FEMALE DRIVE

HLI

SAB110S SAB110L

R717

�

Evaporating temperature

HIGH STAGE

LOW STAGE

Condensingtemperature

Note:SAB 110 standard unitsare nor designed for lowstage

Operatinglimits

R22

(T250837_0)

Note:SAB 110 standard unitsare nor designed for lowstage

--20

--10

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

0

10

--20 --10 0 10 20 C

20

30

40

50

60

CSAB110S SAB110L

MALE DRIVE

FEMALE DRIVE

HLI

R22

�

�

HLI + ECO


HIGH STAGE

LOW STAGE


26 0178-145-EN

Operatinglimits

R134a

(T250820_1)Evaporating temperature


SAB 110S

C�

SAB 110L

--20

--10

--50 --40 --30 --20 --10

0

10

20

LP stage

0 10 20 30 �C

30

40

50

60

70

HLI+

ECO

HP stage

MALE DRIVE

HLI

FEMALE DRIVE

R134a

Note:SAB 110 standard unitsare not designed forlow pressure stages

HLI+

Operatinglimits

R404A - R507

(T250829_2) Evaporating temperature


SAB 110S/L, SAB 128H, SAB 163H Mk3

---20

---10

---30

---70 ---60 ---50 ---40

0

---30 ---20 ---10 0 10 C�

10

20

30

40

50

C�

MALE DRIVE

SAB110---SAB128

NO FEMALE

DRIVE LIMITS

HLI

HP STAGE

SAB163H:

FEMALE DRIVEECO

LP STAGENote:SAB 110 standard units are notdesigned for low pressure stages

R404A-R507

0178-145-EN 27

--30

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

--20

--10

0

10

--20 --10 0 10 20

20

30

40

50

---70

60

VMY 447:Below curve full flowoil pump required

MALE DRIVE

HLI

FEMALE DRIVE

SAB 110standard units notfor Booster opr.

Limit model MB/B

HLI +econ

R407C

(T250133_1)

SAB 110S/L, SAB 128H, SAB 163H Mk3Operatinglimits



R407C

SAB 202:No HLIoperation

LIMIT FOR MODEL M, SAB202LLIMIT FOR MODEL S/H, SAB110L

TC �C

TE �C

0178-130-EN

93.12

28 0178-145-EN

Compressor and unit operation SAB 110

During operation of compressor, below pointsmust be observed. These are described indetail in the following sections.

1. Preparations before starting up.

2. Initial start.

3. Normal start.

4. Current control conditions at normal opera-tion (only for units with instrument pan-el).

5. Normal stop.

6. Emergency stop or incorrect settings.

7. Preparations before a lengthy standstillperiod.

1. Preparations before starting up

After installing compressor unit in its finalplace and after establishing all connectionsfor refrigerant, water and electricity, instru-ments and safety switches, the followingmust be carried out:

a) Check that rotating direction of motor iscorrect. The rotating direction is markedwith an arrow on the suction cover of thecompressor and depends on whether themotor is connected to male or female ro-tor.

Check rotating direction of motor by dis-mantling end cover of motor so that thefan becomes visible.

By briefly supplying electricity to the motorthe rotating direction is observed.

b) For units with instrument panel checkfunction of safety switches in order toensure that they can stop the motor. Ad-settings for the safety switches appear

from the table on Temperature and pres-sure Settings.

c) Connect a vacuum pump to valve Pos. 24and evacuate unit to a vacuum of approx.4-5 mm Hg. If necessary, use a thermo-static vaccum gauge for measuring ofpressure, and charge dry air or nitrogenuntil pressure reaches 1 bar. Then evacu-ate again to 4-5 mm Hg.

d) Charge with new oil of a quality prescribedin the oil instruction. Connect oil hose tovalve Pos. 47. Charge new oil until oil lev-el becomes visible in the upper part of thetop sight glass. The amount of oil appearsfrom the table on Oil charges. With thecompressor in operation, recharging of oilmay be done through valve pos. 62, posi-toned between suction stop valve pos. 20and the compressor. By throttling the suc-tion stop valve pos. 20 to e.g. 0.5 atm. andby connecting valve pos. 62 to the oil tinwith a hose, the oil can be sucked into thecompressor with valve pos. 62 open. Takecare not to drain the oil tin completely, orair will be sucked into the plant.

e) Open all internal valves.

f) Carefully open suction stop valve thus ad-mitting refrigerant gas from suction sideinto the unit. Make sure that rotors arekept still during the gas flow.

g) Once the pressure in the unit is equal topressure on suction side, open suctionvalve completely and also open dischargestop valve, after which the unit is ready forstart-up.

During the whole procedure watch out forleakages.

0178-145-EN 29

2. Initial start-up

a) If the compressor is not started within aperiod of 3 months after having beentested at SABROE, the shaft seal must betaken apart and lubricated with refrigera-tion oil. This eliminates the risk of leakageat the O-rings and to damage the slidesurfaces.

b) Check oil level in oil separator.

c) Open suction stop valve/discharge stopvalve completely. Open all other internalvalves.

d) Check free access for cooling water to oilcooler, if any.

e) Check for power to the compressor con-trol- and security systems.

f) On units with instrument panel, reset but-tons must be depressed for all safetyswitches and all control lamps must indi-cate that everything is in order.

g) For untis with instrument panel and mini-mum switch, check that capacity regula-tion is in ”minimum” position and that theminimum switch is activated.

h) Check position of Vi-slide in accordancewith the desired operating conditions theand diagram in this instruction manual.

i) Set change-over switch to manual and ac-tivate starter switch.

j) Check for abnormal sounds. If nothing ab-normal is notiecable, allow the compres-sor to run at normal operating pressureand set capacity regulation to the desiredcapacity value or to automatic operation.Keep a constant check on pressures, tem-peratures and power consumption.

k) Do not leave compressor for the first 15minutes.

3. Normal start-upa) Check oil level.

b) Open suction and discharge stop valves.

c) Set cooling to oil cooler, if any.

d) Switch on current to unit.

e) Reset all pressure controls and thermo-stats for units with instrument panel.

f) Start compressor.

g) Check all pressure and temperature mea-suring devices for units with instrumentpanel.

h) Once the compressor has reached the de-sired operating conditions, capacity regu-lation may be set on automatic operationor manual operation so that capacity ofthe compressor corresponds to the actualcapacity of the plant.

i) Do not leave compressor for the first 15minutes.

4. Current control at normaloperation

For units with instrument panel the followingshould be noted daily:

S suction pressure (bar)

S suction temperature (�C)

S discharge pressure (bar)

S discharge pipe temperature (�C)

S oil temperature (�C)

S current consumption (amp.)

S number of service hours

S position of Vi-slide

S Oil level

30 0178-145-EN

5. Normal stopS regulate compressor down to minimum

capacity

S et change-over switch to stop

S shut off oil cooling.

6. Emergency stop or incorrectsetting

Units with instrument panel

Safety switches, pressure controls and ther-mostats are fitted in order to stop the com-pressor in case of malfunctioning.

The unit can be equipped with the followingsafety equipment, depending on order speci-fication:

High pressure cut-out KP5 with reset.

Low pressure cut-out KP1 possibly withreset (additional equipment)

S Oil thermostat KP79 with reset (to be ap-plied only in connection with oil coolertypes: OWSG/OWRG, type B or OOSI)

S Discharge pipe thermostat KP 79 for HLIcooling. Discharge pipe thermostat KP 81for units fitted with oil cooler types OWSG/OWRG, type B or OOSI.

S Differential oil pressure cut-out type Arlonfor measuring of pressure drop throughthe oil filter.

S Oil flow switch built into compressor block.

All these devices will stop the compressorwhenever their set value is exceeded.

Do not restart compressor until the cause ofthe stoppage has been found and any mal-function has beeb rectified.

Units with UNISAB II control:Consult separate instruction manual for thiscontrol system.

7. Preparations before a lengthystand-still period

S Close main stop valve after receiver andevacuate evaporators. If necessary, adjustlow pressure cut-out of unit to stop com-pressor at a lower pressure.

S Allow temperature in evaporators to riseand repeat evacuation.

S Once the suction pressure has been re-duced to slightly above atmospheric pres-sure, stop compressor and close suctionand discharge stop valves.

S Shut off oil and condenser cooling. If a riskof freezing exists drain off cooling water.

S Disconnect power supply to master andcontrol circuits.

Pressure testing of the refrigerationplantBefore charging refrigerant to plant it mustbe pressure tested and evacuated.

Pressure test the plant using:

S Dry air. - pressurized cylinder containingdry atmospheric air may be used. - Neveroxygen cylinders.

S air compressor for high pressure.

S nitrogen

ImportantDo not use the plant’s compressorsfor pressurizing plant. Do not use wateror any other fluids for pressure testing.

In case nitrogen is employed, it is importantto place a reduction valve with pressure

0178-145-EN 31

gauge between the nitrogen cylinder and theplant.

During pressure testing, it is important thatpressure transducers and other controlequipment are not exposed to the testingpressure. Likewise, compressor stop valvesmust be closed during pressure testing.

Plant safety valves must normally be blankedoff during pressure testing as their openingpressure is lower than the testing pressure.

ImportantDuring this pressure testing, no personsare allowed in the rooms with plant com-ponents or in the vicinity of the plant out-side the rooms.

S The entire plant should be strength testedaccording to the local rules for pressuretesting.

Attention is drawn to the fact that the com-pressor is strength tested to a maximumof 21 bar in the compressor house.

S Then reduce the pressure to 10 bar for 24hours - as an initial leak testing - as atight plant will maintain the same pressurethroughout this period.

During the leak testing, people are allowed toenter the rooms and approach the plant.

S As second leak test, examine all weldings,flange joints etc. for leakages by applyingsoapy water, while at the same time main-taining the 10 bar pressure.

Make a pressure test report on the pres-sure testing with the following minimumcontent:

S date of pressure testing

S who carried out the testing

S comments

Evacuation of refrigeration plantAfter pressure testing the refrigeration plantmust be evacuated in order to removeatmospheric air and moisture. Evacuationmust be carried out on all types of refrigera-tion plant regardless of type of refrigerant tobe charged into the plant.

The boiling point of a liquid is defined as thetemperature at which the steam pressure isequal to atmospheric pressure.The boiling point of water is 100�C. If thepressure is lowered, so is the boiling point ofthe water.

The below table indicates the boilingpoints of water at very low pressures:

Boiling point ofwater �C

At pressuremm HG

5

10

15

20

6,63

9,14

12,73

17,80

For evacuation, use a vacuum pump whichbleeds the plant of both air and moisture.

The vacuum pump must be able to lower thepressure to approx. 0.1 mm Hg (mercury col-umn) and it must be equipped with gas bal-last valve. Use this valve to the greatest ex-tent possible in order to prevent condensa-tion of moisture in the vacuum pump.

ImportantNever use refrigerating compressor toevacuate the plant.

In order that an evacuation may be satisfac-tory, the final pressure must be below 5 mmHg. Please, observe that there is a risk of

32 0178-145-EN

any water left in the plant freezing in case theambient temperatures are lower than 10�C.In such case, it is necessary to admit heat tothe ambience of the components as evapora-tion of any ice formation can be difficult.

It is recommended that evacuation be car-ried out as follows:

S Evacuate to a pressure below 5 mm Hg.

S Then blow dry air or nitrogen into the sys-tem to reach a pressure corresponding toatmospheric pressure

Never use oxygen bottles

S Evacuate again to a pressure below 5 mmHg.

S Shut off the vacuum pump from the refrig-eration plant and check that pressure

does not rise within the next few hours. Ifwater is still present in the system, it willevaporate and cause a pressure rise. Inthat case evacuation will be unsatisfactoryand must be repeated.

Operating logFor regular checking of operating statis ofcompressor and refrigeration plant, it is rec-ommended to keep an operating log.

This operating log should be kept regularyand may contain useful information about thecause of any unwanted changes in operatingconditions.

The following table is an example of an oper-ating log and must as a minimum contain thefollowing:

0178-145-EN 33

� For compressor withmanometer an indicator is fittedon compressor

� UNISAB II� Thermometer

Oil level

Ampere consumptionof compressor motor

� Oil level glasses onoil separator

� UNISAB II

Observation Place of measuring Measuring unit

Date and hourTime

Suction pressure

Pressure fall throughoil filter

Oil temperature

Suction gas temp.

Discharge gas temp.

Recharging of oilto compressor

Discharge pressure

� Compressor manometer� UNISAB II

� Compressor manometer� UNISAB II

� Thermometer in suction linejust before the compressor(Additional equipment)

� UNISAB II

� Thermometer on theoil separator

� UNISAB II

� Electric board� UNISAB II

(additional equipment)

� Please refer to the sectionOil charges

�C or bar

bar

�C

�C

Must be visible in oillevel glasses

number of litres

�C or bar

Amp.

�C

� Hour counter/Clock

At the same time attention should be drawn to the following(could be checked off in the log):

S whether the cooling system of the compressor works properly

S whether there is any unusual noise coming from the compressor

S whether there are any unusual vibrations in the compressor

0178-028-EN

99.05

34 0178-145-EN

Service Schedules for screw compressorsSAB 110, 128/163 Mk3, 202 & VMY

Good and careful servicing of the compres-sor and the unit is of great importance fortheir proper functioning and service life.

It is therefore recommended that these ser-vice instructions be followed; based on thenumber of operating hours, they indicate theservice tasks to be carried out.

Preparations before compressorinspection

Before dismantling any part of the compres-sor or unit for inspection or repair, the pres-sure must be reduced to atmosphericpressure. This is done as follows:

S Regulate the compressor down to its low-est capacity stage and stop it.

S Now close all stop valves in the pipe con-nections to the unit except for the suctionstop valve pos. 20, which remains openuntil the pressure in the unit has beenequalized to the suction pressure. This isdescribed in the passage called The non-return valve.

S Close suction stop valve pos. 20.

S Any excess pressure in the unit is equal-ized to atmospheric through stop valvepos. 24. See the ”Key to Piping Diagrams”and the chapter on: Protecting the Envi-ronment.The heating element in the oil separatormust remain connected until the pressureis completely equalized, thus boiling therefrigerant out of the oil.

S Remove main fuses for the compressormotor in order to prevent it from startinginadvertently.

Compressor and unit are now ready for in-spection and dismantling, if required.

Replacement of oil filterIn case only the oil filter has to be replaced,follow below procedure depending on the thetype of your compressor:

SAB 110, SAB/163 and SAB 202

Above-mentioned compressors all have built-in oil filters.

Follow the procedure described in the pre-vious passage: Preparations before com-pressor inspection.

Remove oil filter as described in section:Maintenance of the compressor.

VMY with external oil filter

As the units may be fitted with one or two oilfilters (mounted in parallel) apply proceduresA or B.

A: Units with one oil filter only� Bring compressor to minimum ca-

pacity, and stop it.� When pressure in unit is equalized

to suction pressure, close stop val-ves before and after oil filter.

� Any over pressure in filter housingis equalized to atmospheric pres-sure through the evacuation valveon filter housing.

� Cover on filter housing can now bedismantled, as described in sectionOil filter.

0178-145-EN 35

B: Units with two parallel oil filters� While the compressor is operating,

the stop valves before and afterone of the oil filters must be closed.

� Over pressure in filter housing isequalized to atmospheric pressurethrough evacuation valve on filterhousing.

� Cover on filter housing can now bedismantled, as described in sectionOil filter.

Cleansing of oil in the unit

The most critical time for an oil filter is, how-ever, right after initial start-up of compressor.

Although an effort should be made to keepthe plant free of any impurities when as-sembled, experience shows that it may bedifficult to avoid impurities in tubes and ves-sels.

These impurities will be conveyed by the suc-tion gas to the suction filter, where large-sized impurities are intercepted. Smaller im-purities will pass through the filter and beconveyed to the oil separator, where they aresuspended in the oil. From here they are tak-

en to the lubricating system of the unit andabsorbed by the oil filter.

These impurities may result in a need tochange the oil filter cartridge shortly afterinitial start-up.

It is equally important to check the oil atregular intervals as specified in the sectionsChecking the oil and Assessing the oil.

Purification of the oil may be done by meansof a 3 micron filter in a closed system.During this process, the oil must not comeinto contact with the oxygen and moisture inthe air.

In addition, it is important that all pressuresand temperatures be kept within the specifiedvalues and that filters be kept clean; providedinspection is carried out to the schedulesprescribed below, compressor and unit willwork efficiently and achieve a long servicelife.

The following charts indicate the schedulesfor checking the oil in the compressor unitand a more detailed description of the opera-tions to be performed during scheduled ser-vice inspections.

36 0178-145-EN

Checking the oil

20000h 30000h 40000h

5020010002500

500010000150002000025000

300003500040000

�

�

�

�

�

�

�

�

�

�

�

�

�

�

�

�

�

�

�

�

�

�

�

�

�

�

�

�

�

�

�

�

�

�

�

�

�

�

�

�

�

�

�

�

�

�

�

�

�

�

�

�

�

�

�

Serviceterminer efter hvert hovedeftersyn.Serviceterminer efter første igangsætning af kompressoren.

� It is advisable to assess the oil as described in the following chart.

� It is advisable to assess the oil as described in the following chart.

If this assessment is not made, the oil charge must be replaced with fresh oil.

� The oil charge must be replaced with fresh oil.

Service schedules after initial start-up of compressor.

Service schedules after each main inspection.

Operating hours between main inspectionsSee chart for main inspections

Service schedulesNumber of operatinghours from initial start-up and after each maininspection (see foot-note)* R717* R717* R717

NB:It is not advisable to reuse oil drawn from compressor or plant. This oil has absorbed themoisture in the air and is likely to cause operating problems.Always turn off the power to the heating rod before draining off the oil.

0178-145-EN 37

Activities during a service inspection

Daily

Periodic service Activity

1.1 External inspection and leak check.

1.2 Check the oil level in the oil separator.

1.3 Check pressures and temperatures.

1.4 Check for unusual vibrations or noise.

1.5 Record operating data in the log book.

1

5.1 Clean the compressor suction filter.

5.2 Take an oil sample from the oil separator and send it toa laboratory for analysis, as described in Assessingthe oil.

5.3 Fit a new oil filter cartridge.

5.4 Clean all other oil filters and connections to and fromthe compressor.

5.5 Check the coupling and its alignment (SAB 110*)

5.6 Check that the pressure switches and thermostatsfunction correctly (refer to the set values in the instruc-tion book).If UNISAB II computerized control is fitted, check thetransducers(see the instruction manual for UNISAB II )

After 2500 hours’operation

5

2.1 Clean the suction filter.After 50 hours’ operation2


3.2 Take an oil sample from the oil separator and apprai-se it visually, or send the sample to a laboratory foranlysis.Both methods are described in the section entitledAssessing the oil.

3.3 Replace the filter cartridge in the oil filter, unless ithas been replaced earlier.


3.5 Check the coupling and its alignment (SAB 110*)3.6 Check that all screws and nuts have the correct tor-

que.


3


4.2 Take an oil sample from the oil separator and apprai-se it visually, or send the sample to a laboratory foranalysis.Both methods are described in the section entitledAssessing the oil.


4

* Check the elastic intermediate part to see whether there are any visible oblique cracks in the rubber part.If such cracks are observed, replace the intermediate part.

38 0178-145-EN

Periodic service Activity





6.5 Check that the pressure switches and thermostatsfunction correctly (refer to the set values in the in-struction manual).If UNISAB II computerized control is fitted, check thetransducers (see the instructionmanual for UNISAB II)

6.6 Take an oil sample from the oil separator and sendthe sample to a laboratory for analysis, as described in the section entitled Assessing the oil. Pleasealso refer to the table entitled Checking the oil.

After 5000 hours.operation

This service should berepeated after every5000 hours of operation

6

7.1 Total overhaul of the compressor, including fittingnew gaskets. As the compressor is already open,inspect the bearings and, if necessary, fit new ones.Check the regulating system.

7.2 Overhaul and clean the compressor motor.N.B.Follow the service schedule specified bythe motor manufacturer.


7.4 Drain off the compressor oil and charge with new,fresh oil.


7.6 Check that the pressure switches and thermostatsfunction correctly (refer to the set values in the in-struction book).If UNISAB II computerized control is fitted, check thetransducers(see the instruction manual for UNISAB II)

Major service

Carried out as specifiedfor the individual screwcompressor type.(See the diagram for majorservice)

7

* Check the elastic intermediate part to see whether there are any visible oblique cracks in the rubber part.If such cracks are observed, replace the intermediate part.

0178-145-EN 39

Assessing the oil

Oil in refrigeration plants is a vital part of thecompressor, as it not only lubricates andcools the movable parts of the compressor, italso prevents abrasive particles from en-tering the bearings.

An analysis of the oil can give important in-formation on how the compressor is running.We would, therefore, advise that the oil ana-lyses be carried out at the intervals prescri-bed.

An oil sample must be drawn off while thecompressor is in operation, which gives arepresentative sample. Before taking thesample, clean the drain valve and tap a littleoil off, to prevent any impurities which mayhave accumulated in the valve or the pipingfrom mixing with the sample.

Visual assessmentIf you pour the sample into a clean, transpar-ent glass bottle or a test-tube and hold it upto a clear light source, it will be easy to as-sess the quality. You can also compare thesample with the fresh oil of the same makeand grade.

An oil which you approve on the grounds of avisual assessment must:

S be clear and shiny

S not contain any visible particles

S feel viscous, smooth and greasy when adrop is rubbed between two fingers.

If you don’t feel that you can approve the oilby visual assessment, charge with new oil orsend a sample to a laboratory for analysis.

WarningIf the oil sample is poured into a glass bottle,this must not be hermetically sealed until allthe refrigerant in the oil sample has evapora-ted. Refrigerant in the oil may produce ex-cess pressure in the bottle with subsequentrisks of explosion. Never fill a bottle up com-pletely. Do not send glass bottles throughthe postal service -- use purpose-made plas-tic bottles. Please see below.

Analytical evaluation

Naturally, the oil sample can be analysed bythe oil company which supplies the oil.As a special offer to our customersYORK Refrigeration has developed ananalytical concept, which is able to analyseall oil makes. This will mean a uniform report-ing of the results.

The analysis allows the following to be deter-mined:

S Whether or not the oil is still usable,if necessary after filtering.

S Whether solid particles possibly present inthe oil originate from the bearings or othercomponents exposed to wear and tear inwhich case the compressor must be in-spected.

S Each report will include the correspondingmeasuring results from the previous 3 oilanalyses. In this way you will be able tofollow up on the state of both the oil andthe compressor from one analysis to thenext.

40 0178-145-EN

Procedure

S A form set with a plastic sampling bottleand a dispatching envelope can be re-quested from the local YORKRefrigeration representative.

S The oil sample must be drained from thecleaned oil drain valve into the samplebottle. Screw the lid loosely on and let thebottle stand for a few hours to enable re-frigerant contained in the oil sample toevaporate before sending it to the labora-tory.Do not fill the bottle completely.

S Please follow the Sampling and ShippingInstructions enclosed in the form set inwhich the address of the laboratory in Hol-land are also mentioned.

Analysing the oil

The following table states some averagevalues that can be applied in practice. How-ever, you should be on the alert wheneverthe results of the analyses approach thesevalues. In some cases the water content of100 ppm in HCFC plants may be too muchand thus lead to Cu-plating in the shaft seal.

Limiting values

Sabroe Olie PAO 68 Sabroe Olie AP 68 Sabroe Olie A 100

Parameter Unit Metode Spec.Værdi Max. Min.

Spec.Værdi Max. Min.

Spec.Værdi Max. Min.

Viskositet @ 40�C cSt ASTM D 445 66 76 53 64 74 51 100 115 80

TAN *1) mg KOH/g ASTM D 664 0,03 0,2 -- 0,01 0,2 -- 0,05 0,2 --

SAN * 2) mg KOH/g ASTM D 665 -- 0 -- -- 0 -- -- 0 --

Vand ppm Karl Fisher -- 100 -- -- 100 -- -- 100 --

Udseende -- -- rapport rapport rapport

Farve -- ASTM D1500

rapport rapport rapport

Uopløseligt Pentan W% MM 490(5μm)

-- 0,05 -- 0,05 -- -- 0,05 --

Oxidering abs/cm IR,1700-1720/cm

-- 5 -- -- 5 -- -- 5 --

Nitrering abs/cm IR,1627-1637/cm

-- 5 -- -- 5 -- -- 5 --

Kvælstofforbindelser abs/cm IR,1547-1557/cm

-- 0,5 -- -- 0,5 -- -- 0,5 --

Max. værdier for metalindhold i olien

Bly ppm ICP -- 10 -- -- 10 -- -- 10 --

Kobber ppm ICP -- 10 -- -- 10 -- -- 10 --

Silicium ppm ICP -- 25 -- -- 25 -- -- 25 --

Jern ppm ICP -- 100 -- -- 100 -- -- 100 --

Krom ppm ICP -- 5 -- -- 5 -- -- 5 --

Aluminium ppm ICP -- 10 -- -- 10 -- -- 10 --

Tin ppm ICP -- 10 -- -- 10 -- -- 10 --

1): TAN (Total Acid Number/ Total Syretal) rapporteres kun for2): SAN (Strong Acid Number/Stærk Syretal) rapporteres kun

for anlæg, hvor ammoniak ikke anvendes anlæg, hvor ammo-niak ikke anvendes

0178-145-EN 41

A report is drawn up for every sample re-ceived. This report concludes:

S Whether the oil can still be used -- withouttaking any further action.

S Whether the oil can be used after it hasbeen filtered through a very fine filter. Ifthis is necessary, the oil must be pumpeddirectly from the compressor unit througha 3 micron filter and back to the unit. The

system must be completely closed, to pre-vent the oil being affected by moisture inthe air.

� Whether the oil is no longer fit for use.

The report will always be sent to the addressstated on the sample label included in theform set. A copy will be sent to YORK Refri-geration so that we are in a position to adviseyou, if required.

42 0178-145-EN

Major Service IntervalsSAB 110, SAB 128/163 Mk3, SAB 202

R717

R717

--50

--30 --20 --10 --5 0--50 5 10 15 20 25

T0177068_0

--10--505

10

20

25

30

35

15

--20--30

40

45

50

55

40000 hour interval

TE (�C)

TC (�C) ”Extreme” operating conditions20000 hour interval

Normal operat. cond.30000 hour interval

Condensing temp.

Evaporating temp.

“Booster” conditions

1.2 1.9 2.9 3.5 4.30.4 5.2 6.2 7.3 8.6 10.0

0.4

2.42.93.54.3

5.2

7.3

8.6

10

11.7

6.2

1.9

0.7

13.5

15.5

17.8

23.1

TC(Bar,a)

TE (Bar,a)

(�C)(Bar,a)

0.7 2.4

1.2

20.3

0178-030-EN

95.10

0177-134-EN

90.02

0178-145-EN 43

Oil charges, Weights and Shipping Volumes SAB 110

Unit with oilseparator

M3

470

Unit totalKg

Oil charge (Oil level visible in the middle of theupper sight glass during operation)

Oil cooler Oil filterLiter

Compr.Liter

TubingLiter

Oil coolerLiter

Unit totalLiter

Oil SeparatorLiter

OOSI1614

OOSI2114

OWSG1615

OWSG2115

B 25

HLI

2 3 2

8

15

17

28

1

0

150 100

95

150

120

185

15

20

Weight (excl. motor, refrigerant, oil and water)Oil cooler Compr..

KgFittingsKg

Oil coolerKg

Oil separatorKg

OOSI1614

OOSI2114

OWSG1615

OWSG2115

B 25

HLI

EconomizerHESS

WeightKg

131746

161736

64

103

Shipping Volume(incl. motor IEC 225M)

SAB110

OHU 3015

2.5

Compressortype

Tegn. nr. 4840-071

545

600

570

635

465

53

60

62

73

46

45

OHU 3015:200

OHU 3015:200

OHU 3015:200

OHU 3015:200

OHU 3015:200

OHU 3015:200

OHU 3015: 38

OHU 3015: 38

OHU 3015: 38

OHU 3015: 38

OHU 3015: 38

OHU 3015: 38

0178-135-EN

96.05

44 0178-145-EN

Temperature and Pressure Settings SAB 110

For Compressor units with UNISAB II Control, the limits for set pressures and temperaturesare programmed in the UNISAB II system.Please refer to the separate instruction manual for UNISAB II.

For compressor units with instrument panels, use the following table:

OWSG= Water-cooled oil cooler

OOSI = Refrigerant-cooled oil cooler

HLI = High-stage liquid injection (Refrigerantinjection into the compressor)

B = Water cooled oil cooler

Oil cooling

1 KP1 Low-pressure cut-out �C TE-5 TE-5 TE-5

2 KP5 High-pressure cut-out bar 17 17 17

3 A12 Differential pressure across oil filter bar 0.7 0.7 0.7

5 Thermometer in discharge pipe max. �C 100 50 TC+30

6 Thermometer in oil distr. pipe min. �C 40 40 TC+25

Thermometer in distr. pipe max. �C 55 55 TC+40

7 Thermometer in suction pipe individual

11 MP55 Oil pressure cut-out bar 2.5 2.5 2.5

12 KP79 Oil thermostat max. �C 60 60 TC+45

13 KP81/KP79 Discharge pipe temperature max. �C 100 60 TC+45

14 KP77 Solenoid valve opens at: �C -- 35 35

15 Suction pipe pressure gauge individual

16 Pressure gauge for cond. pressure(intermediate pressure) max. bar

28 Safety valve on oil separator bar 25 25 25

83 TEAT Injection valve -- ** **

Pos. Type UsageB

HLIOOSI R717

*** *** ***

***

R22*

TE = Evaporating temp. TC = Condensing temp.

* If you have HLI cooling with R12, the oil and the discharge pipe temperatures must be 30�C higherthan the condensing temperature (TC) to prevent the oil from loosing its lubricating ability due to the refrige-rant dissolved in the oil. Due to the higher temperature, a special synthetic oil (SHC) must be used undermost operating conditions.

** The TEAT valve should be finely adjusted to the required oil temperature.*** A lower temperature setting is permitted, if prescribed by the local authorities.HLI cooling when the unit is operating with R717Max. condensing temperature TC = 40�C.The values stated in this table must not be exceeded, especially when using mineral oil.Use the Oil Recommendation to select a suitable oil.

17 15 17

OWSG

0171-470-EN

97.07

0178-145-EN 45

Servicing the Refrigeration Plant

Both during start-up and operation it must bemade sure that the plant is working correctly.

Compressor and condenser must be able towork satisfactorily, safety devices must beintact and the evaporator must function underload. i.e.:

S the desired temperatures are observed,

S the oil pressure and discharge pipe tem-perature on the compressor are correct,

S the condenser pressure is not excessivelyhigh and

S the plant works as it is supposed to.

The service instructions outline some generalguidelines for servicing the refrigeration plantwith some references to the instructionmanual. The service instructions shouldtherefore be read and followed carefully.

Some installations are providedwith a sight-glass featuring mois-ture indicator. If the indicator co-lour switches from green to yel-low, there is moisture in the re-frigerant.

Change the drying filter regularly.

Check Interval Activity

Condensing pressure Excessively high pressure may bedue to:� reduced cooling effect� air in the condenser.Too low condensing pressureimplies a risk of restricting the re-frigerant supply to the evaporator.

Pressureand temp. Daily

Discharge pipe temperature Normal discharge pipe tempera-ture according to instructions.

Filter in-- liquid line-- thermostatic valve-- suction line-- oil return

Accumulated dirt causes reducedrefrigerant supply to the evapor-ator.

If a filter has a hot inflow and colddischarge, this may be due toclogging of the component.

FiltersClean whenrequired

Moisture in the sight glass(on HFC/HCFC installations)

Dehumidi-fier When re-

quired

46 0178-145-EN

Check Interval Activity

Refrigerant charge Inadequate charge results in re-duced plant capacity and oftenleads to an excessively high dis-charge pipe temperature.Refrigerant

Periodically

Oil draining (ammonia plant) Check evaporator, intermediatecooler, receiver, etc. for oil accu-mulation. Exercise caution; use agas mask

Periodically

Leak detection The plant must be searched reg-ularly for leaks. Flanges and jointssettle during the initial operationperiod of the plant. They musttherefore be tightened andchecked.

Safety pressure controlsAutomatic operating controlsAlarms

Adjust operating point and checkthe function. Replace switch sys-tem if sticking.

Automaticcontrols Periodically

Lubrication of electric mo-tors

Clean and lubricate according tosupplier’s instructions. At tem-peratures lower than -25�C, usespecial lubricant.

Electricmotor

PeriodicallyAlignment of couplingV-belt drive

Corrision Marine condensers are normallyprotected against galvanic corro-sion by the mounting of corrosionplugs in the condenser covers.

Metallic contact between corro-sion plug and cover is essential toproper functioning.

Condenser Periodically-- normallymin. 4times ayear

Frosting-up Unproblematic operation is condi-tional on the evaporator beingkept free of ice. Defrost as andwhen required.

EvaporatorWhen re-quired

Check in accordance with the in-structions of the instruction manual.Tighten loose V-belts, if any, or re-place with new ones.

0178-146-EN

98.12

0178-145-EN 47

Maintenance of compressor SAB 110Dismantling and assembly

This instruction contains a description of howto dismantle and assemble a SAB 110 com-pressor.

Such work must only be carried out by atechnically skilled staff on the basis of thisinstruction. This is to prevent break-downand risk of casualties during work and in theoperating period that follows.

Therefore, before starting out read thissection very carefully.

When dismantling and assembling of SAB110 the following points must be observed:

S When dismantling parts make sure theyare marked so that they can be remountedin the same position as before.

S Torque moments for screws and boltsmust always comply with the table of theinstruction manual. Please, see table ofcontents.

S As the o-ring gaskets tend to become toobig when exposed to oil and refrigerants, itis expedient to keep a set of gasketsready before starting out. See list of setsof spare parts at the end of this instructionmanual.

S When working on the compressor the po-wer to the compressor motor must be cutoff and safeguarded in such a way to pre-vent the compressor from starting up inad-vertently. (Main fuses may be removed).

S When cleaning and wiping compressorparts do not use twist or any other fluffycloth.

Preparations before dismantlingIt is possible to make a partial dismantlingand inspection while the compressor is stillclamped on oil separator. In case of total dis-mantling, however, the compressor must belifted off.

In the latter case it is recommended to clampthe compressor on a frame as shown on thebelow sketch:

1

114.3 x 3.6

300

10

1000

1000

30

Fig. 1

2

The flange pos. 1 fits the discharge flange ofthe compressor and is shown on fig. 2.

The base frame pos. 2 may be smaller if it issecurely fixed to the floor.It is recommended to dismantle motor be-fore clamping compressor on the frame.

48 0178-145-EN

T0177141_0/v2

Dia.160

Dia.129

Dia.50

M 16Fig. 2

Tools

For dismantling and assembling of compres-sor use both standard tools and special-pur-pose tools. The necessary tools are specifiedin the List of tools in this manual.

Removal of refrigerant gas

After having closed suction and dischargestop valves on compressor and unit as wellas blocked any other pipe connections to theunit, remove refrigerant from unit as de-scribed in the section on Protecting the Envi-ronment.

Removing compressor from oilseparator

Before removing compressor from oil separa-tor proceed as follows:

S dismantle cable connections to motor

S dismantle motor at flange connection be-tween motor and bearing cover pos. 20.Please refer to section 13. Dismantlingand assembly of motor and coupling.

S close all valves in piping between refrig-eration plant and compressor unit and

equalize pressure in compressor unit toatmospheric pressure as described in sec-tion on Protecting the Environment.

S dismantle pipe connections and wiringconnections to compressor block. Wrapup dismantled pipes while stored to keepthem clean and undamaged.

S fix a soft lifting sling under the compressoron both sides of the discharge flange.Tighten lifting sling to make it support thecompressor block and next dismantlebolts pos. 2 at flange joint against oil sep-arator. (See fig. 3)

Make sure that the lifting sling is fas-tened so that it prevents the compres-sor from rolling over.

In case the compressor is equipped with alifting eye, use this instead.

Note:Lifting of the whole unit in the lifting eyeis not permitted, however.

T0177141_0/v3

Compressor

Gasket

Oil separator

2

�

�

�

Fig. 3

By lifting the compressor slightly up fromflange on oil separator the compressorcan be carefully pulled away from flangepos. 253, where screws pos. 23 should bedismantled (see spare parts dwg.).

Next, lift compressor away from oil sepa-rator.

0178-145-EN 49

Note that oil may be leaking from the com-pressor block when lifted away from oil sepa-rator.

Dismantling of compressor

Dismantling of compressor can normally takeplace while it is still mounted on the oil sepa-rator.

By major operations - e.g. overhauls - it maybe expedient to move compressor blockaway from oil separator in order to obtainmore space. See section on Preparationsbefore Dismantling.

The dismantling of the compressor has beendivided into the following sections:

Section

Suction filter

Safety valveOil filterFloat swichRegulating cylinder for capacity slide

Capacity slideShaft seal and balance piston

Slide stop for Vi--regulation

2

345

678

11

Suction pressure regulator and1

Adjustment of rotors10

Capacity indicator 9

non return valve

Bearing cover, rotors and bearings

Dismantling and assembly of motorand coupling

1213

In the following the position numbers inthe text refer to the spare parts lists andthe blue spare parts drawings at the endof this instruction manual.

Assembling of compressorBefore assembling the compressor give allparts a thorough cleaning. Look out for anydamage or wear and tear. Replace defectiveor worn parts with new ones. Check all gas-kets for possible reuse. In case of doubt, re-place by new ones.

Before reassembling lubricate all parts, in-cluding screws and bolts, with clean new re-frigerating machine oil.

1. Suction filter

Suction filter is built into the compressorframe above the rotors.

Its purpose is to collect all impurities carriedwith the suction gas from evaporator system.

Experience shows that a good deal of impu-ruties are collected in the filter during the ini-tial period following start-up of a new refrig-eration plant.

It is important, therefore, to clean the suctionfilter when the compressor has operated for200 hours after initial start-up.

If the suction filter is not taken out andcleaned, there is a risk of it bursting as a re-sult of too high differential pressure acrossthe filter.

Removal and cleaning of suctionfilterWhen the pressure in the compressor unit isequal to atmospheric pressure, dismountpipes pos. 320, which are connected to thecylinder pos. 270.

50 0178-145-EN

S Dismantle screws at flange joint A asshown on fig. 4a and 4b.

T0177141_0/v4a

Screws pos. 557

Tubes forsafety valve

Oil separator

Flange joint 1

Fig. 4a

T0177141_0/V4b

Fig. 4b Flange joint A

S By dismantling the four long screws pos.557 the tubes for safety valve can beremoved. Pay attention to O-ring pos. 555and gasket at flange joint A.

S Now pull out the complete suction pres-sure regulator with the cylinder pos. 270by hand. Make sure that non-return valvepos. 260 comes out with the suction pres-sure regulator. Remove suction filter pos.170 by hand taking care that no dirt fallsinto the compressor and that the filter tex-ture is left intact.

Clean suction filter in an oil solvent and blowit dry and clean with compressed air.

MountingAfter cleaning the suction filter, check it tosee if any damage has been done to the wiremesh.

S Insert the suction filter in the filter housingas shown on the drawing.

S Put the complete suction pressure regula-tor including non-return valve pos. 260and spring pos. 261 carefully into place.Pay attention to O-ring pos. 252.

S Now mount pipe for safety valve and fas-ten this and suction pressure regulatorwith long screws pos. 557. Notice O-ringpos. 555.

S Tighten flange joint A. Take care not todamage the gasket.

S Mount pipes pos. 320.

2. Suction pressure regulator andnon-return valve

Suction pressure regulator is mounted in cyl-inder pos. 270 and placed in suction cham-ber. The purpose of this regulator is to main-tain a differential pressure from pressure tosuction side of the compressor thus acting asdriving pressure for the lubricant to the bear-ings and rotors.

At compressor stand-still the regulator isclosed by means of spring pos. 272 asshown on spare parts dwg.

At the same time the cone of non-returnvalve pos. 260 is closed against seat pos.253 by spring pos. 261.

When the compressor is started, the non-re-turn valve opens to allow sufficient suction

0178-145-EN 51

gas into the compressor in order to build uppressure in oil separator.

As this pressure rises the regulator is openedby the entire piston pos. 271 moving into cyl-inder pos. 270.

In case the differential pressure falls duringoperation - so that the oil pressure may notbe maintained - the regulator closes modulat-ingly and maintains the necessary differentialpressure.

When the compressor stops the regulatorcloses instantly, thereby preventing rotorsfrom rotating backwards.

Dismantling of suction pressureregulatorS Dismount pipes pos. 320 and screwed

connections that are fixed on the cylinderpos. 270.

S Dismount pipes for safety valve and suc-tion pressure regulator pos. 270 as de-scribed in section on Removal and Clean-ing of Suction Filter.

On the work table, dismantle the followingparts in below order:

S Pull out manually non-return valve pos.260 from piston pos. 271 and removespring pos. 261.

S During dismantling of screws pos. 554,hold safety valve pos. 550 by handagainst cylinder pos. 270 to counteract theforce of spring pos. 272.

S Take out safety valve pos. 550 and springpos. 272.

S Now remove pin bushing pos. 551 fromcylinder pos. 270 by means of piston pos.271 and the entire suction pressure regu-lator is dismantled.

S Dismantle O-ring pos. 552.

Normally, it is not necessary to dismantle thenon-return valve. If need be, the outer lockingring pos. 262 can be removed after whichpiston pos. 260 and guide rod pos. 263 canbe dismantled by hand.

Assembling of suction pressureregulatorBefore assembling make sure that pistonpos. 271 runs smoothly in cylinder pos. 270.Further, lubricate all parts with refrigeratingmachine oil.

Assemble suction pressure regulator in re-verse order to the one described for disman-tling. However, observe the following:

S Pay attention to O-rings pos. 552 and 553.

S When mounting screws pos. 554 presssafety valve pos. 550 against the pressurefrom spring pos. 272.

S Check that the piston moves freely backand forth in the cylinder.

S After mounting of spring pos. 261 and thecomplete non-return valve, check the freemovement back and forth of the non-re-turn valve. Mount the complete suctionpressure regulator in the compressor asdescribed in the section on Removal andCleaning of Suction Filter.

3. Safety valve

Safety valve pos. 550 is a sealed unit thatshould not be opened for inspection. Thevalve is set by SABROE to open at a prefixeddifferential pressure between compressorpressure and suction sides.The differential pressure is indicated on thename plate pos. 558 at the end of the safetyvalve.

52 0178-145-EN

Dismantling and mounting of the safety valveis described in section 2, Suction pressureregulator and non-return valve.

4. Oil filter

The oil filter is one of the most vital parts ofthe compressor lubrication system, protectingthe bearings against particles causing wearand tear.

The oil flows through flange pos. 450, meet-ing first, the magnectic rod pos. 459/460,which filters off all magnetic particles. Fromhere, it passes through filter cartridge pos.470 that filters off all particles bigger than 10micron. The filter cartridge cannot be cleanedbut must be replaced as soon as its filteringcapacity is used up.

Normally, the filter cartridge is changed at theservicing intervals indicated in section onServicing Intervals for screw compressors,but at initial start-up and after any major re-pair work on the refrigeration plant, more fre-quent replacements of filter cartridges mayprove necessary.

Replacing oil filter

Once the pressure in the compressor unithas been equalized to atmospheric pressure,proceed as follows:

S Remove thermo sensor or thermostat item2, see fig. 5, from sensor pocket.

S Loosen flange pos. 450 by removing thefour screws pos. 23.

S By disassembling pipe joint item 1 flangepos. 450 can now be dismantled as pipeitem 3 is pushed in the arrow direction.

T0177141_0/V5

450

23 2

3

1

Fig. 5

��

�

�

�

S Take out filter cartridge with magnetic filterby hand.

S Take out magnetic filter from filter car-tridge by dismantling:

-- Screw pos. 455

-- Washers pos. 456

-- Spring pos. 461

Do not further dismantle magnetic filter butclean it in a detergent and dry it with acloth or use compressed air.

Mounting of oil filterMounting takes place in the reverse order tothe one described in the previous section.

However, note the following:

S Make sure that an O-ring is fitted in thehole of the oil filter. The oil filter is deliv-ered with inserted O-ring.

S Spring pos. 462 must be in place.

S O-rings pos. 451 and 502 must be fitted.

5. Float switch

In order to protect the movable parts of thecompressor against break-down in case offailing oil supply to the compressor, a floatswitch pos. 500 has been built into the inter-nal oil system of the compressor.

The float switch works as follows (fig. 6):

0178-145-EN 53

S The illustrated float (ball) surrounds aclosed stainless steel tube along which itmoves up and down. The float contains apermanent magnet which activates a reedswitch inside the tube.

If during operation, the housing is filledwith oil, the float will be in top position andthe reed switch is connected.

It the oil level in the housing drops duringoperation as a sign of failing oil flow, thefloat will sink to bottom position and there-by disconnect the reed switch. When thecompressor is standing still, the floatswitch housing is emptied of oil and thereed switch thus disconnected.

If the reed switch is disconnected duringoperation, the UNISAB S-Control will stopthe compressor after expiry of the time lagencoded in the control system. For details,refer to the UNISAB S-Control instructionmanual.By relay control this time lag is 10 sec.

Note:It is imperative that the “NO” inscriptionon the float points in the direction shownon fig. 6.

��

Fig. 6

500

�

�

505

508�

511

510

� 506

NO

1�

�

507

Dismantling of float switchS Dismantle the two pipe connections to

float switch pos. 501.

S Dismantle the electric wiring connectionby loosening screw, point 1. See fig. 6.

S By dismantling the four screws pos. 23 itis possible to pull the float housing out ofthe frame by hand.

Float switch pos. 500 is dismantled as fol-lows:

S Using a big locking ring plier, removelocking ring pos. 504 and guide for oilfilter pos. 503 can be removed.

S By removing circlip pos. 511, washer pos.508 can be dismantled, see fig. 6. Next,the threaded nipple pos. 505 with floatswitch pos. 500 can be unscrewed fromfloat housing pos. 501. Spring pos. 510and float pos. 507 can now be removedfrom the float housing.

Mounting the float switchFor mounting of the complete float switch -which is done in the reverse order to the onedescribed above - attention is drawn to thefollowing:

S While fixing the threaded nipple pos. 505with the float switch pos. 500 in the floathousing pos. 501, position float pos. 507and spring pos. 510.

REMEMBER:

-- To mount gasket pos. 506

-- To position float with the NO as shown onfig. 6.

-- To mount washer pos. 508 and circlippos. 511.

S For fitting of locking ring pos. 504 push itright up against oil filter pos. 503.

54 0178-145-EN

S Pay attention to O-ring pos. 502 and gas-ket pos. 506.

6. Regulating cylinder for capacityslide

The purpose of the regulating cylinder pos.50, the built-in piston system and the capac-ity slide pos. 200 is to adapt the compressorcapacity to the immediate refrigeration re-quirements of the plant.

The system functions as follows: piston withsealing ring pos. 204 hydraulically moves ca-pacity slide back and forth. Hereby a modu-lating opening takes place for an internal by-pass channel, which - when piston is to thefar right on the draft - is as open as can be.The compressor is now running at its lowestcapacity.

DismantlingS By dismantling screws pos. 73 it is pos-

sible to remove the following parts:

-- Cover pos. 72

-- Indicator glass pos. 75

-- O-ring pos. 74

-- Supporting ring pos. 224

S Dismantle indicator dial pos. 221 by re-moving screw pos. 223.

S Dismantle indicator housing pos. 70 byremoving screws pos. 71.

S After dismantling of screws pos. 62 it ispossible to pull cover pos. 60 out of thecylinder pos. 50 by dismounting 2 screwsNo. 22.2 from the tools kit in the thread--ed holes of the flange.Watch out for oil in the cylinder !

S Remove cover pos. 60 together with ca-pacity indicator as one unit. Pull the whole

thing straight out in order toavoid damaging spindle pos. 210 andits engagement with the piston. Seedisassembly of the indicator in section 9.

S For dismantling of piston pos. 201, firstremove locking nut pos. 206 and lock--ingplate pos. 208.

S Before further dismantling adjust the Vi--slide to its min. position by unscrewingadjusting screw pos. 180 as far out aspossible, i.e. to max. X length. See sectionon Manual adjustment of the Vi--slide stop.

S Remove screws pos. 52 and pull cylinderpos. 50 straight out. By this movement thetwo washers pos. 201 of the piston arereleased from slide rod pos. 207.

S Piston with sealing ring pos. 204 can nowbe pulled out of the cylinder by hand.

Notice that spring pos. 191 will press capac-ity slide pos. 200 out against the regulatingcylinder.

7. Capacity slideCapacity slide pos. 200 can now carefully bepulled out of the compressor by hand.

Disassembly, if need be, of slide rod pos. 207and capacity slide can be carried out by re-moving screw pos. 311.

MountingMounting takes place in the reverse order tothe one described above. Note the following,however:

S On mounting capacity slide pos. 200spring pos. 191 must be in place asshown on drawing and pin pos. 205 mustbe in place and in order.

S On mounting cylinder pos. 50 press itagainst spring pos. 191 while at the sametime fitting screws pos. 52. Pay attention

0178-145-EN 55

to O-ring pos. 51.Tighten screws pos. 52 with 75 Nm.

S For mounting of piston first assemble thetwo washers pos. 201 with sealing ringpos. 204 in between. Next, insert the en-tire unit in cylinder pos. 50 until it touchesrecess on slide rod pos. 207.

Observe the following:

-- Lubricate thoroughly with refrigerant ma-chine oil. Take care not to damage sea-ling ring pos. 204 when mounting it in thecylinder.

-- Place sealing ring correctly as shown ondrawing.

-- Check that O-ring pos. 203 is in place.

-- Mount locking plate pos. 208 andlocking nut pos. 206. Text on nut mustface outwards and the locking plate mustbe bent so that it firmly locks the nut.

-- When mounting cover pos. 60, make su-re that spindle pos. 210 engages sliderod pos. 207 and catches pin pos. 205.Pay attention to O-ring pos. 61.

Dismantling and assembly ofcapacity indicatorS Dismantle the parts in below sequence:

-- Screw pos. 223

-- Indicator dial pos. 221

-- Nuts pos. 342

-- Cam disks pos. 341 if fitted on yourcompressor

S Dismantle locking ring pos. 213 and nextpress out spindle pos. 210 and ball bear-ing pos. 211.

S After dismantling of locking ring pos. 214,pull ball bearing pos. 211 off the spindle.

-- Dismantle spacer ring pos. 215 and sea-ling ring pos. 212.

S Assembly of parts takes place in reverseorder while observing the following :

-- Insert sealing ring pos. 212 on spindletogether with spacer ringPpos 215.Take care not to damage the sealing ringand that it is positioned with the openingfacing the spacer ring.

-- Fit spindle pos. 201 with bearing pos.211 and locking ring pos. 214 as well asthe sealing ring as one unit in flange pos.60. Also here take care not to damagesealing ring.

-- Remember to fit locking ring pos. 213.

56 0178-145-EN

8. Shaft seal type 680

Oil out

Oil in166

165

162

A

F

83

167

3-4 mm before tightening of screws

B 160 E 168 163

T264107_1

Fig. 1

Designation Pos.No.

Cast iron seat A

Rotating part with carbon face B

Outer O-ring 162

Inner O-ring 160

O-ring for cover 166

Pointed screws, 3 E

Carbon slide ring F

The shaft seal must ensure complete tight-ness between the compressor shaft and thecompressor housing, so that the inside of thecompressor is completely sealed off from theatmosphere.

The shaft seal type 680 has a built-in metalbellow in its rotating part which, apart fromensuring tightness, also assimilates axial dis-placement and provides the necessary com-pressive force between the two slide facesmentioned below.

The seal is a slide ring type, consisting of astationary cast-iron seat pos. A which is posi-tioned in the shaft seal cover pos. 165.Rotation is prevented by a pin pos. 83.

The end face of the cast-iron seat is lappedto ensure that the slide face seals tightly. TheO-ring pos. 162 seals against the shaft sealcover pos. 165.

The rotating part of the shaft seal, in whichthe carbon face pos. F is fitted, is fastenedon the rotor shaft by means of the threepointed screws pos. E and tighten by meansof the static O-ring pos.160.

Please be extremely careful with thelapped surfaces of the cast-iron seatand the carbon face. The slightestscratch will impair the sealing effect.

0178-145-EN 57

Removing the shaft seal

Before taking out the shaft seal, dismantlethe motor as described in section 13, Dis-mantling and Assembly of Motor and Cou-pling.

S Take the pressure off the compressor - asdescribed in the instruction manual - anddismantle the coupling.

S Remove all screws pos. 167. The shaftseal cover pos. 165 can then be pulled outover the shaft. If the cover sticks, so that itis not possible to remove it manually, usetwo cover screws pos. 167 fitted in thethreaded holes of the flange to ease it off.

The cast-iron seat pos. A will come out

together with the cover. It can now bepushed out as shown in fig. 2.

T0177141_0/V15

Fig. 2

A

B

�

S By means of the dismantling tool, as illus-trated in fig. 3, pull the rotating part of theshaft seal out of the compressor.Remember first to loosen the threepointed screws pos. E.

Oil out

Oil in

3-4 mm before tightening of screws

B 160 E 168 163

T264107_1+

Fig. 3

10.120.123.3

1 20.1 2123.3

58 0178-145-EN

Fitting the shaft seal

S Clean the shaft seal cover pos. 165 andthe rotor shaft thoroughly. Check the shaftfor scratches and marks that might causeleaks.

Oil the shaft and shaft seal parts with thesame type of refrigeration oil as the oneused in the compressor.

S Press the rotating part carefully in over therotor shaft until it touches the recess onthe rotor shaft as shown in fig. 1.Do not press the carbon ring but use twoscrew drivers as illustrated by fig. 4.In this way you avoid twisting the bellowsin the shaft seal.

Fig. 4

S Then tighten the 3 pointed screws pos. Ealternately with the supplied 3 mm Allenkey.

S Mount the cast-iron seat pos. A and theO-ring pos. 162 in the shaft seal cover andmake sure that the pin pos. 83 catches theslot in the seat pos. A.

S Carefully ease the shaft seal cover in overthe shaft until it meets resistance from therotating part. Before screw pos.167 hasbeen tightened, there will be a gap of 3 to4 mm between the two flanges, as shownin fig. 1.Check to ensure that O-ring pos. 166 iscorrectly placed.

S Tighten screws pos. 167 alternately - takecare not to damage the shaft seal by tight-ening unevenly. Tighten the screws withthe torque indicated in the instructionmanual.

S Fit the coupling as described in theInstruction Manual and turn the shaft (byhand) to check that it rotates freely.

S Remember first to loosening the 3 pointedscrews pos. E.

0178-145-EN 59

9. Capacity indicator

Dismantling and assemblyAs it appears from the spare parts drawing,the following two types of standard systemsfor capacity indication can be mounted.

A: Visual capacity indicator

B: Capacity indicator with position trans-mitter.

Look at page 1 to see which system yourcompressor is using.

��

T0177135_0/V23

210

Fig. 9.1

218 217 61 60 219 223 71

224

74

70 221 7350

216

350

75

1 2

T0177135_0/V23

210

218 217 61 60 219 223 71

224

74

70 221 7350

216

350

72

75

3

62

Magnetic coupling pos. 216

Magnetic coupling for capacityindication type A and BThe rotating movement from spindle, pos.210, see fig. 9.1, is transferred to the trans-mitter pos. 350 through a magnetic coupling,pos. 216, which is completely tight to both oiland refrigerant.

Dismantling

S By removing screws, pos. 73, the follow-ing parts are taken apart:

-- Flange pos. 72

-- Sight glass, pos. 75, available in twodifferent designs, either for visual in-dication or for mounting of transmitter.

-- O-ring pos. 74

-- Supporting ring pos. 224

S Remove screws, pos. 71, and indicatorhousing, pos. 70, can be taken down.

S Dismantle the screws, pos. 62, whereuponthe flange, pos. 60, and the spindle, pos.210, can be pulled out gently.

S Dismantle indicator dial, pos. 221, by loos-ening screw, pos. 223.

S By removing screws, pos. 219, the entiremagnetic coupling, pos. 216, can bepressed out of the flange, pos. 60, byhand.

60 0178-145-EN

S By dismantling circlip no. 1 the inner mag-net retainer no. 2 and spindle, pos. 210,can be pulled out against the magneticforce.

S Dismantle spindle, pos. 210, by looseningscrew, pos. 218.

Assembly

Assembly of the complete unit is carried outin reverse order to the dismantling.

Pay attention to the following, however:

S On mounting of the magnetic coupling incover, pos. 60, O-ring, pos. 217, must befitted.

S Before fastening indicator dial, pos. 221,with screw, pos. 223, it should be posi-tioned so that the slot points to the left and40� below horizontal. See sketch.

40�

S On mounting of sight glass, pos. 75, itshould be positioned so that the 0% markis right above the slot in the indicator dial,pos. 221.

Position transmitter

Usage:

The position transmitter is used for remoteindication of compressor capacity. By inte-grating electronic limit switches into the con-trol, max. and min. compressor capacity canbe signalled, for instance.

The indicator disc rotates the positiontransmitter arm by using pin no 3, whichengages with the slit of the disc.

Assembly

S The position transmitter, pos. 350, mustbe fitted on the sight glass, pos. 75, insuch a way that the electric socket isturning downwards when the 0% mark onthe sight glass is opposite the slit in theindicator disc as described above.

S The retaining pin no. 3 of the transmittermust engage in the slot in indicator wash-er, pos. 221, on mounting sight glass, pos.75.

T0177063 0

13

2

0%2.

2.5

3.

4.5 4.3.5

SPAN + ZERO

100%

Slide position

Volume ratio

3

Position transmitter

0178-145-EN 61

Connect the position transmitter to the con-trol system according to the following dia-gram:

Terminal Used for

12

Signal 0 - 20 mAVoltage supply24 V DC +/--20%Frame OVNot used

3

Adjustment:

S Turn the transmitter shaft until the outputsignal is approx. 4mA. On UNISAB II thedisplay shows 0%. Secure the arm oppo-site the 0% mark on the sight glass. Fitsight glass with transmitter on the com-pressor. Make sure that the pin GT8.1catches the slot on the indicator dial!

S Turn the sight glass until the 0% markaligns with the indicator dial with the ca-pacity slide in its minimum position.

S With the Zero screw adjust to the desiredminimum signal. With controls supplied bySABROE, adjust to 4mA signal. One turnwith the ZERO screw changes the signalto 2mA.

S With the capacity slide in maximum posi-tion, adjust the output signal to 20mA onthe SPAN screw. One turn changes thesignal to 1mA.

Note:The adjustment of the slide will affect themax. position of the capacity slide. Themax. signal of the position transmittermust therefore be adjusted on the SPANscrew after adjustment of the Vi slide.

62 0178-145-EN

Limiting the minimum capacity of the screw compressor - SAB 110 S/L

�

T0177135_0/V23

229210,2 75.2228

The above mentioned screw compressors,which are used at evaporating temperaturesbelow --20�C for refrigerant R717 or R22, arefitted with a spacer ring pos. 228 whichchanges the minimum capacity of the com-pressor from normally approx. 10% to:

SAB 110 S

SAB 110 L ca. 35 %

ca. 50 %

The limitation eliminates undesirable noise inthe compressor in the start and stop periods.

Each individual part in the system is shownon the above drawing. Reference is made tothe List of Parts at the end of this instructionmanual.

Pos. 228 Spacer ringPos. 229 O-ringPos. 210.2 SpindlePos 75.2 Glass for indicator

Dismantling and assemblyThe system is dismantled and asembled asdescribed in section 9 Capacity indicator, andthe spacer ring pos. 228 can be removed byhand by catching the hole in the middle.When the spacer ring is mounted it can bepositioned arbitrarily.

0178-145-EN 63

10. Bearing cover, rotors andbearings

Dismantling and assembly

This section describes how bearing coverpos. 20, rotors pos. 110, and the bearingsare dismantled and assembled in the com-pressor.

Before dismantling the parts mentioned,carry out the following:

S Dismantle motor and coupling as de-scribed in section 13.

S Dismantle shaft seal as described insection 8.

Dismantling of bearing coverpos. 20:10.1 Dismantle the attachment of the bea-

ring cover to the oil separator.

10.2 Unscrew adjusting screw pos. 180 forthe Vi--slide stop to its extreme posi-tion by turning it anticlock-wise.

10.3 The capacity slide system as descri-bed in section 7 is not necessarily di-sassembled but can be pulled slightlyout of the compressor in order to re-move the spring pressure from springpos. 191.This is done by dismantling screwspos. 52 and the pipe connection to thecapacity cylinder pos. 50.Pull the capacity cylinder approx. 100mm out of the compressor frame, let-ting it stick to the capacity slide. Payattention to the spring pressure andhold back the cylinder, while at the sa-me time dismantling screws pos. 52.

10.4 Knock out the two cylindrical guidepins pos. 22 using punch No 56 andHammer No 55.1.

Before knocking out the guide pins thepipe joints on the side of the compres-sor must be dismantled first in order tosave space.Pay attention to the nozzle in the pipejoint to the rotor injection.

10.5 Dismantle screws pos. 23 and threa-ded plug pos. 24.

10.6 By means of screws No 22.2 from thetools kit, which are fitted in the threa-ded holes in the flange on the bearingcover pos. 20, this can now be pushedaway from the compressor housingpos. 10 until loose. Then lift it away.Support bearing cover during the dis-mantling.

Now the two main bearings pos. 111 can bedismantled as described in the following sec-tion as well as the Vi--slide stop pos. 190, de-scribed in section 12.

Dismantling of main bearingspos. 111 on the suction sideAfter dismantling of bearing cover pos. 20,the main bearings can be dismantled in thefollowing way:

10.7 Dismantle suction port pos. 30/31 byremoving screws pos. 32 as shownon fig. 1.

Fig. 1

T0177141_0 V33

20 111 32

30/31

64 0178-145-EN

10.8 Carefully knock the outer rings ofthe main bearings out of the bearingcover by means of punch No 56 andhammer No 55.1.

10.9 Pull the inner rings of the mainbearings off the rotor shafts by meansof the tools shown on fig. 2.

Fig. 2

T0177141_0/V16

23.121 20.2

10.1

5922.3

In order to prevent the rotors fromturning when the inner rings are pulledoff, lock the rotors at the opposite endas shown on fig. 3.

Fig. 3

110

11

T0177141_0 V34B

22.5

Before this tool can be mounted, theparts mentioned in pt. 10.10 to 10.13must be dismantled.

Dismantle main bearings pos. 111 and ax-ial bearings pos. 132 and take out the ro-tors.

10.10 Loosen the locking screws pos. 45,then loosen the two adjusting screwspos. 44 3-4 turns.

10.11 On dismantling the screws pos. 43 it ispossible to remove cover pos. 40.

10.12 With screw No 22.1 pull out the twocovers pos. 153.

10.13 Dismantle screws pos. 115 and thrustplates pos. 114.For this purpose use tools as shownon fig. 4, which are mounted at the ot-her end of the rotors in order to lockthe rotors.

Fig. 4

31 14 T0177141_0 V34A

110

22.3

30

Please, notice that the inner rings ofthe main bearings on the suction sidecan now be dismantled as describedin pt. 10.9.

10.14 Dismantle all auxiliary tools as mentio-ned in pt. 10.13.

10.15 With tools arrangement fig. 5 pressout the rotors, one at a time.

0178-145-EN 65

Fig. 5

122.2 10.2

T0177141_0 V38

22.2

21

142 110

142

Make sure in tool No 1 to select theholes for screws No 22.2 that centreNo 1 in relation to the rotor shaft.Tighten screws No 22.2 so that No 1touches the screw heads pos. 142.

10.16 Carefully remove the rotors from thecompressor, and take out by hand theaxial ball bearing pos. 132, the shimspos. 133, the inner rings for main be-arings pos. 111 and the balance pistonpos. 130.The axial ball bearings pos. 132 con-sist of 3 main parts which must bekept together so that they are not in-terchanged or mixed with parts fromthe bearing on the other rotor.

10.17 After remounting of screws pos. 142and sealing plates pos. 143, press outthe discharge ports pos. 140 and 141and the main bearings pos. 111 bymeans of the tools shown on fig. 6.

The discharge ports pos. 140/141 cannow be removed by hand and the ringfor the balance piston pos. 139 sepa-rated from the discharge ports (fig.6)

Fig. 6

T0177141_0 V37

140/1412

22.4 10.1 153 111

16121

Mounting of bearing cover, rotorsand bearingsBefore mounting check that all parts arecleaned and ready for reuse.

It is not recommended, however, to reuse thebearings. Further, make sure that the O-ringsand gaskets are OK.

All parts should be lubricated with new refrig-erant machine oil of the same type as theone used in the refrigeration plant. Use Moly-cote grease on pressing the bearings intoplace as already described.

Tighten the screws with the moments as pre-scribed in the table on Torque moments forscrews and bolts, provided that no othermoment is stated in the text.

10.18 Before mounting of the dischargeports pos. 140 and 141 make surethat these are free of burrs on the ed-ges. Also check that the inner surfa-ces of the compressor housing areclean so that the discharge ports canbe placed right next to the bottom sur-face of the housing.Turn discharge ports as shown onthe spare parts drawing.

66 0178-145-EN

Mount and tighten screws pos. 142.

In view of tightness, use new sealingplates pos. 143, and position them sothat they centre the screw in the hole.

10.19 Position the two rotors in the compres-sor housing, one at a time, and placethem as shown on fig. 7 for either ma-le or female drive.

Fig. 7

T0177141_0/V19

Male drive

Female drive

The rotors are marked with a numberon the end surfaces that are turned

towards the suction side of the com-pressor.

The number has no value in itself butthe same number must be on both ro-tors and on mounting the engage-ment between the rotors must be asshown on fig. 8.

Fig. 8

8

T0177141_0/V20

8

8

Now make bearing cover pos. 20 ready formounting on the compressor housing, butbefore that mount the inner rings of the mainbearings pos. 111 on the suction side.

10.20 Mount the inner rings of the mainbearings with tools as shown on fig. 9.Tighten nut No 23.2 with 40 Nm. Forlocking of the rotors mount tools, fig.3, at the other end of the rotor.

152420.3T0177141_0 V36

113

23.2

”B””A”

7

Fig. 9

0178-145-EN 67

10.21 Position Vi-slide stop pos. 190 in thebearing cover as described in section12.

10.22 Press the outer rings of the mainbearings into place in the bearingcover using the two suction portspos. 30 and 31 as pressing tools.Remember to turn the inscriptionon the bearings so that it faces thebearing cover.Fix the suction ports by means ofscrews pos. 32.

Now mount the complete bearing cover pos.20 on the compressor housing as describedin the following:

10.23 Carefully insert bearing cover pos. 20and mount screws pos. 23 -- tightenonly slightly.Pay attention to O-ring pos. 21.

10.24 By means of hammer No 55.1 knockthe two cylindrical guide pins into pla-ce and mount screws pos. 23.

At the other end of the compressor mountbearings and all other parts as described inthe following:

10.25 Mount the outer and inner rings pos.139 and 130 of the balance piston atboth rotors.

For mounting of the inner balance ringit will be an advantage to use tool No7 as shown on fig. 10 .

T0177141_0/V21

140/141 130 7

Fig. 10

10.26 Mount the innermost main bearingring on both rotors with tool arrrange-ment as shown on fig. 9. Tighten nutNo 23.2 with 40 Nm and turn the in-scription on the bearing ring so that itfaces outwards.

In order to prevent the rotors from tur-ning they must be locked at the otherend with tools shown on fig. 4.

Before mounting lubricate the shaftwith Molycote grease.

10.27 Mount the outer rings of the mainbearings with tool shown on fig. 6.The inscription on the bearing facesoutwards.

10.28 Press the innermost inner ring of theball bearing pos. 132 on both rotorsby means of tools shown on fig. 9 andfig. 4.

Make sure that the 3 bearing parts arepositioned in the same way as theywere in the original packing and thatthe inscription on the bearing facesoutwards.

Turn tool No 7 with its smooth end Atowards the bearing ring.Tighten nut No 23.2 with 40 Nm.

68 0178-145-EN

10.29 From the set with shims pos. 133 se-lect thickness 0.82 mm, which is inser-ted in front of the main bearing pos.111. Now insert the outer ball bearingring with balls pos. 132 by hand.

Turn the ball bearing in relation tothe pressed in inner ring as theywere placed in the original packing.

11. Adjusting the rotorsAfter assembly of the compressor as de-scribed in section 10 the position of the tworotors is adjusted, one at a time, adjustingthe driving rotor first, i.e. the rotor to whichthe motor is connected.

11.1 Mount clamping tool No 8, as shownon fig. 11, and tighten with screw pos.115.Tighten with 61 Nm.

11.2 Mount thrust cover pos. 153 as shownon spare parts drawing, without theO-ring pos. 154, however. Mount co-ver pos. 40 and fix with screws pos.

43. Do not tighten adjusting screwpos. 44 completely against the thrustcover pos. 153.

11.3 At the opposite end, the suction side,of the compressor, mount adjustingtools as shown on fig. 12.

Fit tool part No 14 through the hole inbearing cover pos. 20, after removingplug pos. 24.Place the dial meter in front of the ro-tor that is going to be adjusted.

T0177141_0/V24

130 111 8133 132

Fig. 11115

0178-145-EN 69

22.4 23.1PO17714--1a

14

34

35

20

53 22.4 23.1 33 31Fig. 12

110

11.4 As it may be seen from fig. 12, springpos. 34 is going to press the rotoragainst the discharge port at the otherend of the compressor.Adjusting screw pos. 44 must beloose. Position the dial meter on ”0”.

11.5 Tighten ajdusting screw pos. 44 with30 Nm and read the dial meter.The axial displacement of the rotor,the exact measure, must be between0.05 and 0.10 mm by correct adjust-ment.By larger axial displacements insert athicker -- or a thinner -- adjusting shimpos. 133, see spare parts list, and re-peat measuring points 11.4 to 11.5.

11.6 Once correct adjustment has beenachieved, the following is done:

S Note down the exact measure tobe used in pt. 11.11.

S Dismantle measuring tool shown infig. 12.

S Loosen adjusting screw pos. 44.

S Dismantle screws pos. 43 and re-move cover pos. 40.

S Pull out thrust cover pos. 153 bymeans of tools screw No 22.1.

11.7 Mount the auxiliary tool at the otherend of the rotors as shown in fig. 4,and dismantle clamping tool No 8.

11.8 Dismantle the other inner ring on theball bearing pos. 132 as described inpt. 10.28.

11.9 Fit thrust plate pos. 114 and fastenwith screw pos. 115.Torque: 61 Nm.

11.10 With the O-ring pos. 154 fitted, posi-tion thrust covers pos. 153.

The first part of the adjustment of the drivingrotor is now completed. Repeat the proce-dure from pt. 11.1 to 11.10 for the other rotor.

Please, notice that the adjusting tools men-tioned in pt. 11.3 must be mounted as shownon fig. 13.

70 0178-145-EN

22.4 23.1

PO17714--1b

14

53 22.4 23.1 33 31

Fig. 13

34

100

40

Final adjustment

After both rotors have been adjusted and theexact measures noted down, we are nowready for the final adjustment of the rotors.

11.11 The exact measure for each of therotors is compared with the measuresin column 1 in the following table. Co-lumn 2 provides you with the final ad-justing measure.

If, for instance, the exact measure is0.061 mm for the female rotor, it is so-mewhere between 0.060 and 0.069,which yields a final adjusting mea-sure of 0.04 mm according to the ta-ble.

Exact measurebetween

Finaladjusting measure

mm mm

1 2

0,050-0,055 0,0400,056-0,060 0,0450,061-0,065 0,0500,066-0,070 0,0550,071-0,074 0,0600,075-0,079 0,0650,080-0,084 0,0700,085-0,089 0,0750,090-0,094 0,0800,095-0,100 0,085

With the adjusting tools mounted andadjusted as shown on fig. 12 or 13and with the dial meter positioned on

0178-145-EN 71

”0”, tighten adjusting screw pos. 44while at the same time reading the dialmeter.The hand of the dial meter must movethe final adjusting measure.

11.12 After the final adjustment lock adjus-ting screw pos. 44 with pointed screwspos. 45, and the adjustment of the ro-tor is now completed.

11.13 Repeat the final adjustment points11.11 to 11.12 for the other rotor.

11.14 Check that the rotors are easy to turnby hand.

12. Slide stop for Vi-regulation

The purpose of the Vi-regulation system is toadjust the built-in volume ratio of the com-pressor so that the compression ratio of thecompressor is the same as the pressure ratiobetween condensing pressure and evapora-tion pressure in the refrigeration plant.

The system works as follows:

Vi-slide pos. 190 is displaced and thus -via the regulating slide pos. 200 - changingthe size of compressor discharge port. Thismodification of the size of discharge port in-creases - or reduces - the compressionchamber, thus regulating the compressionratio.Adjustment of slide stop is done manually asdescribed in a separate section of thisinstruction manual. Please, see table of con-tents.

Dismantling of Vi-slide stopS First dismantle bearing cover pos. 20 and

next suction port pos. 30 and 31. See sec-tion 10.

S After dismantling vent screw pos. 107 andgasket pos. 108, slidestop pos. 190 canbe pulled out by hand.

S When dismantling screws pos. 106 it ispossible to take out and disassemble pis-ton pos. 103 with sealing ring pos. 101and retainer pos. 105.

S Check the following:

-- that cylinder in bearing cap pos. 20 is wit-hout any scratches or marks that couldcause leakage.

-- that sealing ring pos. 101 is flawless.

Mounting of Vi-slide stopWhen mounting - which is to be carried out inreverse order of dismantling - observe thefollowing:

S Turn adjustment screw pos. 180 to mini-mum position by turning it anti-clock-wise.

S Lubricate cylinder pos. 20 and sealing ringpos. 101 thoroughly with refrigerating ma-chine oil before fitting them together verycarefully.

S Remember to mount vent screw pos. 107with gasket pos. 108.

72 0178-145-EN

13. Dismounting and assembly ofmotor and coupling

The electric motor is secured to bearing cov-er pos. 20 by means of M16 screws, and canbe dismounted in the following ways:

A: By means of a crane or other liftinggear in which the motor is suspended.

B: By means of a sliding tool mounted onthe base frame under the motor.

In the following you will find a description ofthe two methods:

Dismounting the motorA: If a crane or other lifting gear is availa-

ble, the following method can be used.

A1: Dismantle electric cable connec-tions in terminal box of motor.

A2: The motor is suspended in a lif-ting sling fastened to the liftingeye on the motor.

A3: Carefully loosen the screws secu-ring the motor to bearing coverpos. 20 and make sure that themotor is securely suspended inthe lifting sling.

A4: Carefully pull motor in its longitu-dinal direction away from bearingcover hereby splitting couplingbetween motor and compressorshafts.

8 19 5 2 6

T3083118_0

M16x130

M16x90

8 9

M16x130

M16x90

7

7

3

4

310550

10

Fig. 14

0178-145-EN 73

B: If no lifting gear is available, we recom-mend that you use a sliding tool whichcan be supplied by SABROE.The sliding tool is used in the followingway. See Fig. 14 below.

1B: Dismount the electric cable connec-tions in the terminal box of the motor.

2B: Mount the parts Nos 5 to 8 of the sli-ding tools on the base frame as shownon the drawing. Fit the screws No. 8into the threaded holes in the lifting ey-es of the unit. Place the supporting partNo. 6 loosely on the shell of the oil se-parator.

3B: Screw the bottom nuts No. 7 in sodeep that slide No. 1 with spindels No.2 can be placed under the motor.

4B: By means of screws No. 7 the entiresliding system is elevated, and by shif-ting slide No. 1 in its longitudinal andtransverse direction, it is ensured that itis placed below the centre of gravity ofthe motor.

5B: The sliding system is elevated so muchthat it is able to carry the motor whenthe screws between the motor and thecompressor are removed. In connec-tion with direct air--cooled motors, the

sliding system can support the motordirectly.If the motor is equipped with coolingfins on the outside, a supporting platemust be placed between the slidingsystem and the fins.

6B: When the screws between the motorand the compressor are loosened, itmay be necessary to fine adjust the he-ight of the sliding system by means ofnuts No. 7. Then counter tighten withthe upper nuts No. 7Please, observe that the sliding systemmust be parallel with the longitudial ax-is of the motor in horizontal plane.

7B: By carefully turning the spindles No. 2the motor can be rolled away from thecompressor. Hereafter, slide No. 1 maybe moved sideways in order to obtainmore space between the motor and thecompressor. For motors with a smalloutside diameter on the jacket, the twodouble bars No. 10 can be used duringmounting on No. 1.

Note:On marine plants, the motor must be se-cured to prevent it from falling off the slid-ing system in a heavy sea.

74 0178-145-EN

Dismantling of coupling

After having carried out A or B as describedabove, the coupling can be dismantled.

In the following two sections a description isgiven of the procedure for couplings typeE128 and type 65 HEW.

Coupling type E128

Dismantling

T0177141_0/V10

1

Fig. 14.1

�

S Coupling flange on compressor can bedismantled by hand (fig. 14.1) - afterscrews point 1 on the bushing have beenloosened a couple of turns. (Fig. 14.1)

S Coupling flange on motor is pressed onand can if necessary be pulled off bymeans of a draw tool. Observe thatpointed screw M10 must be loosenedbefore dismantling!

Mounting of coupling and motorS Before the coupling half-section is

mounted on the compressor shaft, thecompressor shaft, the coupling half-section and the bushing must be de-greased with an oil solvent. The cou-pling half-section on the compressor mustbe positioned correctly, in accordance withfig. 14.2.

S Depending on motor flange dimension Aand length L of shaft, the distance fromend surface of coupling flange to end sur-face of shaft must be as indicated on fig.14.1, picture 1, i.e. end surfaces must beon the same level or, like in picture 2, witha 22 mm distance.

S After correct positioning of couplingflange, tighten screws pos. 1 (fig. 14.1)in the following way:First tighten the screws manually, nextturn each of them 1/2 a turn at a timeclockwise until the correct torque momentof 8 Nm has been obtained for all screws.

S Carefully push motor in its longitudinaldirection towards bearing cover pos. 20making sure that the two coupling flangesengage in each other with the rubber ringin between.

During the mounting check the distancebetween the two coupling flanges throughthe inspection hole on the side of thebearing cover. The distance between theend surfaces of the two coupling flangesmust be 3.5� 1 mm as shown on fig. 14.2.

S Secure motor with screws and fit cableconnections.

S Remove the lifting gear or the sliding tool.

S When starting the compressor check rotating direction by looking through the in-

0178-145-EN 75

spection hole in bearing cover pos. 20which is closest to the coupling. At correct

rotating direction, the visible part of thecoupling will move downwards.

Picture 1

Motor shaft

M10

Compr. shaft 822

Picture 2

M10

L

T0177141_0/V11

Motor

Dia.A

Motor shaft Compr. shaft

Fig. 14.2

110

Shaftlengthonmotor

Lmm

140

Pict. I

Pict. II

Pict. II

Pict. I

Motor flange diameterA mm.

400 450

Pict. II

Pict. I

550

76 0178-145-EN

Coupling type 65 HEW

Dismantling

T4840139_0

Fig. 14.3

�

1

After removing the motor as described pre-viously, dismantle the coupling in the follow-ing way:

S At the coupling flange on the compressorloosen screws pos. 1, fig. 14.3, a fewturns. Mount 3 of the loosened screwspos. 1 in the threaded holes pos. H,shown on fig. 14.4, and by tightening themalternately the bushing is loosened. Nowtake out the coupling flange by hand.

Fig. 14.4

3 x M8

1

3 2

4

5

6T4840139_0

H

S At the motor coupling flange, first disman-tle the elastic intermediate part pos. 4 byremoving screws pos. 5, fig. 14.7.Next, loosen screw pos. 2, fig. 14.8.It is now possible to pull the couplingflange off the shaft by means of the twothreaded holes in the flange, as shown onfig. 14.5.

Fig. 14.5

T4840139_0

2 x M8

0178-145-EN 77

Mounting of coupling and motor

Mount the coupling flange on the compressorand motor as described in the following:

S Before mounting of the coupling flange onthe compressor shaft, clean couplingflange, the individual parts in the bushingand the compressor shaft.Next, lubricate all parts in a little of the re-frigerant machine oil. Do not lubricate withMolybdändisulfide, high pressure oils orlubricating grease.

S The coupling flange on the compressormust be positioned correctly in accor-dance with fig. 14.8 so that the distancefrom shaft end to end surface of the cou-pling flange constitutes E = 7¦0.5 mm.

S After correct positioning of the couplingflange tighten all screws pos. 1 cross-wiselike the numbers on fig. 14.4. First tightenwith half the torque moment and thentighten with the full torque = 38 Nm.

On tightening the screws pos. 1 it might be agood idea to use the two tools pos. 6 asshown on fig. 14.6.

Fig. 14.6

T4840139_0

��

�

� 6

4

5

6

Secure the tools on the intermediate partpos. 4 with the screws pos. 5 and positionthe unit on the compressor flange as shownon fig. 14.7.

Hereby the pins on the tools engage thebearing cover pos. 20, thus preventing thecoupling flange from rotating during tighten-ing.

Fig. 14.7

T4840139_0

� 4

1

�

� 6� 5

S On mounting the coupling flange pos. 3 onthe motor shaft a press tool should beused. If the flange is knocked on there is arisk of damaging the bearings in the mo-tor.Position the coupling flange at a distanceC from the end surface of the motor shaft,depending on motor flange diameter Aand shaft length L.See table in fig. 14.8.Tighten the pointed screw M10, pos. 2with 40 Nm.

S Mount the elastic intermediate part pos. 4on the motor coupling flange and securewith screws pos. 5. Tighten screws with35 Nm.

S Carefully lead the motor in its longitudinaldirection towards the bearing cover, pos.20, making sure that the two coupling

78 0178-145-EN

parts engage in each other.Through the two openings in the bearingcover check whether the teeth on the twocoupling parts have engaged within themeasure D=0/+2 mm.

S Secure the motor with the screws and fitthe wiring connections.

S Remove the lifting gear or the slidingtools.

S When starting up the compressor checkthe sense of rotation by looking throughthe inspection opening in the bearing cov-er, pos. 20, closest to the coupling. By cor-rect sense of rotation the visible part of thecoupling must move downwards.

Fig. 14.8

T4840139_0

M10 x 10

8 x M20 x 20

Fig. F

6 x M8 x 35

Fig. G

Lmm

Amm 400 450 550

Fig. F Fig. G Fig. G

140 Fig. F Fig. F Fig. F

110

Motor

Compressor

Motor

�

3

4

�

E= 7¦ 0.5

�

�

�2

1

5

A

Compressor

Motor

E=7¦ 0.5

L

C=40¦ 1.5

C=70¦ 1.5

D=0 /+ 2

0178-132--EN

01.10

0178-145-EN 79

Systems for regulation of compressor capacityand Vi-ratio of SAB 110

In this section the following systems aretreated:

1. Regulation of compressor capacity

2. Manual regulation of Vi-slide

Please, check the system of your compres-sor on page 1.

1. Regulation of compressorcapacity

The regulating system is a complete unit asshown on the following drawing. It regulatesthe compressor capacity by admitting ordraining oil from capacity cylinder Pos. 50(see spare parts drawing.)

The system is connected to oil pressure atconnecting piece B and oil returns from ca-

pacity cylinder through connecting piece A.Connecting piece C is connected to capacitycylinder.

The system has two throttle valves Pos. 72built in, whereby oil flow and thus movingspeed of capacity piston can be regulated.The throttle valves are meant to ensure asmooth and easy movement of capacity pis-ton, adapted to operating conditions.

If spindles are turned clockwise oil flow isreduced.

Pos. 70 is a normally closed valve.

Pos. 71 is normally open, which is to say thatby a non energized coil, it is open for throughflow.

80 0178-145-EN

Fig. 1

7272

B

AC

Filter

NO NC

71 74 70 73

Function1. At constant capacity, both solenoid valves

are closed as Pos. 70 is dead while cur-rent is being supplied to Pos. 71.

2. When regulating to higher capacity, cur-rent is switched on to coil Pos. 70, where-by both coils are energized. This opensPos. 70 and puts oil pressure on capacitycylinder while Pos. 71 remains closed.

3. When regulating to lower capacity, currentis shut off to both coils. This makes Pos.70 close and cuts oil pressure to capacitycylinder. Pos. 71 opens and allows oil toflow away from capacity cylinder by thepower from spring Pos. 191.

4. When compressor stops, the current toboth solenoid valve coils is switched off.

This moves capacity piston to 0% position- as described in point 3 - and the com-pressor is unloaded when starting upagain.

On HFC/HCFC plants the oil contains a fairamount of refrigerant. Therefore, the oil pres-ent in the cylinder of the capacity slide can,under the influence of heat from the com-pressor frame and possibly pressure drops,separate some of the refrigerant. Hereby, theoil/gas mixture will become compressible.

It may happen that the capacity slide movesin jumps. It may also happen that when thecompressor capacity is going to be changed100% to a lower capacity, the slide will hes-itate and not move right after being activated.

0178-145-EN 81

2. Manual regulating of Vi-slide

T0177141_0/V6

180

��

190

Fig. 2

x

�

181

The above drawing - which is a section fromthe blue spare parts drawing - shows the de-sign of the manual Vi-system operating asfollows:

FunctionThe Vi-slide Pos. 190 functions as a movablestop for capacity slide Pos. 200 when this isin its max. position. On turning the adjustingscrew Pos. 180 the compressor Vi is set sothat its compression ratio is adapted to the

pressure ratioCTET of the plant when working

at max. capacity.

This way the compressor works most eco-nomically.

S By turning the spindle clockwise a higherVi is obtained.

S By turning the spindle anti-clockwise alower Vi is obtained.

Note:On adjustment of the Vi the compressormust be stopped and the pressure be-tween the compressor discharge side andsuction side must be equalized.

Adjusting of ViBefore the initial start-up of the compressor,check the x measure as shown in fig. 2,while the compressor is idle.

S Turn the spindle Pos. 180 anti-clockwiseuntil it gets loose and is easy to turn byhand.

S By hand, turn the spindle clockwise untilit touches the end of the Vi-slide stop asshown in fig. 2.

S Check the distance x which, depending onthe compressor size, must be:

SAB 110S, x = 44 mmSAB 110L, x = 54 mm

S If necessary, the x measure can be ad-justed by loosening the two nuts Pos. 181and counter-tightening them again afterthe adjustment.

For correct adjustment of Vi-slide position,use the diagrams on the next pages as fol-lows:

82 0178-145-EN

Use diagram for either SAB 110S or SAB110L. For the actual refrigerant (R717 orR22, R134a, R404A/R507, R407C) andevaporating temperature TE, follow horizon-tal line to intersection with curve for actualcondensing temperature TC.

From this intersection point, two readings canbe made by following the line vertically up ordown:

S Vertically up, the Vi-ratio referring toscale on compressor capacity indicator isread. Observe whether or not the com-pressor is connected to an economizer.

S Vertically down, the length x is read inmm (fig. 2), to which the adjusting screwPos. 180 must be adjusted in order toachieve the correct Vi-setting. Also hereobserve whether or not the compressor isconnected to an economizer.

The setting of the Vi-slide may be checked byreading of the scale on the indicator glass.

Note, that the values of the Vi-scale are onlyvalid as long as the compressor runs at100% capacity.

0178-145-EN 83

Adjusting theVi-slide stopposition

(T250815)

Evaporatingtemperature


--60

--50

C

102040

10203040

--20--25

mm0

100

--10

Economizer

mm0

--40

--30

--20

--10

0

10

20

TE

403020

5055

C

TC

R717

Volumeratio 2 2.5 3 3.5 4

2 2.5 3 3.5

Single stage

4.5

4 4.5

Vi

Economizer

Vi

SAB 110S

T250815

�

�

SAB 110 S

Adjustment Free length of adjusting screw x

Single stage

R717

position

(T250816)

SAB 110 L


Condensingtemperatture

--60

--50

C�

Adjustment 10203050

--20--25

Single stage

mm0

100

--10

Economizer

--40

--30

--20

--10

0

10

20TE

403020

5055

C

TC�

R717

Volumeratio Vi 2 2.5 3 3.5 4

2 2.5 3 3.5

Single stage

4.5

4 4.5

Vi

Economizer

Vi

SAB 110L

10203050 0

Free length of adjusting screw x

Adjusting theVi-slide stop

R717

84 0178-145-EN

(T250813)

--60

--50

C�

Adjustment

--20--25

0

10203040

102040

--10

Single stage

302010

0

Economizer

mm0

--40

--30

--20

--10

0

10

20TE

40

5550

C�TC

Volumeratio Vi

2 3 3.5 4 4.5

2 2.5 3 3.5 4 4.5

Vi

Economizer

Vi

SAB 110S

mm

--60

--50

C

0

10203040

102040 Free length of adjusting screw x

302010

Economizer

mm0

--40

--30

--20

--10

0

10

20TE

40

5550

C

TC

Volume

2 3 3.5 4 4.5

2 2.5 3 3.5

Single stage

4 4.5

Vi

Economizer

Vi

SAB 110S

mm



Adjusting theVi-slide stoppositionSAB 110SR22R134aR404A/R507R407C

R22R134aR404A/R507R407C

(T250814)



--60

--50

C�

Adjustment

--20--25

0102050

1020304050

--10

Single stage

mm

302010

0

Economizer

mm0

--40

--30

--20

--10

0

10

20TE

40

5550

C�TC

Volumeratio Vi

2 3 3.5 4 4.5

2 2.5 3 3.5

Single stage

4 4.5

Vi

Economizer

Vi

SAB 110L

Free length of adjusting screw x

Adjusting theVi-slide stoppositionSAB 110LR22R134aR404A/R507R407C

R22R134aR404A/R507R407C

0171-465-EN

00.10

T0177082_0

0178-145-EN 85

Torque moments for screws and bolts

Metric thread (ISO 8.8)

M 4 5 6 8 10 12 14 16 18 20 22 24 27

0.28

2.1

2.7

0.53

3.9

5.2

0.94

6.8

9.2

2.2

16

22

4.1

30

40

7.0

50

69

11

80

108

15

110

147

23

170

225

30

220

295

38

270

375

52

370

510

68

490

670

Kpm

ft.lbf.

Nm

Metric thread (ISO 12.9)

M 4 5 6 8 10 12 14 16 18 20 22 24 27

Kpm

ft.lbf.

Nm

0.42

3.0

4.1

0.78

5.7

7.6

1.4

10

14

3.2

23

31

6.1

44

60

10

75

98

16

120

157

23

160

225

34

240

335

44

320

430

55

400

540

76

550

745

100

720

980

Connecting rods with UNF thread

HPO/CMO HPC/SMC 100 SMC 180

UNF

Kpm

ft.lbf.

Nm

5/16”

2.1

15

20

3/8”

4.4

32

43

5/8”

17

130

167

Bolts for top-, side- and end covers

T/CMO T/SMC 100 T/SMC 180

Kpm

ft.lbf.

Nm

M12

85

HPOTop/side End

coverscovers

130

Top/sidecoverscoversEnd Top/side and end

covers

135

M14 M12

200

M14

135

M14

HPC

200

M14

420

M20

Top/side and endcovers

Top/side and endcovers

63 100 95 147 100 147 310

8.6 13.7 13.2 20.3 13.7 20.3 42.7

M

Location

Compressor

B

B

AMR

Serie 52

D

86 0178-145-EN

Bolt on discharge valve

HPO/CMO HPC/SMC 100 SMC 180

Kpm

ft.lbf.

Nm

3.2

23

32

10.2

75

101

35

255

344

Compressor Type Coupling ThreadTorque

Kpm. ft.lbf. Nm

34

55

128

275

34

34

41

55

128

177

245

275

25

40

95

200

25

25

30

40

95

130

175

200

3.5

5.6

13

28

3.5

3.5

4.2

5.6

13

18

25

28

5/16”

7/16”

1/2”

11/16”

AMR225

AMR312S

AMR350S

AMR450S

200

225

262

312

350

375

425

450

HPO/CMO/TCMO

104-108

112-116

186-188

HPC/

SAB

VMY

5/16”

5/16”

3/8”

7/16”

1/2”

9/16”

5/8”

11/16”

SMC/TSMC

Serie52

34

41

25

30

3.5

4.2

5/16”

3/8”

225

262

128

163

Serie52

202 55405.6312 7/16”

ThreadTorque (B)

Kpm. ft.lbf. Nm

B D

13

20

20

13

96

96

147

147

B D B D

130

130

200

200

Type

CouplingTypeCompressor Type

Dependson the sizeof the motor

0178-133-EN

98.05

0178-145-EN 87

Component descriptionSAB 110

In the component descriptions of this sectionthe same position nos. are used as in thepipe diagram. Some descriptions includedrawings. In case wearing parts or gasketsare included in the component, the spare partnumbers can be found in the list on unitspare parts.

Oil separator, pos. 25

The oil separator of the compressor unit hasseveral functions:

S It serves as oil reservoir for the oil systemwhich ensures lubrication and cooling ofthe screw compressor.

S It also serves as basis for compressorblock with flanged on motor. On fig. 1 and2 is shown the application of the individualconnections.

S Further, the oil is separated from the dis-charge gaz in the oil separator by makingthe discharge gaz pass through a wire-mesh filter in which the major part of theoil is separated, and then a fine filtercalled a hydrophobic filter element, inwhich the smaller oil drops are held back.

In this way the oil separation is made soeffective that the oil remains after the oilseparator becomes less than 25 ppm.

At the other end of the oil separator aflange is fitted through which the hydrop-hobic filter element can be removed forinspection and replacement, if necessary.

ServiceNormally, there is no need to inspect neitherthe wire-mesh filter nor the hydrophobic filterelement.

Only in case of an abnormal rise in oil con-sumption should an inspection of the hy-drophobic filter element be carried out.

Note:The hydrophobic element is secured by anumber of stay bolts. If you dismantle theelement, the stay bolts - which are allscrewed into the intermediate plate - mustbe tightened with teflon tape in thethreads. In this way, the necessary tight-ness is obtained for the oil between thetwo chambers of the oil separators.

The oil held back in the hydrophobic elementis returned to the suction side of the com-pressor through a filter pos. 51 and a nozzlepos. 52.

During operation the oil level in the oil sepa-rator must be visible between the middle ofthe lower sight glass and the middle of theupper sight glass, both of which are placed inthe flat end plate as illustrated in fig. 2.

88 0178-145-EN

Connection Applied for

1234

Oil inlet refrigerantOutlet refrigerant gasOil for oil coolerOil from fine separator

5 Discharge pressure to instrument panel or UNISAB II

4

2

2

5

15

4

83

83 Sensor positioning for injection valve for HLI cooling

Fig. 1

Fig. 2

31

31

3647

30

28/29

24

5

13

14

Applied for

Oil admission to oil cooler/oil filter

UNISAB II = sensor PT 100

No.

3631 Oil level sight glass

Discharge temp. Instr. panel = thermometer

Service valve

Safety valve G 3/4”

Discharge temp. external oil cooler = sensor KP81

HLI injection oil cooling

Injection oil cooling discharge temp. =sensor KP77

Service valve

24

28/29

13

14

47

(only where instrument panel applied)

(only where instrument panel applied)

5

5

= sensor KP79

Heating rod30

In the table on oil charging you may see theoil quantity for the compressor unit but it

does not include the amount of oil which is

circulating in the refrigerating plant. In R22systems with large quantities of refrigerant

special allowance must be made for the

amount of oil dissolved in the refrigerant.

Consequently, attention must also -- duringthe operating period after the initial start-up --be paid to the fact that the oil level may sinkrather quickly until the oil contents in the re-frigeration system has stabilized.

0178-145-EN 89

Discharge stop valve andnon-return valve

Discharge stop valve:

The standard unit is delivered with a stopvalve welded on the discharge branch of theoil separator. The discharge branch of thestop valve is made for welding connectionand has the following dimensions:

Units with the fol-lowing compr.type

Stop valve dimensionmm

SAB 110 DN 50

Non-return valve:

Next to the discharge stop valve a non-returnvalve must be fitted in the discharge pipewhich closes tightly whenever the pressure inthe oil separator is reduced to suction pres-sure in the unit standstill period.

The non-return valve must be positioned onthe uppermost part of the discharge pipe asshown in fig. 3. This prevents any condensa-tion that may have been created in the dis-charge pipe during the standstill of the unitfrom running into the oil separator during re-start of the unit.

The size of the non-return valve must becalculated on the basis of the current operat-ing conditions of the unit.

Stop valve on unit

Common discharge pipe

Non-return valve

Fig. 3

0170-017-EN

01.06

90 0178-145-EN

Heating Rods, pos. 30, Element for Oil Heating

In order to keep the lubricating oil in the com-pressor warm during an idle period, the oilreceiver has one or two built-in heating rods.Before start-up, the heating rod/s must havebeen activated for six to eight hours to en-sure that there is only a minimum of refriger-ant in the oil. When containing much refriger-ant, the oil will lose its lubricating propertyand the following operational interruptionsmay occur:

In reciprocating compressors there is aserious risk that the oil will foam when thecompressor starts as a result of the fallingsuction pressure.

For screw compressors starting with muchrefrigerant dissolved in the oil, there is a riskof the compressor being stopped by the flowswitch. The reason for this is that the oil will

foam owing to the fall in pressure through oilpipe and oil filter.

As illustrated in the drawing Fig. 1.1 the hea-ting rod consists of an electric heating ele-ment incorporated in a pipe with a diameterof 30 mm. The entire heating cartridge isscrewed on tight at the G 1 1/4” thread.

Note:The heating rod must not be energized ifthe oil level in the receiver is below theminimum mark in the sight glass, and itshould generally be switched off duringcompressor operation. For reciprocatingcompressors, remember to turn off theheating rod whenever the crankcase isopened for inspection.

The following table shows which heating rodsare used for the various compressor types.The spare parts lists for compressor and unitinclude the current part numbers.

Fig. 1.1

Marking: Prod. noWattVoltManu. date

L1

L2

NV 50G 1 1/4”

80

5030 Ø30

Fig. 1.2Heating rods

PowerWatt

VoltageV

L1mm

L2mm

Used for:

270270270

250230115*

CMO - TCMO - SMC 100 - TSMC 100

460460460

250230115*

158 175 HPO-HPC-SMC180-TSMC180-SAB81/83/85/87/89-SAB110-SAB128Mk3/4-SAB163Mk3/4-SAB128HR-SAB163HR-SAB202-SAB330-VMY536-SAB283L/E-SAB355L

* Can be delivered with a UL approval. All heating rods are executed in Degree of Protection IP54.

0171-561-EN

95.10

0178-145-EN 91

Water-cooled oil cooler, type OWSG/OWRG forscrew compressors typesSAB 110, SAB 128/163 Mk3, SAB 202

2

3

4 5

1

T0177037_0

No Application12345

Hot oil inletCooled oil outletWater inletWater outletType plate

6

6 Air purging from water side

For oil cooling with water a welded shell andtube heat exchanger of the OWSG/OWRGtype can be supplied.

Design

In principle the oil cooler consists of a cylind-rical shell with a steel tube insert.

The cooler has oil inlet and outlet branches inthe shell, whereas the water inlet and outletare positioned in one of the end covers.

The covers are made of cast iron. The tubeinsert consists of two tube plates into which anumber of tubes are welded.

Baffle plates are positioned between thetubes to extend the oil passage through thecooler, thus causing the oil to flow across the

tubes. This improves the heat transmissionfrom oil to cooling water significantly.

The end covers are designed to lead the wa-ter back and forth a number of times to en-sure adequate water velocity.

Oil cooler, type OWRG, is made of stainlesssteel and available in two versions, one forfreshwater and one for sea water. The type isindicated on the name plate.

Furthermore, the oil cooler can be fitted withend cover corrosion plugs. To ensure the oilcooler corrosion resistance, the pipes mustnever become overheated. Consequently,they must not be uncovered.

To avoid this, it is important that:

S there are no air pockets on the water side.Therefore, the oil cooler must be supplied

92 0178-145-EN

with a purge valve at the top of the coverwithout connections. This valve may beleft out if the water discharge pipe pointsupwards so that air can escape togetherwith the water.

S the water velocity through the oil cooler isnever be below 1.5 m/sec. Furthermore,the high water velocity prevents fouling inthe oil cooler.

In the fresh water versions, the content ofchloride (Cl-) in the water must not exceed400 ppm.

In the case of a chlorine treatment, if any, ofwater for the sea water version, the amountof chlorine must not exceed 0.5 mg Cl2 perlitre water for 30 min. once every 24 hrs.

Besides, the oil cooler must be drained ofwater for longer standstill periods (more than1 or 2 weeks).

ApplicationThe OWSG type oil cooler is designed forconnection to a freshwater system incorpor-ating anti-corrosion and anti-scaling meas-ures.

When operating with a cooling tower, rust in-hibitors, algicides and anti-fouling must be

added to the water according to normal prac-tice in connection with cooling tower sys-tems.

The OWRG oil cooler type is used where thequality of the water cannot be guaranteedsatisfactory and constant.

Cleaning

Fouling or soiling of the water side will re-duce the heat transfer, and hence the coolercapacity.

The cooler must therefore be checked andcleaned at regular intervals, depending onthe degree of cooling water purity. The inter-nal pipe diameter is 8 mm.

The OWSG/OWRG oil cooler can be cleanedby removing the end cover with no connec-tion branches and scrubbing the tubing cleanwith a bronze brush.

Give the tubing a final rinse with fresh water.Alternatively, ready-mixed inhibitive scouringacids can be used with subsequent neutrali-zation. Such agents must be designed foruntreated steel tube heat exchangers. Thechemical manufacturer’s instructions shouldbe followed precisely.

0178-145-EN 93

Regulating the oil temperature

Open system:

If the oil cooler is connected in an open sys-tem, i.e. it cools by means of cooling towerwater, other fresh water or sea water, the oiltemperature must not be regulated by alter-ing the water flow through the cooler.

A decreasing water flow will result in foulingand perhaps in clogged-up tubes whichwould lead to corrosion on the tubes.

Instead, the following is prescribed:

S If necessary, use a temperature-regulatedthree-way valve to regulate the oil flowthrough the cooler.

On SAB 202 the oil temperatur regulationis based on a two-way valve incl. pilotvalve. See piping diagram.

S Or use a temperature-regulated three-wayvalve on the water side in connection witha water pump to maintain the prescribedwater flow through the oil cooler.

Closed system:

OWSG

If this oil cooler is connected in a closedsystem, such as a heat recovery system, thewater flow can still be regulated.

OWRG

Only use the mentioned oil coolers for theprescribed water flow in order to minimize therisk of corrosion as a result of the combina-tion of high temperature and Cl÷ content inthe cooling water.

Therefore, we recommend the use of thesame regulating system as prescribed underOpen system.

0171-562--EN

95.10

94 0178-145-EN

Water-cooled oil cooler, type BSAB 110, SAB 128/163 Mk3, SAB 202

5 1 4

2 3

T0177038_1

No Application

1234

Hot oil inletCooled oil outletWater inletWater outlet

DesignThe type B oil cooler, is a stainless steelplate heat exchanger. A V pattern is mouldedinto each plate together with the inlet andoutlet holes. The plate heat exchanger is as-sembled by turning the V patterns alternatelyupwards and downwards. All points of con-tact between the V patterns are soldered withcopper. On each side a supporting plate issoldered. Between the supporting plate fittedwith connecting branches and the first heatexchanger plate a row of channels is visible.Check by means of a welding rod that the Vpattern faces upwards so that water will notaccumulate. The heat exchanger cannot bedismantled and must not be used in R717plants.

Application

The type B oil cooler can only be used withfreshwater as cooling agent.

For water cooling of oil in units with HFC/HCFC, a type B soldered plate heat ex-changer can be used. Refer to page 1 to seethe type of oil cooler used for this unit.

Cleaning

Since the oil cooler cannot be dismantled,mechanical cleaning is not possible. It istherefore recommended to fit the water filterbefore the oil cooler. Cleaning can only becarried out with a cleaning fluid. The cleaningintervals for the cooling water side of the heatexchanger should be determined on thebasis of the hardness of the water and itstendency to leave deposits.

For cleaning purposes a weak acid can beused, e.g. a 5% phosphoric acid or if theheat exchanger is cleaned often, a 5% oxalicacid solution. Afterwards it is necessary torinse with plenty of pure water to remove anyremaining acid and dirt.

0178-145-EN 95

Oil temperature regulation

Open system

If the oil cooler is connected in an open sys-tem, ie that it is cooled by means of waterfrom a cooling tower, other fresh water or seawater, the oil temperature must not be regu-lated by altering the water flow through thecooler.

A decreasing water flow could lead to foulingand perhaps clogged-up cooling pipes whichwould lead to corrosion on the pipes.

Instead, the following is prescribed:

S Adjust the oil flow through the cooler bymeans of the temperature-regulated three-way valve.

S Or use a temperature-regulated three-wayvalve on the water side in connection witha water pump to maintain the prescribedwater flow through the oil cooler.

Closed system

Only use the type B oil coolers for the pre-scribed water flow in order to minimize therisk of corrosion as a result of the combina-tion of high temperature and Cl÷ content inthe cooling water.

Therefore, we recommend the use of thesame regulation system as prescribed underOpen system.

0171-563-EN

97.02

96 0178-145-EN

Refrigerant-cooled oil cooler type OOSISAB 110, SAB 128/163 Mk3

1 Oil inletOil draining (oil side)Oil draining (refrigerant side)

56

23

4Oil outletRefrigerant inlet

Refrigerant outlet

1 pass

2 pass

36

63

2

1

1

4

5

5 2

4

T0177101_0/1

Construction

The oil cooler consists of a cylindrical shellwith welded-on tube plates in which iswelded a number of tubes. Each tube platehas an end plate welded in. The oil cooler isthus an assembled, all-welded construction.The end plates are provided with weldingbranches for oil connection and drainage.The shell has welding branches for refriger-ant connection, and for draining oil when op-erating with the R717.

Function

Oil flows through the tubes, which are de-signed for extremely efficient heat transferbetween oil and tube walls.

For cooling of the oil, liquid refrigerant fromthe system receiver or a special priority tankis fed to the oil cooler. The refrigerant partlyevaporates on the outside of the tubes, andthe mixture of liquid and gas is piped to thecondenser.

The receiver or priority tank is normally posi-tioned at a suitable height above the oil cool-er, thus supplying adequate refrigerant bynatural circulation. Alternatively, a pump canbe used to effect refrigerant supply.

CleaningSince both the oil side and the refrigerantside of the oil cooler form part of closed sys-tems, no cleaning will be required.

0178-277-EN

98.05

0178-145-EN 97

Oil temperature regulating systemSAB 110, 128, 163, 202 and VMY 536

In above screw compressor units, in whichthe oil system is cooled by means of either arefrigerant-cooled oil cooler type OOSI or awater-cooled oil cooler type OWSG, the oiltemperature is usually regulated by a ther-mostatic three-way valve as illustrated infig. 1.

Fig.1

A

This thermostatic three-way valve is used inthe following dimensions for above-mentio-ned compressor units:

Compres-sor unit

Valvedimension

Weldedconnection

SAB 110 RT3 DN 25

SAB 128 RT3 DN 25

SAB 163 RT5 DN 40

SAB 202 RT6 DN 50

SAB 330 RT6 DN 50

VMY 536 RT6 DN 50

The valve dimension can be read from thenameplate on the valve cover.

Function

Valve pos. 46 is fitted in a bypass piping sys-tem as shown in fig. 2:

Fig. 2To the compressor

Oil cooler

From oil receiver

Three-wayvalve

As shown in fig. 3 and 4, it works by letting abuilt-in thermo element, pos. 1, regulate acone, pos. 2, so that cold and warm oil ismixed to the set temperature.

In fig. 3 the thermo element is shown in itscold position, i.e. the flow of cold oil has beenshut off whereas the flow of warm oil is com-pletely unobstructed. Fig. 4 illustrates the op-posite situation in which the thermo elementis in its warm position, hereby shutting off theflow of warm oil.

98 0178-145-EN

During operation the thermo element will ad-just the regulating cone modulatingly so thatthe two oil flows are mixed to the set oil tem-

perature, leaving the valve through connect-ing branch A.

Fig. 3 Fig. 4

BVarm oilfrom oilseparator

C

A

B

A

Cooledoil fromoil cooler

Oil withcorrectmixed temp.

Thermo element in cold position Thermo element in warm position

C

2

1

�

�

Varm oilfrom oilreceiver Cooled

oil fromoil cooler

The thermo element is factory set to maintaina mixed oil temperature of 48�C, allowing fora few degrees’ deviation and it cannot bereadjusted.

Service:

As a rule, it is not necessary to dismantle awell-functioning three-way valve as it doesnot contain any gaskets or wearing parts thatmust be replaced at fixed intervals.

Dismantling:

During dismantling, if any, apply the followingprocedure:

S After the pressure in the piping systemhas been equalized to atmospheric, un-screw the four Allen screws that keep thecover fixed to the valve housing.

S The cover which reaches down into thevalve housing in order to keep the thermoelement in a fixed position, is most easilydismantlled by turning it slightly and then

lift it up by means of a big screwdriver.Watch out ! There may still be oil in thesystem.

S The thermo element can now be extractedfrom the valve housing by hand.

Assembling:

Assembling the valve is done in the reverseorder and attention should be paid to the fol-lowing:

S The O-ring, fitted in the cover, should bereplaced by a new one. See section SpareParts Survey in this manual.

S No sealing ring should be fitted betweenthe inner guideway of the cover and thevalve cone.

S In case the three-way valve does not reg-ulate the oil temperature correctly, thethermo element and cone can be replacedas one entire unit. See section SpareParts Survey in this manual.

0178-137-EN

92.11

0178-145-EN 99

Injection of refrigerant into compressor HLI(High-stage Liquid Injection) SAB 110

FunctionDuring compression of refrigerant vapoursfrom evaporator pressure to condensingpressure, some heat is generated that mustbe dissipated in order to keep gas and oiltemperatures at a suitable level. This is doneby injecting liquid refrigerant from the receiv-er into the compressor at a suitable stage inthe compression process, controlled by amodulating injection valve type TEAT. Theliquid refrigerant evaporates in the hot mix-ture of oil and refrigerant gas, whereby themixture is cooled.

HLI

T4840097_0

96

Eco.97

Size of injection valve and temperature rangeof thermo couple have been chosen on thebasis of evaporation temperature of refriger-ant, condensing temperature and cooling re-quirements as specified in order.

The thermo couple, measuring discharge gastemperature at inlet to oil separator, is avail-able in 2 different versions with workingareas: A: 35--65�C

B: 55--95�C

Sensor type A is always used for refrigerantR717. For refrigerant R22, both thermo ele-

ments can be used, provided that:Type A is used up to and including

TC = 35�CType B is used above

TC = 35�C

An economiser can be connected to the com-pressor. An economiser is a heat exchangercooling liquid from receiver to plant. A minorpart of the liquid will evaporate and besucked to compressor gate no. 97.

The liquid supply to the HLI--system must betaken from a place in the plant in which re-frigerant is always sure to be found. In thisway cooling of compressor is ensured!

AdjustmentThe injection valve is factory opening tem-perature in the middle of the temperaturearea of the thermo couple.

Before starting compressor, adjust openingtemperature of injection valve to:

20�C lower than the desired discharge gastemperature.

See Diagram for Adjusting Values and Dan-foss Instructions for setting the injectionvalve.

Fine adjust the valve once the instalation is instable operation.

By HLI operation, there is normally a thinfoam layer on the oil in oil separator. Heavyfoaming may be a sign of excessive liquidsupply in which case it must be checked thatthe discharge gas temperature is not too lowin relation to condensing temperature!See Adjustment Diagram.

0171-566-EN

95.10

100 0178-145-EN

Safety and monitoring devicesSAB 110, SAB 128/163 Mk3, SAB 202, SAB 283L/283E

Compressor units with relay control or termi-nal strip for remote control are normallyequipped with the following instruments forsafety and operating control, depending onthe specific order.

Safety devices

Pos. 28 Safety valve on oil separatorwith exhaust to the atmosphere.The exhaust line must be routedfrom the engine room out intothe open air.

The SAB 110 compressor has abuilt-in by-pass safety valvewhich, in case of too high differ-ential pressure across compres-sor, will lead gas from the oilseparator to the compressorsuction chamber. The openingpressure the of safety valve isindicated on its name plate.

Pos. 43 Flow control in the oil distributorpipe. A spherical float with apermanent built-in magnet isable to actuate a reed switch inthe float guide. The switch is wi-red up to a timing relay whichwill stop the compressor if theflow control chamber is not filledwith oil within max. 50+10 sec.after start-up, or after 10 sec.without oil during normal opera-tion.

Pos. PAZ1 Pressure cut-out KP1, whichstops the compressor in theevent of the suction pressurefalling below the set value. The

pressure cut-out is not equippedwith a reset, so the compressorstarts again when the pressurehas risen above the differencebetween the setpoints of thepressure cut-out.

Pos. PAZ2 High pressure cut-out KP5. Thepressure cut-out is intended tosafeguard the compressoragainst excessive dischargepressure.

Note: On units to be approved by TÜV(Germany), the KP5 is replacedby a pressure cut-out KP 7ABSwhich has been approved byTÜV. This high pressure cut-outwill stop the compressor in theevent of damage to the cut-outbellow or excessively high dis-charge pressure.

Pos. PDAZ 11 Differential oil pressure cut-out MP55. This pressure cut-outis designed to ensure sufficientlubricating pressure and oilpressure for capacity regulation.The pressure cut-out is equip-ped with a time lag of 45 secs.If the preset differential pressurehas not been obtained by thattime, the compressor will stop.The MP55 is equipped withmanual reset.

Pos. 0376-A12Differential pressure cut-out forcontrol of pressure drop acrossoil filter. If pressure drop acrossoil filter becomes excenssive

0178-145-EN 101

due to impurities, the pressurecut-out will stop the compressorand a pilot lamp will light. Futh-er, the differential pressure cut-out contains a visual indicationof presure drop represented bya green field for permissiblepressure drop and a red field in-dicating excenssive a pressuredrop across oil filter in whichcase the pressure cut-out willstop the compressor.

Pos. TAZ12 Thermostat KP79 with sensor inoil flow control. Designed to sa-feguard against excessive oiltemperature.

Pos. TAZ13 Thermostat KP79 or KP81 withsensor in oil separator.Designed to safeguard againstexcessive discharge gas tempe-rature.

Pos. TC14 Thermostat KP77 with sensor inoil separator. Designed to safe-guard against too low discharge

pipe temperature and hence toolow oil temperature in connec-tion with HLI oil cooling.

Please see section on setting of safety devi-ces for various values.

Monitoring devicesPos. PI15 Suction pressure gauge

(evaporator pressure)

Pos. PI16 Discharge pressure gauge (con-denser/intermediate pressure)

Pos. TI5 Thermometer in oil separator(discharge gas temperature)

Pos. TI6 Thermometer in oil flow control(oil temperature)

Pos. TI7 Thermometer with sensor insuction pipe. Supplied as extra.Used to calculate superheat ofthe suction gas. Superheat isthe temperature differencefound by deducting the tempera-ture read off the suction pressu-re gauge from the temperatureread off the thermometer.

0171-464-EN

94.05

102 0178-145-EN

Refrigeration Plant Maintenance

Operational reliability

The prime causes of operating malfunctionsto the plant are:

1. Incorrect control of liquid supply to theevaporator.

2. Moisture in the plant.

3. Air in the plant.

4. Anti-freezing liquid is missing.

5. Congestion due to metal shavings anddirt.

6. Congestion due to iron oxides.

7. Congestion due to copper oxides.

8. Inadequate refrigerant charge.

Below, some information is given about waysof keeping contaminants out of the refrigera-ting system and at the same time facilitatingday-to-day supervision of the refrigerationplant.

Pumping down the refrigerationplant

Before dismantling any parts of the refrigera-tion plant for inspection or repair, pump-downmust be carried out.

1. Open suction and discharge stop valveson compressor.

2. Close liquid stop valve after condenser orreceiver so that liquid refrigerant can becollected in the tank. Any solenoid valvesin the liquid line should be opened byforce, adjusting the thermostat to its low-est position so that the liquid line can be

bled of refrigerant. Adjust any constant-pressure valves to bring evaporator pres-sure down to atmospheric.

3. Start up the compressor. Adjust regulat-ing system to lower suction pressure.

4. Keep a close eye on the suction pres-sure gauge!When the suction pressure isequal to atmospheric, stop the compres-sor and quickly shut off the discharge stopvalve. Shut off any stop valve in the oil re-turn line.

If the receiver has an extra stop valve inthe feed line, this can be closed; practical-ly the entire refrigerant charge will thenremain shut off in the receiver.

Note:The receiver must not be overfilled! Thereshould be a minimum gas volume of 5%.

5. A slight overpressure should normally re-main in the piping system - this safe-guards the system against the penetrationof air and moisture.

6. Before dismantling parts, the operatorshould put a gas mask on.

Dismantling plant

In order to prevent moisture penetrating intothe refrigeration plant during any repair work,it is advisable to follow the rules below:

1. No component should be opened un-necessarily.

2. When dismantling the system, the pres-sure in the system should be a little higherthan atmospheric.

0178-145-EN 103

3. Note:If the piping system is colder than the sur-roundings, there is a considerable risk ofdamp precipitation (condensation) on coldplant parts. Plant components to be dis-mantled must be warmer than the ambi-ent temperature.

4. No two points in the system should beopened at the same time.

5. Plug, close or at least cover opening withoiled paper or suchlike.

6. Be aware of the possibility of filtersbeing very moist.

Tightness testing and pump-downof refrigeration plantBefore charging refrigerant into that part ofthe refrigeration plant which has beenopened, this should be pressure-tested asdescribed in the section entitled Pressuretesting.

Afterwards, pump down in order to eliminateair and moisture. In this regard, consult thesection on Evacuation.Otherwise, follow the instructions given in theseparate instruction manual on plant compo-nents.

Note:If the oil in the crankcase of the pistoncompressor or the oil separator of thescrew compressor has been in contactwith the atmospheric air for any length oftime, it must be replaced with fresh oil ofthe same grade and make.

0171-627--EN

95.01

104 0178-145-EN

Troubleshooting on the Screw Compressor Plant

Operating condition

Experience shows that pressure and temper-ature variations in a refrigerant system canprovide information about the operating con-dition of the refrigeration plant.

In particular, suction and condenser pres-sures as well as the temperatures of suctionand discharge gases may provide importantinformation as to the operating conditions ofthe plant.

Considerable changes in operating condi-tions can often be produced by only veryslight modifications to variable pressures andtemperatures.

Using the following troubleshooting chart, it ispossible to ascertain the cause of and reme-dy for any operating disturbance.

Using the troubleshooting chartIn the following chart each individual errorpossibility is indicated by a code number inthe left hand column, with the error brieflydescribed in the second column. The thirdcolumn states code numbers for the possiblecauses of the error.

The code numbers refer to the subsequentchart. The section entitled Remedying mal-functions states how to remedy the observederror. See the following example for the cor-rect procedure.

ExampleObserved error: “excessive suctionpressure” - error code 5.Cause codes: 2. (compressor lacks capac-ity) and 48. (safety valve leaky or opens pre-maturely).The entry keys to the subsequentsection are therefore (5,2) and (5,48).

FaultCode

Observed Fault Probable causes

1 Excessive suction pressure 2, 28, 48, 49.2 Suction temperature is too low 31, 32.3 Suction pressure is too low 1, 14, 27, 28, 29, 30, 33, 40, 42.

4 Compressor starts and stops too frequently, atlow-pressure cut-out 1, 14, 27, 28, 29, 30, 33, 39, 42, 49.

5 Excessive suction pressure 2, 48.6 Compressor starts and stops too frequently, at

high-pressure cut-out 38, 41, 43, 44.

7 Excessive condensing pressure 22, 23, 24, 26, 38, 41, 43, 44.8 Condensing pressure too low 2, 22, 23, 24, 26.9 Oil pressure too low 5, 11, 25, 31, 32.

10 Oil temperature too high 13, 18, 19, 20, 37, 48.11 Oil temperature too low 21, 50.12 Excessive pressure drop across oil filter 19.

13 Excessive capacity -- aut. controls out of order 3, 4, 12.14 Insufficient capacity -- aut. controls out of order 3, 4.15 Oil level in the reservoir falls 15, 16, 17.

16 Oil foams vigorously during standstill 31, 32.17 Oil reservoir sweating during standstill 47, 50.18 Abnormal noise from compressor 5, 7, 8, 9, 10, 31, 32, 48, 52.

19 Compressor motor will not start 6, 12, 13, 19, 34, 35, 36, 40, 41, 45, 46, 4720 Compressor runs continuously 2, 3, 4, 42, 48, 49.21 Liquid in the suction line 1, 31, 32.

0178-145-EN 105

1 Compressor has excessive capacity2 Compressor lacks capacity3 Solenoid valve in regulating system

fails to open4 Timer or other automatic control out

of order5 Excessive capacity during

decrease in temperature

6 Capacity regulation not set to 0%7 Loose foundation bolts8 Misalignment of motor and

compressor9 Friction between rotors and housing

or defective bearings10 Loose bolts in coupling

11 Oil pressure regulating valve set toolow

12 Oil pump out of order13 Oil too hot - oil thermostat cut out14 Too much oil circulating in system

(evaporators)15 Filter in solenoid valve in oil-return

line clogged

16 Solenoid valve in oil return out oforder

17 During initial start-up, some of theoil will be led out into the plant

18 A valve in the oil line is beingthrottled

19 Oil filter clogged20 Insufficient water through oil cooler

21 Excessive oil cooling - oil too cold22 Insufficient water or air through

condenser23 Condenser tubing clogged by

sludge or scale24 Cooling water too hot25 Too much water through condenser

26 Water filter clogged27 Filter before valve in liquid or

suction line clogged28 Excessive suction gas superheating29 Freezing-up of thermostatic

expansion valve30 Thermostatic expansion valve has

lost its charge

31 Excess flow through expansionvalve (liquid in suction line)

32 Loose or misplaced sensor33 Solenoid valve in liquid or suction

line not opening34 Oil filter needs cleaning - pressure

cut-out has cut35 Oil pressure too low - pressure

cut-out has cut

36 Oil too hot - oil thermostat has cut37 Oil thermostat set too high38 High-pressure cut-out set too low39 Low-pressure cut-out set too high40 Low-pressure cut-out shut off

41 High-pressure cut-out shut off42 Insufficient charge in plant43 Too much charge in plant44 Air or non-condensable gases in

system45 Fuses blown

46 Thermal relay reset47 Main switch interrupted48 Safety valve leaky or opening

prematurely49 Evaporator soiled or iced up50 Heating element blown52 Liquid in suction line

Code CodeCause Cause

106 0178-145-EN

Remedying Malfunctions

1. Excessive suction temperature

1.2 Inadequate capacity Increase capacity

Safety valve leaky or opening pre-maturely

Check condenser pressure and adjust or repairsafety valve

1.28 Excessive superheating of suctiongas

Check and regulate thermostatic valves on eva-porators

1.48

2. Suction temperature too low

2.31 Liquid in suction line Regulate expansion valves or float valves

2.32 Loose or misplaced sensor Check whether sensors are making good contactwith suction pipe and whether correctly posi-tioned

3. Suction pressure is too low

3.1 Excessive capacity Reduce compressor capacity

3.14 Too much oil in evaporators Draw oil off evaporators

3.27 Filter in liquid line clogged Examine and clean filters in the liquid lines

3.28 Excessive superheating of suctiongas

Regulate expansion valves

3.29 Freezing in thermostatic expan-sion valve

De-ice thermostatic expansion valve with hot wetcloths and run the liquid from the receiverthrough the drying filter

Note:Never add methanol to the system to avoidfreezing, as this will give rise to corrosion andchemical attacks in compressor, etc.

3.42 Insufficient charge Charge more refrigerant into the plant

3.30 Thermostatic expansion valve haslost its charge

Valve fails to open - change the valve

3.33 Solenoid valve in liquid or suctionline not opening

Coil may have blown - change the coil

0178-145-EN 107

4. Compressor starts and stops too frequently at low-pressure cut-out

See point 3.14.1

4.14 See point 3.14

4.27 See point 3.27

4.28 See point 3.28

4.29 See point 3.29

4.30 See point 3.30

4.33 See point 3.33

4.39 Low-pressure cut-out set too high Adjust pressure cut-out

4.42 See point 3.42

4.49 Evaporator soiled or iced up Clean or defrost evaporator

5. Excessive suction pressure

5.2 Compressor lacks capacity Regulate compressor capacity

5.48 Safety valve leaky or opening pre-maturely

Adjust or repair valve

6. Compressor starts and stops too frequently at high-pressure cut-out

See point 7

7. Excessive condensing pressure

7.22 Insufficient water or air throughcondenser

Regulate water supply or clean condenser

7.23 Condenser tubing clogged bysludge or scale

Clean condenser tubing

7.24 Cooling water too hot Procure colder cooling water or reduce compres-sor capacity

108 0178-145-EN

7.26 Water filter clogged Clean water filter

7.38 High-pressure cut-out set too low Adjust pressure cut-out

7.43 Too much charge in plant Draw fluid off into empty vessel

7.44 Air or non-condensable gases insystem

Blow air out at condenser

8. Condensing pressure too low

8.2 Compressor lacks capacity Check whether compressor capacity corres-ponds to load on plant. Regulate water supply tocondenser.

8.25 Too much water through conden-ser

Adjust water supply

9. Oil pressure too low

9.5 Excessive capacity duringdecrease in temperature

Excessive capacity during temperature decrase(run-down) may result in liquid being suckedalong in suction line. This liquid may cause theoil in the oil reservoir to foam vigorously so thatthe oil pressure drops, thus stopping the ma-chine. Before restarting, check whether there isliquid in the oil reservoir.

This liquid must be boiled off using a heatingelement or by heating the oil reservoir with hotwater or steam. The plant must therefore be run-down at reduced capacity.

9.11 Oil pressure regulator set too low The regulator is set to the 2.5 kp/cm prescribedby the manufacturer, but must be checked duringoperations.

9.31 Excess flow through expansionvalve (liquid in suction line)

See comments under point 9.5

9.32 Loose or misplaced sensor Loose sensor on expansion valve may causeliquid throughflow to suction line - see also com-ments under point 9.5.

0178-145-EN 109

10. Oil temperature too high

10.13 Thermostat cut out See section Pressure and temperature settingsfor setpoint.. The reason for the oil overheatingmust be found in the following points

10.18 A valve in the oil line is beingthrottled

Check whether all valves are open

10.20 Insufficient water or refrigerantthrough oil cooler

Check whether valves are open or whetherwater filter or oil cooler need cleaning


Adjust or repair valve

11. Oil temperature too low

11.21 Excessive cooling of oil Regulate oil cooling

11.50 Heating element in oil reservoirout of order

Change heating element

12. Excessive pressure drop across oil filter

12.19 Oil filter clogged Change filter element

13. Excessive capacity - automatic controls out of order

13.3 Solenoid valve in regulating sys-tem fails to open

Change valve or coil

13.4 Timer or other automatic controlout of order

Change or fix

13.12 Auxiliary pump out of order When the compressor stops, the auxiliary pumpmust ensure capacity regulation is set to 0% ca-pacity so that the compressor is ready for re-starting.

Check whether the pump is being energized orwhether pump or motor is out of order.

14. Insufficient capacity - automatic controls out of order

14.3 See point 13.3

14.4 See point 13.4

110 0178-145-EN

15. Oil level in the reservoir falls

15.15 Filter for solenoid valve in oil-re-turn line clogged

Clean filter

15.16 Solenoid valve in oil return out oforder

The oil return line must be hot during operation.

15.17 During initial start-up, some of theoil will be let out into the plant

On HCFC plants, particularly, some of the oil willcirculate in the plant.

When the system is balanced, top up with oil, ifnecessary.

16. Oil foaming vigorously during standstill

16.31 Excess flow through expansionvalve (liquid in suction line)

Check expansion valve

16.32 Loose or misplaced sensor Check sensor positioning

17. Oil reservoir sweating during standstill

17.47 Main switch interrupted If the compressor is stopped and the current in-terrupted at the main switch, any refrigerant inthe oil reservoir will evaporate. As the heatingelement in the oil reservoir has also been cut off,the heat needed for evaporation must be takenfrom the surroundings. The oil will therefore govery cold and will require heating up before re-starting.

17.50 Heating element blown See point 17.47

0178-145-EN 111

18. Abnormal noise from compressor

If any abnormal noise is coming from the compressor, the machine must be stopped immediately,and the cause pinpointed and remedied before restarting.

18.5 Excessive capacity duringrun-down

Excessive capacity during run-down may resultin liquid being sucked along into the compressorsuction line. Therefore, operate at reduced capa-city during run-down.

18.48 Safety valve opens Check opening pressure of safety valve

18.7 Loose foundation bolts Tighten bolts

18.8 Misalignment of motor and com-pressor

Adjust alignment

18.9 Friction between rotors.Friction between rotors anddefective bearings

Do not start the compressor. Open and repair.

18.10 Loose bolts in coupling Stop compressor and tighten bolts

18.31 Liquid in suction line Check and adjust the valves with excessthroughflow

18.32 Loose or misplaced sensor Check sensor positioning

19. Compressor motor will not start

19.6 Capacity regulation not set to 0% See under points 13.3-13.4 and 13.12

19.46 Thermal relay has interrupted Check cause of overloading

19.12 Auxiliary pump out of order See under point 13.12

19.13 Excessive oil temperature See under point 10

19.19 Oil filter clogged Clean oil filter. Reset pressure cut-out

19.34 Differential oil pressure cut-outhas cut

Clean oil filter. Reset pressure cut-out

19.35 Oil pressure too low See under point 9

19.36 Oil too hot See under point 10

19.40 Low-pressure cut-out interrupted The compressor will restart after a rise in suctionpressure sufficient to re-activate the pressurecut-out - see point 3 also.

19.41 High-pressure cut-out interrupted See under point 7

19.45 Fuses blown Check cause and change fuses

19.47 Main switch interrupted Switch power on

112 0178-145-EN

20. Compressor runs continuously

20.49 Evaporator soiled or iced up Clean or defrost evaporators

20.2 Compressor lacks capacity See under point 14

20.3 Solenoid valve in capacity regula-ting system fails to open

See under point 13.3

20.4 Timer or other automatic controlout of order

See under point 13.4

20.42 Insufficient charge on plant Top plant up with refrigerant


See point 10.48

21. Liquid in suction line

21.1 Compressor has excessive capa-city

Reduce capacity

21.31 Excess flow through expansionvalve

Adjust expansion valve

21.32 Loose or misplaced sensor for ex-pansion valve

Check sensor positioning and rectify

0170-151--EN

00.06

0178-145-EN 113

Selecting Lubricating Oil for SABROE Compressors

During the past few years YORKRefrigeration has experienced a number ofproblems with mineral oils, particularly inR717 plants. The problems can be dividedinto two groups:

a: The oil changes viscosityb: The oil decomposes (becomes very black)

The problems have been seen with severalmineral oil brands, often occuring within afew operating hours and resulting in severeconsequences for both compressor andplants.

Following the careful investigation undertak-en by YORK Refrigeration during the pastfew years, it has been decided to introduce arange of synthetic oils which can fulfil the de-mands of modern refrigeration plants.

Mineral oils may continue to be used in re-frigeration plants, providing the lubricatingquality is carefully monitored. For modern,high capacity refrigeration plants, where longlifetime for both lubricants and moving partsis expected, YORK Refrigeration recom-mends the choice of synthetic lubricating oils.

The application areas and specifications forthese synthetic oils can be found in the fol-lowing pages. Installers and/or users are atliberty to choose either YORK Refrigeration’sown or alternative oil brands which fulfil thenecessary specifications.

General

This recommendation only deals with the lu-brication of the compressor. The perfor-mance of the lubricant in the plant (receiver,evaporator, etc.) must, however, also be tak-en into consideration.

Lubricating oils with relatively high viscositiesmust be used to ensure satisfactory lubrica-tion of refrigeration compressors.

To obtain the best lubrication, the oil must:

S Provide the required fluidity at the lowestevaporating temperature encountered inthe plant and at the highest permissibletemperatures in the compressors.

S Provide acceptable fluidity at start-up.

S Provide sufficient oxidation stability (the oilmust be moisture-free when added to thesystem).

S Provide sufficient chemical stability whenused together with the particular refriger-ant.

In addition, the extent to which different re-frigerants dissolve in the oil must be deter-mined, so that the oil return systems, etc. canbe designed to function properly.

Stratification

It should be noted that in certain plants, par-ticularly with HFC and HCFC refrigerants, theoil may stratify into layers in the refrigerantreceivers and evaporators at certain operat-ing conditions and at particular oil concentra-tions.

The Oil recommendation diagrams forSABROE compressors for HFC and HCFCwill indicate the limits for Sabroe oils at whichthis stratification occurs. The oil concentra-tions stated in these diagrams must not beexceeded. This will enable suitable oil rectifi-cation/return systems to be designed to bal-ance with the compressor oil ”carry-over” sothat the maximum concentration is not ex-ceeded.For area A in the diagrams, the max oil con-centration in liquid phase must not exceed

114 0178-145-EN

2%. For the other area, the max. oil con-centration must not exceed 5%. For area B:please contact YORK Refrigeration.

Plants with several different compressortypes/makes

In plants comprising several different inter-connected compressor types and makes, it isstrongly recommended that all compressorsshould use the same type of oil. This is es-sential where automatic oil return systemsare employed.

If it is intended to change the oil from onetype to another, please refer to the Oil chang-ing on SABROE compressors later in thispublication.

Selecting the lubricating oil

There are a number of operating diagramsfor the selection of lubricating oils for Sabroecompressors operating with various refriger-ants. Once the general conditions concern-ing the lubrication of the compressor and oiltype in the plant have been considered, thespecific plant conditions must be takeninto consideration.

Use the Oil recommendation diagrams to se-lect the appropriate oil code number.

The oil code number consists of letters des-ignating the oil type together with the Sabroeviscosity grade number.

Codedesign

Oil types

M Mineral oil

A Synthetic oil based onAlkylbenzene

PAO Synthetic oils based onPolyalphaolefin

AP Mixture of A and PAO-oils

E Synthetic ester-based lubricants

In the oil recommendation diagrams for eachrefrigerant and compressor type, it is pos-

sible to determine the code number for theoil best suited to the operating conditions.With this code number, it is possible to se-lect the correct Sabroe oil for the application.The marked area on each side of the sepa-rating line in the diagram shows the zonewhere both oils are useable.

Oil types and oil companiesAs a result of the large number of oil compa-nies world-wide that deals in oil for refrigera-tion plants, it is impossible for YORKRefrigeration to test the many differentbrands of oil on the market. It is our experi-ence, however, that some oil brands duringuse can change character and thus no longerfit the specifications given by the companiesat delivery. We have thus experiencedchanges in the specifications as well as inthe formula and performance without havinghad any information about this from the oilcompany. This makes it very difficult forYORK Refrigeration to give a general ap-proval of the various oil brands.

For this reason YORK Refrigeration has, incooperation with a large recognised oil com-pany, developed a series of three oils whichcover most purposes. YORK Refrigerationhas however, also listed a limited number ofoils which can be supplied through YORKRefrigeration. The typical data of these oilscan be found in the Data Sheet for SabroeOils. We suggest you to use these Sabroeoils, which are delivered in 20 litre pails and208 litre drums and can be ordered using theparts no. listed in the List of Oils.

It is of course possible to use similar oils fromother oil companies, and in this connection,the Data Sheet for Sabroe Oils may be help-ful.

0178-145-EN 115

Please note, however, that YORKRefrigeration has not tested any other oilsthan our own brand, and hence we cannotanswer for the quality, the stability or the suit-ability of other oils for any purposes. The oilcompany in question is thus solely responsi-ble for the quality and suitability of the oil de-livered, and if any problems are experiencedwith these oils in the compressors or in therefrigeration plant, the oil supplier should becontacted directly.

When choosing oils from other oil compa-nies, please pay particular attention to theoil’s effectiveness in the compressor and therefrigeration plant as a whole.

Pay particular attention to the following as-pects:

S Oil type

S Refrigerant type

S Compressor type

S Miscibility between refrigerant and oil

S Operating data for the compressor

� Discharge gas temperature

� Oil temperatures:

Reciprocating compressors:

Normal oil temp. in the crankcase50-60 �C

Max. permitted oil temperature = Set-ting point for alarm

Min. permitted oil temperatures = set-ting point for alarm - if fitted

Screw compressors:

The oil temperature before injection inthe compressor, but after the oil cooler

Max. permitted oil temperature = set-ting point for alarm

Min. permitted oil temperature = set-ting point for alarm

� Condensing pressure

� Evaporating pressure

S Oil viscosity in the compressor duringoperation and under the influence of:

� Refrigerant type and solubility of refrig-erant in the oil

� Operating temperatures

� Vapour pressure in the oil reservoir

Reciprocating compressor: Suctionpressure and oil temperature in thecrankcase.

Screw compressor: Discharge pressureand gas temperature.

S Compatibility with the neoprene O-rings:the aniline point gives an indication of howthe O-ring material reacts to the oil.At an aniline point less than approximately100�C the material tends to swell, and atan aniline point higher than approximately120�C it tends to shrink.

For this reason it is not recommended tochange oil type from M oil to PAO oil as aleakage may occur if the O-rings are notchanged. YORK Refrigeration thereforerecommends using the Sabroe AP68 oilas it reduces the risk of leaks considerablyin this case.

116 0178-145-EN

YORK Refrigeration can supply a calculationshowing the operating data on request.

Attention is drawn to the following viscositylimits during operation:

S Optimum viscosity range(to be designed for) = 20 to 50 cSt

S Max. permissible viscosity =100 cSt

S Min. permissible viscosity =10 cSt(only applicable to HCFC and HFC undercartain operating conditions: 7cSt)

S Max. permissible viscosity during thestarting of the compressor = 500 cSt

Maximum refrigerant concentration in the oilat running condition: 25% - also if viscosityrequirements are met.

Use of mineral oil

Lately we have experienced a number ofproblems with mineral oil, particularly in R717plants. The problems can be divided into twogroups:

a: The oil changes viscosity within a fewoperating hours.

b: The oil decomposes (becomes veryblack) within a few operating hours.

The problems have been seen with severaloil brands and have resulted in severe con-sequences for both compressors and plants.

When using mineral oil, it is thus importantthat the plant is monitored very closely, thatoil samples are taken regularly (every1-2,000 hours) and that the condition/colourof the oil is checked on a weekly basis.

YORK Refrigeration therefore recom-mends only to use M oil at moderate oper-ating conditions - cf. the attached oil rec-ommendation diagrams.

YORK Refrigeration is aware, however, thatseveral customers have been using mineraloils for many years without problems. Thosecustomers who wish to continue using miner-al oils in existing, as well as new, compres-sors can do so, providing the compressortype and operating conditions are similar tothe existing ones (excepting the HPC andHPO series compressors).

YORK Refrigeration has therefore decided tomarket a brand of mineral oil which has beentested and found to be suitable for most gen-eral refrigerating purposes.

If another brand of mineral oil is chosen, thespecifications in the data sheet in this recom-mendation should be followed as a guideline.

Mineral oil can be used in refrigeratingplants, providing the lubricating quality iscarefully monitored. For modern, high capac-ity refrigeration plants, in which a long life-time for both lubricant and moving parts isexpected, YORK Refrigeration recommendsusing synthetic lubricating oils.

A benefit of using the synthetic lubricant oil isa much lower oil carry-over to the plant andlonger intervals between oil changes.A better fluidity at lower temperatures alsogives an easier drainage at the cold parts ofthe plant.

How to use the oil recommendation dia-grams:

To determine the code number, first refer tothe Oil recommendation diagram for the re-frigerant and compressor type and then plotthe proposed operating conditions.

0178-145-EN 117

Example (recip. compressors):Refrigerant: R134aCondensing temp. TC +35�CEvaporating temp. TE --3�C

Please observe !Plants may operate at different conditionsfrom time to time, for example at differentevaporating temperatures due to plantvariations or at different condensing tem-peratures due to seasonal changes.By plotting TC and TE in the oil recom-mendation diagram, this example wouldrequire a No 1 oil. If, however, TEchanges at certain times, e.g. from --3 to+7�C, a No 2 oil should be utilised. But, as+7�C is inside the marked area, the No 1oil can be utilised also at this TE.



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R134a

By referring to the Oil recommendation tableplaced at the bottom of each oil recommen-dation diagram, it is possible to select thecode number for the appropriate oil type. In

the example above, a oil code number E5can be selected.

E5 Y

E9 Y

1 2

Code no Area no

In plants which incorporate both screw andreciprocating compressors and where therecommendations indicate the use of differ-ent oil types, please contact YORKRefrigeration for advice.

Changing oil on Sabroe compressors

The oil should never be changed to anothertype without consulting the oil supplier. Nor isit advisable to ”top up” compressors with another oil than the one already used for theparticular plant and compressor.

Mixing different oils may result in operatingproblems in the refrigerant plant and damageto the compressors. Incompatibility betweenthe different oil types may degrade the lubri-cating properties or may cause oil residues toform in the compressor or oil separator or inthe plant. These oil residues can block filtersand damage the moving parts in the com-pressor.

Furthermore, changing the oil from one typeor make to another should only be undertak-en in connection with a careful procedure in-volving the drainage and thorough evacua-tion of the refrigeration plant. Information ona suitable procedure can be obtained fromYORK Refrigeration as well as from a num-ber of oil companies.

118 0178-145-EN

It is imperative that oil is only used from theoriginal container and that both the make andtype complies with the specification for theplant.

Ensure that the original container is sealedduring storage to prevent moisture from theair being absorbed into the oil - many oils,particulary the polyolester oils, are extremelyhygroscopic. Consequently, it is recom-mended that the oil is only purchased in con-tainers corresponding to the amount to beused on each occasion.

If the oil is only partially used, make sure thatit is effectively re-sealed in the original con-tainer and that it is stored in a warm, dryplace. Ideally with nitrogen blanking of the oilto keep the water content below 50 ppm.

Oil drums should, ideally, be ”racked” andmounted with a proper barrel tap to ensurean effective airtight seal.

Oil changing intervals

A list of the recommended intervals forchanging the oil can be found in the com-pressor instruction manual. These are pro-vided for guidance only. The actual intervalbetween oil changes will often be determinedby a variety of operating parameters withinthe plant.

It is strongly recommended to monitor thequality of the oil by carrying out oil analyseswith regular intervals. This will also give agood indication of the condition of the plant.The service can be supplied by YORKRefrigeration or the oil suppliers.

Oil recommendation diagram symbols:

Y : In case of a new plant. Very suitable.

l : In case you wish to change from mineral oil: Max oil concentration in liquid phase at: TE: 2% W

: Max oil concentration in liquid phase: contact YORK Refrigeration: Min suction temperature --50�C: at TE< --50�C superheating must be introduced.

* : Dry expansion systems only. Flooded systems to be considered individually: contact YORK Refrigeration

SH : Suction gas superheat, K (Kelvin)

: Zone in which both oils are useable: Calculation must be performed using COMP1

A

B

C

0178-145-EN 119

Data Sheet for Listed Sabroe OilsTypical data for lubricating oils for Sabroe compressors

Sabroe Viscosity Viscosity Spec. Flash p. Pour p. Anilin Acid no.

code cSt40�C

cSt100�C

Index grav. at15�C

COC�C

�C �Cpoint

mgKOH/g

M1 63 6.4 14 0.91 202 --36 81 0.02

A3 97 8.1 13 0.86 206 --32 78 0.05

AP1 64 9.3 121 0.858 195 --51 121 0.04

PAO3 66 10.1 136 0.835 266 <--45 138 0.03

PAO5 94 13.7 147 0.838 255 <--45 144 0.03

PAO9 208 25 149 0.846 260 <--39 154 0.03

E3Due to the big difference between polyolester-based lubricants from various suppliers it is

E5Due to the big difference between polyolester-based lubricants from various suppliers, it isnot possible to present typical data for these oils. When using another oil brand than the one

E9p p yp g

recommended by YORK Refrigeration, please contact the oil supplier to select the correctoil type

E11oil type.

The listed data are typical values and are intended as a guideline only when selecting a similaroil from a different oil company. Data equivalence alone does not necessarily qualify the oil foruse in YORK Refrigeration’s Sabroe compressors.

120 0178-145-EN

List of part numbers for available Sabroe oils

Oil brand Oil code noPart no.

Oil brand Oil code no.20 litre pail 208 litre pail

Mobil Gargoyle Arctic 300 M 1 (M68) 1231-264 1231-296Sabroe Oil A100 A 3 (A100) 1231-263 1231-262Sabroe Oil AP68 AP 1 (AP68) 1231-257 1231-260Sabroe Oil PAO68 PAO 3 (P68) 1231-256 1231-259Mobil Gargoyle Arctic SHC 228 PAO 5 (P100) 1231-282 1231-283Mobil Gargoyle Arctic SHC 230 PAO 9 (P220) 1231-284 1231-285Mobil EAL Arctic 68 E 3 (E68) 1231-272 1231-273Mobil EAL Arctic 100 E 5 (E100) 1231-274 1231-275Mobil EAL Arctic 220 E 9 (E220) 1231-279

Sabroe H oil E11 (E370) 3914 1512 954 1) 9415 0008 000

1) 18.9 litre pail (5 US gallons)

The oils recommended by the former Stal Refrigeration correspond to the following oils:

Stal Refrigeration oil type Sabroe oil

A Mobil Gargoyle Arctic 300 -- M1 (M68)

B Sabroe Oil PAO 68 -- PAO 3 (PAO 68)

C Mobil Gargoyle Arctic SHC 230 -- PAO 9 (PAO 220)

H Sabroe H oil -- E 11 (E 370)

0178-145-EN 121

R717one-stagereciprocatingcompressors



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M1 See note

Note: YORK Refrigeration recommends that the use of M oils is restricted to moderately loaded compressors andthat the oil quality is monitored carefully via regular oil analyses.


l : In case you wish to change from mineral oil

122 0178-145-EN

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R717two-stagereciprocatingcompressors

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32

14

-4

-22

F�68503214-4-22-40-58-76TE

TC

�

PAO 3 Y

AP 1 l/Y

1

Code no Area no

M1 See note




0178-145-EN 123

0

10

20

30

-30 -20 -10 0 10 20 30 40 50

40

50

60

70

80

C

C�



R717HPO and HPCreciprocatingcompressors

1

F

140

122

104

86

68

50

32

�

158

F�8668503214-4-22TE

104 122

�

176

TC

PAO 5 Y

1

Code no Area no

Please observe: PAO 5 oil is the only oil which can be used in the HPO and HPC compressors.


124 0178-145-EN




-30

-20

-10

0

-60 -50 -40 -30 -20 -10 0 10 20

10

20

30

40

50

C�

1

C�F

122

104

86

68

50

32

14

-4

-22

TC

�

F�68503214-4-22-40-58-76TE

A

A 3 Y

1

Code no Area no

C

Contact YORK Refrigeration

2

Y : In case of a new plant. Very suitable.: Max oil concentration in liquid phase at: TE: 2% W

: Min suction temperature --50�C: at TE< --50�C superheating must be introduced.

AC

0178-145-EN 125

A 3 Y

1

Code no Area no

-30

-20

-10

0

-60 -50 -40 -30 -20 -10 0 10 20

10

20

30

40

50

C�

C�




1

F

122

104

86

68

50

32

14

-4

-22

TC

�

F�68503214-4-22-40-58-76TE

A

A 3 Y

1

Area no

C



A

C

126 0178-145-EN

R134aone-stagereciprocatingcompressors



E 5 YE 9 Y

1 2

Code no Area no

-30

-20

-10

-60 -50 -40 -30 -20 -10 0 10 20 30

0

10

20

30

40

50

60

70

1

2

F

140

122

104

86

68

50

32

�

158

TC

14

-4

-22

C�

F�8668503214-4-22-40-58-76TE

C�

Y : In case of a new plant. Very suitable.: Zone in which both oils are useable

0178-145-EN 127

R134atwo-stagereciprocatingcompressors



�

-30

-20

-10

-60 -50 -40 -30 -20 -10 0 10 20 30

0

10

20

30

40

50

60

70

1

C-40

F

86

68

50

32

�

14

-4

-22

-40

140

122

104

158

-70

F�8668503214-4-22-40-58-76TE

-94

�C

TC

E 5 Y

1

Code no Area no


128 0178-145-EN

E 3 Y

1

Code no Area no

-30

-20

-10

0

-60 -50 -40 -30 -20 -10 0 10 20

10

20

30

40

50

C�

C�



R407Cone-stagereciprocatingcompressors

F

122

104

86

68

50

32

14

-4

-22

TC

�

F�68503214-4-22-40-58-76TE

1

B

C

Y : In case of a new plant. Very suitable.: Max oil concentration in liquid phase: contact YORK Refrigeration


B

C

0178-145-EN 129

E 3 Y

1

Code no Area no

-30

-20

-10

0

-60 -50 -40 -30 -20 -10 0 10 20

10

20

30

40

50

C�

C�



R407Ctwo-stagereciprocatingcompressors

F

122

104

86

68

50

32

14

-4

-22

TC

�

F�68503214-4-22-40-58-76TE

1B

C



BC

130 0178-145-EN

-30

-20

-10

0

-60 -50 -40 -30 -20 -10 0 10 20

10

20

30

40

50

C�

C�



R404Aone-stagereciprocatingcompressors

F

122

104

86

68

50

32

14

-4

-22

TC

�

F�68503214-4-22-40-58-76TE

E 3 Y

E 5 Y

1 2

Code no Area no

1

2

C

Y : In case of a new plant. Very suitable.: Min suction temperature --50�C: at TE< --50�C superheating must be introduced.

: Zone in which both oils are useble

C

0178-145-EN 131

E 3 Y

1

Area no

-30

-20

-10

0

-60 -50 -40 -30 -20 -10 0 10 20

10

20

30

40

50

C�

C�



R404Atwo-stagereciprocatingcompressors

F

122

104

86

68

50

32

14

-4

-22

TC

�

F�68503214-4-22-40-58-76TE

1

E 3 Y

1

Area no

C

Y : In case of a new plant. Very suitable.: Min suction temperature --50�C: at TE< --50�C superheating must be introduced.C

Code no

132 0178-145-EN

R410AHPO og HPCreciprocatingcompressors

F

122

104

86

68

50

32

14

-4

-22

TC

�

F�68503214-4-22-40-58-76TE

E 5 Y

1-40

-30

-20

-60 -50 -40 -30 -20 -10

0

10

20

30

40

50

60

C�

0 10 20 30 40 50

1

A

A-10

Y : In case of a new plant. Very suitable.: Max oil concentration in liquid phase at: TE: 2%

Code no Area no



0178-145-EN 133

-30

-20

-10

0

-60 -50 -40 -30 -20 -10 0 10 20

10

20

30

40

50

C�

C�




F

122

104

86

68

50

32

14

-4

-22

TC

�

F�68503214-4-22-40-58-76TE

1

E 5 Y

1

Code no Area no

C

Y : In case of a new plant. Very suitable.: Min suction temperature --50�C: at TE< --50�C superheating most be introduced.C


134 0178-145-EN

E 5 Y

1

Code no Area no

-30

-20

-10

0

-60 -50 -40 -30 -20 -10 0 10 20

10

20

30

40

50

C�

C�




F

122

104

86

68

50

32

14

-4

-22

TC

�

F�68503214-4-22-40-58-76TE

1

1

Area no

C


0178-145-EN 135

R717screw compressors

Area noCode no

PAO 3 Y

AP 1 l/Y

1



-60 -50 -40 -30-30

-20

-10

0

10

-20 -10 0 10 20

20

30

40

50

C�

C�

1

F

122

104

86

68

50

32

14

-4

-22

�

TC

F�68503214-4-22-40-58-76TE

C

M1 See note



: Min suction temperature --50�C: at TE< --50�C superheating must be introduced.: Calculation must be performed using COMP1.


HLI: Calculation must be performed using COMP1

C

136 0178-145-EN

-30

-20

-10

0

-60 -50 -40 -30 -20 -10 0 10 20

10

20

30

40

50

C



1

R22screw compressorswith journal bearingsor roller bearings

�CF

122

104

86

68

50

32

14

-4

-22

�

F�68503214-4-22-40-58-76TE

�

TC

A 3 Y

PAO 5 Y

1 2*

Code no Area no

A

C

Using the calculating programme COMP1 it is possible to optimize the requirement for suction superheat values(SH) as stated in the diagram. See Oil types and oil companies in this section. Due to the ongoing development oflubrication oils, please contact YORK Refrigeration for an update on the requirement for superheat.





: Calculation must be performed using COMP1

A

C

HLI: Calculation must be performed using COMP1.

SH20

SH5

SH10 SH20 SH10SH5SH25

2

0178-145-EN 137

-30

-20

-10

0

-60 -50 -40 -30 -20 -10 0 10 20

10

20

30

40

50

C



1

R22screw compressorswith roller bearingsonly

�CF

122

104

86

68

50

32

14

-4

-22

�

F�68503214-4-22-40-58-76TE

�

TC

A 3 Y

1Code no Area no

A

C

Using the calculating programme COMP1 it is possible to optimize the requirement for suction superheat values(SH) as stated in the diagram. See Oil types and oil companies in this section. Due to the ongoing development oflubrication oils, please contact YORK Refrigeration for an update on the requirement for superheat.






A

C


SH20

138 0178-145-EN

C�



R134ascrew compressors

Area noCode no

E 5 YE 9 Y

1 2

-20

-10

-50 -40 -30 -20 -10

0

10

20

0 10 20 30

30

40

50

60

70C�

2

F

86

68

50

32

�

14

-4

140

122

104

158

F�8668503214-4-22-40-58TE

TC

1


Using the calculating programme COMP1 it is possible to optimize the requirement for suction superheat values(SH) as stated in the diagram. See Oil types and oil companies in this section. Due to the ongoing developmentof lubrication oils, please contact YORK Refrigeration for an update on the requirement for superheat.

Y : In case of a new plant. Very suitable.SH : Suction gas superheat, K (Kelvin)

: Zone in which both oils are useable: Calculation must be performed using COMP1

SH20

SH5

SH10

SH20

SH30

(See note)

Note: For the compressors type ”S”, ”Rotatune”, ”SAB 81”, ”SAB 83”, and ”SAB 85” only Sabroe oil H is approved.

0178-145-EN 139

E 3 YE 5 YE 9 Y



R404Ascrew compressors

-20

-10

-30-70 -60 -50 -40

0

-30 -20 -10 0 10 C�

10

20

30

40

C�

3

Area noCode no

1 2

F

104

86

68

50

32

14

-4

-22

�

F�503214-4-22-40-58-76TE

-94

TC

B

C




: Min suction temperature --50�C: at TE< --50�C superheating must be introduced.SH : Suction gas superheat, K (Kelvin)

: Zone in which both oils are useable


B

C

1

2 (3)

3 SH15

SH10

SH15

(See note)


(2)

140 0178-145-EN

R407Cscrew compressors



-20

-10

-30-70 -60 -50 -40

0

-30 -20 -10 0 10 C�

10

20

30

40

C�F

104

86

68

50

32

14

-4

-22

�

F�503214-4-22-40-58-76TE

-94

TC

E 3 YE 9 Y

1

Code no Area no

50122

20

68

1B

C


2

1

2



: Min suction temperature --50�C: at TE< --50�C superheating must be introduced.SH : Suction gas superheat, K (Kelvin)

: Zone in which both oils are useable


B

C

SH5

SH5

SH10

(See note)


0178-145-EN 141




R507screw compressors

-20

-10

-30-70 -60 -50 -40

0

-30 -20 -10 0 10 C�

10

20

30

40

C�

1

F

104

86

68

50

32

14

-4

-22

�

F�503214-4-22-40-58-76TE

-94

TC

E 5 YE 9 Y

1

Code no Area no

C


2

Y : In case of a new plant. Very suitable.: Min suction temperature --50�C: at TE< --50�C superheating must be introduced.

SH : Suction gas superheat, K (Kelvin): Zone in which both oils are useable


C

2

SH30

SH15

SH5

SH5


(See note)

142 0178-145-EN

List of Major Oil Companies

The oil from the companies listed below are NOT tested by YORK Refrigeration and are there-fore NOT approved by YORK Refrigeration either. The following list reflects the information pro-vided by the companies themselves. The assessment of durability and suitability of specific oilsfor specific purposes are entirely at the companies’ own discretion. Oils tested and approved byYORK Refrigeration can be found in the ”List of part numbers for available Sabroe oils”.

Oil Oil TypesCompany M A PAO AP E

Aral� �

Avia�

BP� � � �

Castrol� � � �

Chevron (UK: Gulf Oil)� � �

CPI Engineering Services� � �

DEA� � � �

Elf / Lub Marine 1� � �

Esso/Exxon� � �

Fina� � �

Fuchs� � � �

Hydro-Texaco� � � �

ICI�

Kuwait Petroleum (Q8)� �

Mobil� � � � �

Petro-Canada�

Shell� � � �

Statoil� �

Sun Oil� �

0178-138-EN

95.03

0178-145-EN 143

Alignment of compressor unit SAB 110

This chapter gives a desciption of the proce-dure in connection with setting up of a com-pressor unit, as f.inst.:

1. Alignment of compressor unit on founda-tion.

2. Connection of electricity, refrigerant andany cooling water connections.

In order to secure a long life for the unit aswell as noise- and vibration free running, it isessential that the compressor unit is carefullyaligned. Misalignment may produce stressesand vibrations that can be transmitted tocompressor and bearings of motor and there-by cause break-down.

Vibrations may be due to:

S Distortion between compressor unit andfoundation.

S Stains from pipe connections betweencompressor and plant.

1.0 Alignment of unit onfoundation:

When mounting the unit on foundation or ma-chine floor, it must stand free from stress andrest evenly on all its supports.

The unit can be mounted in the followingways:

S On vibration dampers.

S Directly on foundation or machine floorwith foundation bolts.

In both cases, the unit must be aligned be-fore fitting connecting pipes to the plant.

T0177040_0

A1

A1

A2

Standard type

Marine type

H Hmax.

A2

Fig. 1

144 0178-145-EN

1.01 Mounting of vibration dampers

Depending on whether compressor unit is to

be used on land 1 or on a ship 2 vibrationdampers are included in the delivery asshown on fig. 1.

The purpose of vibration dampers is todampen vibrations from compressor unit tofoundation. Further, marine vibration damp-ers must dampen vibrations from foundationto compressor unit, at the same time keepingthe unit fixed to foundation.

It is extremely important that the vibrationdampers be placed correctly as shown ondrawing forwarded to client or distributor.This drawing is valid only for the unit inquestion.

When applying vibration dampers it is as-sumed that the foundation has the necessaryBearing strength and is level so that the ad-justment of the vibration dampers can bekept within the adjusting measures indicatedon the drawing submitted.

In order that each vibration damper functionsproperly, must be sufficiently stressed. Mea-sure A1 and H in non-stressed and A2 in astressed situation.

Industrialtype

Marinetype1 2

Flexion

Height adjustment

A1-A2

min 3,0

H = H+12max

All measures are in mm

min 1,0

max 2,0 max 5,0

The flexion of the industrial type is adjustedby increasing or reducing the load in propor-tion to the other supports. The foot can beraised by screwing the adjusting spindledown, thereby increasing the load and hencealso the flexion.

Vibration dampers of the marine type arenot adjustable. Therefore, it is essential thatthe foundation is even within a max. devi-ation of 2 mm.

If the foundation is not even within max. 2mm, line under the vibration dampers untilthe prescribed flatness is obtained.

Once the plant has cooled down, check dur-ing operation that the flexion of the dampersis still correct!

1.02 Direct mounting on foundationOn direct mounting on foundation with em-bedded foundation bolts, carefully check thatall 4 legs are stable. Alternatively, use shimsin order to avoid distortion of compressorunit.

0178-145-EN 145

1.1 Making of various connectionsPipe connections

After aligning of unit on foundation, establishpipe connections to refrigeration plant.

Pipes which that are exposed to sizeabletemperature fluctuations must be laid so asto allow for deflexion at appropriate points.

This is to safeguard against the transmissionof excessive forces to the compressor andthe unit. Enclosed pipes may give rise to veryimportant stresses for instance in connectionwith changes in temperature from installationtemperature to operating temperature.

Therefore, once the plant has cooled down,the vibration dampers of compressor unitshould be checked for correct flexion.

The following sketch shows a rigid and unac-ceptable piping (1) and a more flexible one(2) which is recommended.

Electric connections

On initial start-up of unit immediately checkwhether the rotating direction of compressoris correct as indicated by the arrow on top ofbearing cover Pos. 20.

1 2

> 1.5 m

T0177057_0

0171-575-EN

01.03

146 0178-145-EN

Key to Piping Diagrams/Component List

CS Screw compressor

OS Oil separator

M Electric motor

EC Electronic control system

240 Coupling

_______________ S _________________

PT1 Pressure transducer(suction pressure)

PT2 Pressure transducer(discharge pressure)

PT3 Pressure transducer(oil pressure after oil filter)

PT4 Pressure transducer(oil pressure before oil filter)

PT5 Pressure transducer(oil pressure after oil pump)

TT5 Temperature transducer(discharge gas temperature)

TT6 Temperature transducer(oil temperature in flow control)

TT7 Temperature transducer(suction gas temperature)

GT8 Position transmitter (capacityslide)

GT9 Position transmitter (Vi slide)

PAZ10 Safety pressure cut-out(for TÜV, SDM and SA only)

PAZ1 Low-pressure cut-out(only for classified systems)

PAZ2 High-pressure cut-out

PDAZ3 Differential pressure cut-out(pressure drop across oil filter)

TI5 Thermometer(discharge gas temperature)

TI6 Thermometer (oil temperature)

TI7 Thermometer (suction gas tem-perature) - only if specially or-dered

PDAZ10 Oil pressure difference cut-out(oil pressure - discharge pressure)

PDAZ11 Oil pressure difference cut-out(oil pressure - suction pressure) -for classified systems only

TAZ12 Thermostat(oil temperature in manifold)

TAZ13 Thermostat(discharge gas temperature)

TC14 Thermostat(pilots solenoid valve pos. 82)

PI15 Suction pressure manometer

PI16 High-pressure manometer

PDI17 Oil difference manometer

FT18 Level switch

YY1 Double acting, four-way solenoidvalve -- unload capacity

YY2 Double acting, four-way solenoidvalve -- load capacity

YY3 Double acting, four-way solenoidvalve -- volume ratio/increase

YY4 Double acting, four-way solenoidvalve -- volume ratio/decrease

SC1 Throttle valve

SC2 Throttle valve

SC3 Throttle valve

SC4 Throttle valve

0178-145-EN 147

BP Throttle valve -- by-pass

LIT1 Oil level transmitter

19 Compressor safety valve

20 Suction stop valve

21 Non-return valve

22 Flanged joint discharge pipe -compressor

23 Suction filter built into compressor

23a External suction filter

24 Service valve - air purge valve

25 Oil separator

26 Non-return valve in outlet pipefrom oil separator

27 Stop and non-return valve in out-let pipe from oil separator

28 Safety valve - the unit

29 Change-over valve for doublesafety valve

30 Immersion heater in oil separator

31 Oil level indicators (2 pieces)

32 Oil cooler OOSI (refrigerant-cooled)

33 Oil cooler (water-cooled)

34 Stop valve for oil purging (oil side)

35 Stop valve for oil purging(refrigerant side)

36 Oil outlet branch to oil cooler/filter

37 Oil branch to pump suction end

38 Stop valve before oil filter

39 Oil filter

40 Oil inlet from pump

41 Non-return valve built into oil filter

42 Stop valve after oil filter

43 Combined flow control andoil distributing manifold

44 Check valve, rotor lubrication

45 Nozzle in injection pipe for rotors

46 Thermostatically-controlled 3-wayvalve for oil temperatureregulation

47 Service valve for oil drainage

48 Oil purge valve on oil filter

49 Thermostatic water valve forwater-cooled oil cooler

50 Stop valve

51 Oil filter

52 Nozzle/throttle valve

53 Oil level indicator

54 Stop valve

55 Oil separation element(fine separation)

56 Non-return valve

57 Hand-regulated valve

58 Temperature regulated main valve

59 Oil receiver

60 Stop valve

61 Oil filter

62 Oil charging valve

63 Oil pump

64 Stop valve for air purging of pump

65 Stop valve

66 Non-return valve for oil charging

67 Solenoid valve (NC) - open duringprelubrication

68 Stop valve

69 Non-return valve

70 Solenoid valve (NC) - capacityregulation min. --> 100%

148 0178-145-EN

71 Solenoid valve (NO) - capacityregulation 100 -> min.%

72 Throttle valve for regulation ofslide velocity

73 Solenoid valve (NC) - capacityregulation min. --> 100%

74 Solenoid valve (NO)

75 Non-return valve

76 Three-way non-return valve

80 Stop valve

81 Liquid refrigerant filter

82 Solenoid valve (NC)

TC83 Liquid injection valve TEAT

84 Stop valve

90 Oil supply to bearings atdischarge end

91 Oil supply to shaft seal and bear-ings at suction end

92 Oil injection in compressor

93 Oil return from capacity regulation

94 Oil to and from regulating cylinder

95 Liquid supply for HLI coolingVi 4.0

96 Liquid supply for HLI coolingVi 2.6

97 Economizer connection

98 Oil connection from flow switch

99 Oil to and from Vi regulation(only by auto-Vi)

100 Oil return from fine oil separator

101 Bypass throttle valve at suctionstop valve

102 Non-return valve

103 Stop valve

104 Nozzle

105 Flow switch

106 External oil filter

107 Oil filter for units with full flowoil pump

108 Oil regulating valve

110 Stop valve

TC111 Thermostatic valve


113 Liquid filter

114 Stop valve

115 Stop valve for oil purge

116 Economizer vessel

120 Stop valve

122 Main valve


124 Stop valve for oil drainage

125 Safety valve

126 Float valve

127 Stop valve

128 Stop valve


130 Stop valve

131 Stop valve

132 Liquid filter

PI139 Oil pressure manometer

140 Stop- and non-return valve

141 Main valve

142 Pilot valve

143 Solenoid valve

144 Stop valve

145 Float valve

0178-145-EN 149

147 Liquid filter

148 Stop valve for oil purge


150 Stop valve

151 Safety valve

152 Solenoid valve

153 Stop valve

154 Stop valve

160 Stop valve

200 Gas-powered stop valve


202 Stop/non-return valve

203 Non-return valve in discharge pipe

204 Stop valve after oil separator

205 Filter

206 Nozzle

207 Solenoid valve (NO)


FT209 Oil level switch in oil separator


211 Stop valve

212 Service valve - air purge valve


214 Filter

215 Non-return valve (5 bar)

220 Compressor protecting valve(main valve)

221 Compressor protecting valve(pilot valve for pos. 220)

222 Filter in economizer pipeconnection

223 Brake motor for capacity slide

224 Three-way solenoid valve

225 Oil return pump

226 Solenoid valve for baby slide (NC)

227 Quick closing oil drain valve

Note:On units supplied without valves thebracketed figures near the branches referto the component numbers in this list.These components are to be fitted by thecustomer.

0171-466-EN

94.05

150 0178-145-EN

Ordering Spare Parts

When placing an order for spare parts,please state the following:

1. Shop No.

All compressors are fitted with an identifica-tion plate, which states the type and shop no.of the compressor and indicates what refrig-erant is to be used.

2. Part No.

Spare parts drawings and parts lists insertedin an instruction manual identify spare partswith the following:

a) Spare part no. -- which is a referencenumber to facilitate finding a part in thedrawing and cross-referencing in the partslist or vice versa.

b) Designation of the part.

c) Part no. -- a 7-digit number which refers toSABROE’s stores.

When you order spare parts, please alwaysadvise at least the designation and part num-

ber. If you are in any doubt, add the sparepart no. too.

3. Forwarding instructions

When ordering spares, please advise the for-warding address, and the address to whichthe invoice should be sent. If appropriate,please state the name of your local bank, theway in which you want the goods transportedand required delivery date.

4. Classification certificate

If you require a certificate from a Classifica-tion authority, please mark the orderappropriately, as the inspection and issuingprocedures take extra time and incur extraexpenses.

5. Quotation No.

If a quotation no. has been given during earli-er correspondence, please refer to this whenplacing your order -- it will help us to identifyand execute your order quickly.

0178-145-EN 151

Spare Part Sets for Screw Compressor and UnitTypes: SAB 110 - 128 (HR) - 163 (HR) - 202 - VMY347/447 and VMY 336-436-536

It is always an advantage to have a stock of spare parts for both compressor and unit. In thisway the customer or a YORK Refrigeration service engineer is able to carry out the necessaryreplacements without wasting time waiting for new spare parts to arrive.

On contacting YORK Refrigeration’s local representative, you may receive specifications forthe following spare part sets for compressor and unit.

Compressor Block:

S Standard set of sparesThis set contains a representative select-ion of O-rings and gaskets.

S Certificate set of sparesBesides the parts from the standard setof spares this set also includes all bear-ings as well as shaft seal.

Basic Unit:

S Standard set of spares:This set includes the following spare partsfor the below-mentioned components:

-- Oil separator:O-rings, gasket

-- Service valves:Gaskets, O-rings

-- Capacity regulating system:Gaskets, O-rings

-- Pressure outlet stop valve:Gaskets

-- Suction Inlet stop valve:O-rings, sealings rings, gaskets,teflon ring

-- Safety valve:Gaskets, cone, O-rings

-- Oil by-pass system:Gaskets, teflon ring

-- Oil pump:O-rings

S Certificate set of spares:Further to the parts contained in the stan-dard set of spares, this set also includesspare parts for the below-mentioned com-ponents:

-- Coupling:Screws and discs

-- Oil separator:Sight glass, oil separator element,heating element

-- Capacity regulating system:Solenoid valve

-- Safety valve:Spring

-- Solenoid valves:Coils

-- Oil pump:Shaft seal, filter

0171-945-EN

01.05

instruction manual for sab 110

Documents