01.

06

Instruction manual
for

SAB 202

The screw compressor and the unit may differ in equipment, depending on their functions and requirements. Part of these variants are treated in this

instruction manual although they may not be fitted on your particular unit. In the below table the x-mark indicates which variants are fitted on your particular unit with shop no stated below.

Type of drive Refrigerant Shop no Designation

Male drive R717 110.062 - 063 - 077

Female drive R22

SM LM Other

SF LF

Transducers and manual regulation of Vi slide Instrumentation Manual regulation of Vi slide UNISAB II and automatic regulation of Vi slide Oil filter Internal External Dobbelt Type B OWSG/OWRG OOSI

Water-cooled oil cooler Oil cooling Water-cooled oil cooler Refrigerant oil cooler Oil separator With 1 discharge valve With 2 discharge valves Oil temp.reg. Thermostatisc oil valve PM3 Main valve Ex-execution Both compressor and unit are safeguarded

0178-250-EN

Preface
The aim of this instruction manual is to provide the operators with a thorough knowledge of the compressor and the unit and at the same time provide information about: S the function and maintenance of the individual components; S service schedules; S procedure for dismantling and reassembling of the compressor. This instruction manual draws attention to typical errors which may occur during operations. The manual states causes of error and explains what should be done to rectify the errors in question. It is imperative that the operators familiarize themselves thoroughly with the contents of this instruction manual to ensure a safe, reliable and efficient operation of the product as YORK Refrigeration is unable to provide a guarantee against damage of the product occurring during the warranty period as a result of incorrect operation. Dismantling and assembly of compressors and components should only be carried out by authorized personnel to prevent accidents. The contents of this instruction manual must not be copied or passed on to any unauthorized person without YORK Refrigerations permission. YORK Refrigerations General Conditions for the Supply of Components and Spare Parts will apply.
00.07 0171-500-EN

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

0178-250-EN

Table of Contents
Instruction manual for SAB 202 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Preface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Table of Contents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . First Aid for Accidents with Ammonia . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . First Aid for Accidents with HFC/HCFC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Protecting the Operator as well as the Environment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Description of SAB 202 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Handling of the compressor, areas of application, safety equipment etc. . . . . . . . . . . . . . Sound data for reciprocating and screw compressor units - all types of compressors . . Vibration data for compressors - All Compressor Types . . . . . . . . . . . . . . . . . . . . . . . . . . . Data for SAB 202 compressor & unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Compressor data SAB 202 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Compressor and unit operation SAB 128 Mk3, SAB 163 Mk3 and SAB 202 . . . . . . . . . . Service Schedules for screw compressors SAB 110, 128/163 Mk3, 202 & VMY . . . . . . Assessing the oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Visual assessment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Analytical evaluation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Analysing the oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Limiting values . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Major Service Intervals SAB 110, SAB 128/163 Mk3, SAB 202 . . . . . . . . . . . . . . . . . . . . Oil charging, weight and shipping volume SAB 128/163 Mk3 and SAB 202 . . . . . . . . . . Temperature and pressure settings SAB 202 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Servicing the refrigeration plant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Maintenance of compressor SAB 202 Dismantling and assembly . . . . . . . . . . . . . . . . . . . Magnetic coupling for Vi-indication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Transmitter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . System for regulating the capacity and the Vi-ratio of SAB 202 . . . . . . . . . . . . . . . . . . . . . 3. Manual regulation of the Vi-slide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Adjustment of the Vi-slide position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Torque moments for screws and bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Oil separator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Water-cooled oil cooler type OWSG/OWRG . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Refrigerant-cooled Oil Cooler type OOSI . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Water-cooled oil cooler, type B . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Oil temperature regulating system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Heating rods, pos. 30 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . External oil filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 2 3 5 6 7 10 12 15 19 21 22 26 30 35 35 35 36 36 36 38 39 40 43 45 62 75 76 79 80 82 84 87 90 92 94 96 97

0178-250-EN

Oil pump pos. 63 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . The oil pump filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Safety and monitoring devices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Refrigeration Plant Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Troubleshooting on the Screw Compressor Plant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Remedying Malfunctions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Selecting Lubricating Oil for SABROE Compressors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Data Sheet for Listed Sabroe Oils . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . List of Major Oil Companies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Alignment of VMY/SAB 202 unit and coupling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Key to Piping Diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Ordering Spare Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Spare Part Sets for screw compressor and unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Spare parts drawing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . List of parts for SAB 202 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Spare parts survey for SAB 202 unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Tools for compressor SAB 202 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

99 102 103 105 107 109 116 122 145 146 154 158 159

0661-855 0661-856 0661-853 0661-854

Piping diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . order specific Wiring diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . order specific Dimension drawings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . order specific Placing the vibration dampers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . order specific Instructions for control and regulating equipment . . . . . . . . . . . . . . . . . . . . . . . . . order specific

0178-250-EN

First Aid for Accidents with Ammonia

(Chemical formula: NH3 - refrigerant no.: R717)
Inhalation Warning! No plant can ever be said to be too safe safety is a way of life. General Ammonia is not a cumulative poison. It has a distinctive, pungent odour that even at very low, harmless concentrations is detectable by most persons. Since ammonia is self-alarming, it serves as its own warning agent so that no person remains voluntarily in concentrations which are hazardous. Since ammonia is lighter than air, adequate ventilation is the best means of preventing an accumulation. Experience has shown that ammonia is extremely hard to ignite and under normal conditions a very stable compound. At extremely high, though limited concentrations, ammonia can form ignitable mixtures with air and oxygen and should be treated with respect. Basic Rules for First Aid 1. Call a doctor immediately. 2. Be prepared: Keep an irrigation bottle available containing a sterile isotonic (0.9%) NaCl-solution (salt water). 3. A shower bath or water tank should be available near all bulk installations with ammonia. 4. When applying first aid, the persons assisting should be duly protected to avoid further injuries.
96.01

1. Move affected personnel into fresh air immediately and loosen clothing restricting breathing. 2. Call a doctor/ambulance with oxygen equipment immediately. 3. Keep the patient still and warmly wrapped in blankets. 4. If mouth and throat are burnt (freeze or acid burn), let the conscious patient drink water, taking small mouthfuls. 5. If the patient is conscious and the mouth is not burnt, feed the patient with sweetened tea or coffee (never feed an unconscious person). 6. Oxygen may be administered, but only when authorised by a doctor. 7. If the patients breathing stops, apply artificial respiration. Eye injuries from liquid splashes or concentrated vapour 1. Force the eyelids open and rinse eyes immediately for at least 30 minutes with the salt water solution just mentioned. 2. Call a doctor immediately. Skin burns from liquid splashes or concentrated vapour 1. Wash immediately with large quantities of water and continue for at least 15 minutes, removing contaminated clothing carefully while washing. 2. Call a doctor immediately. 3. After washing, apply wet compresses (wetted with a sterile isotonic (0.9%) NaClsolution (salt water) to affected areas until medical advice is available.

0170-008-DA

0178-250-EN

First Aid for Accidents with HFC/HCFC

Refrigerant no.: R134a - R505A - R507 - R22, etc.
Inhalation Warning! No plant can ever be said to be too safe safety is a way of life. General HFC/HCFC form colourless and invisible gasses which are heavier than air and smell faintly of chloroform at high concentrations. They are non-toxic, non-inflammable, nonexplosive and non-corrosive under normal operating conditions. When heated to above approx. 300C, they break down into toxic, acid gas components, which are strongly irritating and aggressive to nose, eyes and skin and generally corrosive. Besides the obvious risk of unnoticeable, heavy gases displacing the atmospheric oxygen, inhalation of larger concentrations may have an accumulating, anaesthetic effect which may not be immediately apparent. 24 hours medical observation is therefore recommended. Basic Rules for First Aid 1. When moving affected persons from lowlying or poorly ventilated rooms where high gas concentrations are suspected, the rescuer must be wearing a lifeline and be under continuous observation from an assistant outside the room. 2. Adrenaline or similar heart stimuli must not be used. 1. Move affected persons into fresh air immediately. Keep the patients still and warm and loosen clothing restricting breathing. 2. If the patient is unconscious, call a doctor/ ambulance with oxygen equipment immediately. 3. Give artificial respiration until a doctor authorizes other treatment. Eye Injuries 1. Force the eyelids open and rinse with a sterile isotonic (0.9%) NaCl-solution (salt water) or pure running water continuously for 30 minutes. 2. Contact a doctor or get the patient to a hospital immediately for medical advice. Skin Injuries - Freeze Burns 1. Wash immediately with large quantities of lukewarm water to reheat the skin. Continue for at least 15 minutes, removing contaminated clothing carefully while washing. 2. Treat exactly like heat burns and seek medical advice. 3. Avoid direct contact with contaminated oil/ refrigerant mixtures from electrically burnt-out hermetic compressors.

0178-250-EN

Protecting the Operator as well as the Environment

Warning! No plant can ever be said to be too safe safety is a way of life. Increasing industrialisation threatens our environment. It is therefore absolutely imperative to protect nature against pollution. To this end, many countries have passed legislation in an effort to reduce pollution and preserve the environment. This legislation applies to all fields of industry, including refrigeration, and must be complied with. Be especially careful with the following substances: S refrigerants S cooling media (brine, etc) S lubricating oils. Refrigerants usually have a natural boiling point considerably below 0C. This means that liquid refrigerants can be extremely harmful if they come into contact with skin or eyes. High concentrations of refrigerant vapours are suffocating when they displace air. If high concentrations of refrigerant vapours are inhaled, they will attack the human nervous system. When halogenated gasses come into contact with open flame or hot surfaces (over approx. 300C), they will decompose to produce poisonous chemicals, which have a very pungent odour, thus warning the personnel of their presence. At high concentrations R717 causes respiratory problems, and when ammonia vapour and air mix 15 to 28 vol. %, the combination is explosive and can be ignited by an electric spark or open flame. Oil vapour in the ammonia vapour increases this risk significantly as the point of ignition falls below that of the mixture ratio stated. Usually the strong smell of ammonia will warn the personnel before the concentrations become dangerous. The following table shows the values for the max. permissible refrigerant content in air measured in volume %. Certain countries may, however, have an official limit which differs from those stated.
Ammonia HCFC R507 R22 R717

0170-009-EN

01.02

Halogenated refrigerants HFC R134a Unit TWA Time weighted average during a week Warning smell vol.% 0.1 0.1 0.1 0.1 0.1 0.1 R404A R407C R410A

0.005

vol.%

0.2

0.002

0178-250-EN

Furthermore, it can be said about refrigerants:

S If released to the atmosphere, halogenated refrigerants of the type HCFC (e.g. R22) will contribute to the depletion of the ozone layer in the stratosphere. The ozone layer protects the earth from the ultraviolet rays of the sun. Refrigerants of the types HFC and HCFC are greenhouse gases which contribute to an intensification of the greenhouse effect. They must, therefore, never be released to the atmosphere. Use a separate compressor to draw the refrigerant into the plant condenser/receiver or into separate refrigerant cylinders. S Most halogenated refrigerants are miscible with oil. Oil drained from a refrigeration plant will often contain significant amounts of refrigerant. Therefore, reduce the pressure in the vessel or compressor as much as possible before draining the oil. S Ammonia is easily absorbed by water: At 15C 1 litre of water can absorb approx. 0.5 kg liquid ammonia (or approx. 700 litres ammonia vapour). S Even small amounts of ammonia in water (2-5 mg per litre) are enough to wreak havoc with marine life if allowed to pollute waterways and lakes. S As ammonia is alkaline, it will damage plant life if released to the atmosphere in large quantities. Refrigerant evacuated from a refrigerant plant must be charged into refrigerant cylinders intended for this specific refrigerant.

If the refrigerant is not to be reused, return it to the supplier or to an authorized incineration plant. Halogenated refrigerants must never be mixed. Nor must R717 ever be mixed with halogenated refrigerants.

Purging a Refrigeration Plant

If it is necessary to purge air from a refrigeration plant, make sure to observe the following: S Refrigerants must not be released to the atmosphere. S When purging an R717 plant, use an approved air purger. The purged air must pass through an open container of water for any remaining R717 to be absorbed. The water mixture must be sent to an authorized incineration plant. S Halogenated refrigerants cannot be absorbed by water. An approved air purger must be fitted to the plant. This must be checked regularly using a leak detector.

Cooling Media
Salt solutions (brines) of calcium chloride (CaCl2) or sodium chloride (NaCl) are often used. In recent years alcohol, glycol and halogenated compounds have been used in the brine production. In general, all brines must be considered as being harmful to nature and they must be used with caution. Be very careful when charging or purging a refrigeration plant. Never empty brines down a sewer or into the environment. The brine must be collected in suitable containers clearly marked with the contents and sent to an approved incineration plant.

0178-250-EN

Lubricating Oils
Warning! When charging oil, avoid that your skin comes into direct contact with the oil. Direct contact with oils may in the long run develop allergy attacks. Use therefore always protective equipment - goggles and gloves - when charging oil. Refrigeration compressors are lubricated by one of the following oil types depending on the refrigerant, plant type and operating conditions.

- Mineral oil - Semi-synthetic oil - Alkyl benzene-based synthetic oil - Polyalphaolefine-based synthetic oil - Glycol-based synthetic oil. - Ester oil When changing the oil in the compressor or draining oil from the vessels of the refrigeration plant, always collect the used oil in containers marked waste oil and send them to an approved incineration plant.

NOTE This instruction only provides general information. The owner of the refrigeration plant is responsible for ensuring that all codes, regulations and industry standards are complied with.

0178-250-EN

Description of SAB 202

The SAB 202 compressor is a capacity adjustable screw compressor with oil injection. The two rotors are equipped with 4 lobes (male rotor) and 6 lobes (female rotor), respectively, executed with asymmetric profile according to SRM licence. As indicated on the spare parts drawing at the end of this manual, the rotors at the suction end are fitted with slide bearings, whereas the bearing at the discharge end consists of a combined bearing set with slide bearings, absorbing the radial load, and ball bearings, absorbing the axial forces. The axial forces are partly relieved by means of the rotating balance pistons mounted on the rotors. The rotors are designed for both male drive and female drive. The driving rotor is fitted with a shaft. The compressor is fitted with a large built-in suction filter, which effectively prevents dirt particles from the refrigeration plant from being led with the suction gas into the compressor. The suction filter housing also has a built-in compressor protection valve which - controlled by a pilot valve - safeguards the compressor against any unwanted high compression pressures. For efficient filtration of the oil that lubricates the bearings in the compressor, an oil filter cartridge has been inserted in the compressor block. Furthermore, the compressor contains a built-in non-return valve, preventing the compressor from running backwards whenever the power to the driving motor is disconnected. The driving shaft is fitted with a shaft seal of the slide ring type, consisting of a fixed cast iron ring with an O-ring sealing against the shaft seal cover and a rotating springloaded carbon ring with O-ring sealing against the shaft. It is possible to regulate the compressor capacity steplessly from approx. 10% to 100% by means of a regulating slide mounted under the rotors. Once the slide has moved away from the slide stop a gap is created so that some of the sucked-in gas is returned to the suction side. The bigger the gap, the lower the compressor capacity. The regulating slide is moved hydraulically by a regulating piston and controlled by a solenoid valve system. The compressor also features a regulating system by which the built-in Vi volume ratio can be adjusted. The result hereof is that the compressor works optimally at varying operational pressures in the plant. To optimize the compressor volume ratio the position of the Vi regulating slide must be changed whenever the compressor works at max. capacity. This is done by changing the position of the slide stop. At partial load the Vi volume ratio will only be approaching the optimum. Regulating the built-in Vi volume ratio can be done in the following two ways, depending on the compressor type (as to your type of compressor, see page 1).

10

0178-250-EN

0178-253-EN

96.12

S Manual regulation of the Vi slide: By turning the spindle, pos. 180, in accordance with the curves in the instruction manual. S Automatic regulation of the Vi slide: By means of the oil pressure and two solenoid valves, controlled by a UNISAB II control system. The type of screw compressor can be determined by means of the nameplate, placed on the compressor block.

Fig. 1

AARHUS DENMARK
Type Shop no Max. speed Swept volume Working pressure Test pressure Refrigerant Year r.p.m. m3/h bar bar
T0177093_2

SABROE

The name-plate indicates the compressors serial number as shown in fig. 1. When contacting SABROE about the compressor, remember to state the serial number.

0178-250-EN

11

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

Direction of rotation In order to reduce the noise level from the electric motors these are often made with specially shaped fan wings, thus determining a particular direction of rotation. Consequently, it is essential that the motor is ordered with the correct direction of rotation made for the compressor. The direction of rotation of the compressor is indicated by an arrow cast into the compressor cover as shown on the following sketch. Please, notice that male and female drive have different directions of rotation. Female Male During transportation and handling care should be taken not to damage any of the components, pipe or wiring connections.

Areas of application of the screw compressors

Compressor 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 application of the compressor, which could cause injuries to the operating staff or lead to technical damage, the compressors may only be applied for the following purposes: S As a refrigeration compressor with a number of revolutions and with operating limits as indicated in this manual or according to a written agreement with SABROE. S With the following refrigerants: R717 - R22 - R134a - R404A - R507 R600 - R600A - R290 - LPG Other HFC refrigerants in accordance with SABROEs instructions. All other types of gas may only be used following a written approval from SABROE. S In an explosion-prone environment, provided the compressor is fitted with approved explosion-proof equipment. The compressor must NOT be used: S For evacuating the refrigeration plant of air and moisture,
98.03

Seen towards shaft ends

Handling of compressor and unit For lifting of the compressor it has been equipped with a threaded hole for mounting of the lifting eye. As to the weight of the compressor, see table on compressor data. Note: The compressor block alone may be lifted in the lifting eye. The same applies to the motor. The unit is lifted by catching the lifting eyes welded onto the unit frame. These have been clearly marked with red paint. The weight of the unit is stated on the package as well as in the shipping documents.

12

0178-250-EN

0170-120-EN

S For putting the refrigeration plant under air pressure in view of a pressure testing, S As an air compressor. Emergency device The compressor control system must be equipped with an emergency device. In case the compressor is delivered with a SABROE-control system this emergency device is found as an integrated part of the control. The emergency device must be executed in a way to make it stay in its stopped position, following a stop instruction, until it is deliberately set back again. It must not be possible to block the emergency stop without a stop instruction being released. It should only be possible to set back the emergency device by a deliberate act, and this set back must not cause the compressor to start operating. It should only make it possible to restart it. Other demands to the emergency device: S It must be possible to operate it by means of an easily recognizable and visible manual handle, to which there is free access. S It must be able to stop any dangerous situation, which may occur, as quickly as possible without this leading to any further danger.

Combustion motors If combustion motors are installed in rooms containing refrigeration machinery or rooms where there are pipes and components containing refrigerant, you must make sure that the combustion air for the motor is derived from an area in which there is no refrigerant gas, in case of leakage. Failure to do so will involve a risk of the lubricating oil from the combustion motor mixing with the refrigerant; at worst, this may give rise to corrosion and damage the motor. Explosion-proof electrical execution If the compressor is delivered in an explosion-proof electrical execution, this is stated in the table on page 1 of this instruction manual. Likewise, the compressor will, besides the SABROE name plate, be equipped with an Ex-name plate like the one illustrated below.

T2516273_0

0178-250-EN

13

The temperature of tangible surfaces When a compressor is working, the surfaces that are in contact with the warm discharge gas also get warm. However, the temperature depends on which refrigerants and under which operating conditions the compressor is working. Often, it exceeds 70C which for metal surfaces may cause your skin to be burnt even at a light touch. Consequently, the compressors will be equipped with yellow warning signs informing you that pipes, vessels and machine parts

close to the warning signs during operation are so hot that your skin may be burnt from 1 seconds touch or longer.

14

0178-250-EN

Sound data for reciprocating and screw compressor units - all types of compressors In the following tables the noise data of the compressors is stated in: - A-weighted sound power level LW (Sound Power Level) - A-weighted sound pressure level LP (Sound Pressure level) The values for LW constitute an average of a large number of measurings on various units. The measurings have been carried out in accordance with ISO 9614-2.
99.02

For screw compressors the average values are indicated in the tables for the following components. S SAB 128, SAB 163, SAB 202, SV and FV: 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 compressors 5 dB for VMY screw compressors As to the reciprocating compressors the values are stated for the compressor block only. The dimensional values are stated for 100% capacity.

0170-114--EN

The values are further stated as average sound pressure in a free field above a reflecting plane at a distance of 1 meter from a fictional frame around the unit. See fig. 1. Normally, the immediate sound pressure lies between the LW and LP values and can be calculated provided that the acoustic data of the machine room is known.

Fig. 1

Fictional frame

Dimensional plane

1 meter

1 meter

Reflecting plane

0178-250-EN

15

Note the following, however: S at part load or if the compressor works with a wrongly set Vi the sound level can sometimes be a little higher than the one indicated in the tables. S additional equipment such as heat exchangers, pipes, valves etc. as well as the choice of a different motor type can increase the noise level in the machine room. S as already mentioned, the stated sound pressures are only average values above a fictional frame around the noise source. Thus, it is sometimes possible to measure higher values in local areas than the ones stated - for inst. near the compressor and motor.

S the acoustics is another factor that can change the sound level in a room. Please note that the sound conditions of the site have not been included in the stated dimensional values. S by contacting SABROE you can have sound data calculated for other operating conditions. The tables have been divided into reciprocating and screw compressors, respectively. The reciprocating compressors are further divided into one- and two-stage compressors as well as in a heat pump. In each table the operating conditions of the compressor during noise measuring have been stated, just as the refrigerant used has been mentioned.

16

0178-250-EN

RECIPROCATING COMPRESSORS One-stage Evaporating temperature =-15C Condensing temperature =+35C Refrigerant = R22/R717 Number of revolutions =1450 rpm. Compressor block
CMO 24 CMO 26 CMO 28 SMC 104 S SMC 106 S SMC 108 S SMC 112 S SMC 116 S SMC 104 L SMC 106 L SMC 108 L SMC 112 L SMC 116 L SMC 104 E SMC 106 E SMC 108 E SMC 112 E SMC 116 E

Two-stage Evaporating temperature Condensing temperature Refrigerant Number of revolutions Compressor block
LW 81 95 97 96 98 96 98

=-35C = +35C = R22/R717 =1450 rpm.

LP 66 79 81 80 82 80 82

LW
84 86 87 95 96 97 99 100 96 97 98 100 101 96 97 98 100 101

LP
69 71 72 79 80 81 82 83 80 81 82 83 84 80 81 82 83 84

TCMO 28 TSMC 108 S TSMC 116 S TSMC 108 L TSMC 116 L TSMC 108 E TSMC 116 E

Evaporating temperature Condensing temperature Refrigerant Number of revolutions Compressor block

TSMC 188

=-35C = +35C = R22/R717 = 900 rpm. LW

100

LP
82

Evaporating temperature Condensing temperature Refrigerant Number of revolutions Compressor block

SMC 186 SMC 188

=-15C = +35C = R22/R717 = 900 rpm. LW

101 102

Heat pump Evaporating temperature Condensing temperature Refrigerant Number of revolutions Compressor block
HPO 24 HPO 26 HPO 28 HPC 104 HPC 106 HPC 108

= +20C = +70C = R22/R717 =1450 rpm. LW

91 93 94 97 98 99

LP
76 78 79 81 82 84

LP
83 84

0178-250-EN

17

SCREW COMPRESSORS Evaporating temperature Condensing temperature Refrigerant Number of revolutions *Number of revolutions
Compressor block SAB 110 SM SAB 110 SF SAB 110 LM SAB 110 LF SAB 128 HM Mk2 SAB 128 HF Mk2 SAB 128 HM Mk3 SAB 128 HF Mk3 SAB 163 HM Mk2 SAB 163 HF Mk2 SAB 163 HM Mk3 SAB 163 HF Mk3 SAB 202 SM SAB 202 SF SAB 202 LM SAB 202 LF SV 17 SV 19 FV 19* SV 24 FV 24* SV 26 FV 26* SAB 81 SAB 83 SAB 85 SV 87 SV 89 LW 98 98 98 98 102 106 101 104 105 109 103 106 104 105 104 105 100 101 101 103 104 103 107 101 102 103 105 108

=-15C = +35C = R22/R717 = 2950 rpm. = 6000 rpm.

LP 81 81 81 81 84 88 84 86 86 90 86 87 85 86 85 86 83 84 86 85 86 85 85 86 85 86 86 85

Evaporating temperature Condensing temperature Refrigerant Number of revolutions

=-35C =-5C = R22/R717 = 2950 rpm.

Compressor unit
SAB 163 BM SAB 163 BF

LW
106 110

LP
88 92

Evaporating temperature Condensing temperature Refrigerant Number of revolutions

=-15C =+35C = R22/R717 = 2950 rpm.

Compressor block
VMY 347 H VMY 447 H VMY 536 H

LW
97 100 104

LP
82 85 88

Evaporating temperature Condensing temperature Refrigerant Number of revolutions

= 0C =+35C = R22/R717 = 2950 rpm.

Compressor block
VMY 347 M VMY 447 M VMY 536 M

LW
99 101 105

LP
84 86 89

18

0178-250-EN

Vibration Data for Compressors - All Compressor Types

Vibration data for YORK Refrigerations Sabroe reciprocating compressors complies with: the ISO 10816, standard, Part 6, Annex A, group 4, AB, which fixes max. permissible operating vibrations at 17.8 mm/s. Vibration for YORK Refrigerations Sabroe screw compressors complies with: ISO 10816 standard, part 1, Annex B, Class III, C, which fixes max. permissible operating vibrations at 11.2 mm/s. The measurements are made as illustrated in the figure below (points A-D).

0170-115-EN

01.01

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 vibration dampers delivered by YORK Refrigeration (additional), the vibrations against the foundation are reduced by: - 85-95% for screw compressor units - 80% for recip. compressor units S However, a higher vibration level may occur if:

- Motor and compressor have not been aligned as described in the Instruction Manual. - For screw compressors, if the compressor runs at a wrong Vi-ratio. - The pipe connections have been executed in a way that makes them force pull or push powers on the compressor unit or transfer vibrations to the unit caused by natural vibrations or connected machinery. - The vibration dampers have not been fitted or loaded correctly as indicated in the foundation drawing delivered together with the order.

0178-250-EN

19

Data for SAB 202 compressor & unit

For removal of the fine separator element IEC 355
UNISAB II

Height

700

700

Lenght

Width

1) OWSG = Heat exchanger w/shell (water) OOSI = Heat exchanger w/shell (refrigerant)

2) Excl. motor, oil, water and refrigerant

Fig. 1
AARHUS DENMARK

Type of compressor unit

On the base frame of the compressor unit a name plate has been fitted as shown in fig. 1. This name plate provides you with all relevant information in accordance with CE labelling.

Type Approval no. Serial no.

Max. operating pressure Test pressure Compressor and vessel data: See their nameplates

bar bar

20

T290927_0

0178-250-EN

0178-254-EN

SAB 202

R717 R22 R134a R404A/R507 R407C

OWSG, OOSI

1905

3234

1915

4000

00.05

Compressor type

Refrigerant

Oil cooling system 1)

Max. dimensions Width mm Length mm Height mm

Max. net weight Kg 2)

Compressor data SAB 202

Compressor Rotor Intern. Rotor L/D P Motor at 2950 Motor at 3550 type drive volume dia. max. male rotor swept vol. male rotor swept vol. ratio 1) Vi mm bar r/min m3/h r/min m3/h
SAB 202 S-M SAB 202 S-F SAB 202 L-M SAB 202 L-F male female 1.8-4.5 male female 2.0-4.5 202 202 202 202 2.2 16 1.7 20 2950 4425 2950 4425 1229 1843 1590 2385 3550 5325 3550 5325 1479 2218 1914 2870

L = Rotor length

D = Rotor diameter

1) See permissible operating limits, however, in the Operating Limits Diagrams

Block weight Kg
SAB 202 S-M SAB 202 S-F SAB 202 L-M SAB 202 L-F 950 950 1050 1050

Centre height mm
315 315 315 315

Operating limits
The enclosed diagrams for R717, R22, R134a, R404A/507 and R407C indicate the limits within which the compressor is permitted to work.

Please observe the following: S The upper operating limits are for Male Drive and Female Drive, respectively (see compressor type on p. 1). S The use of an ecconomizer is allowed within the entire permissible operating area of the compressor.

0178-250-EN

21

Operating limits R717

SAB202S SAB202L
C 60 50 40 Condensing temperature 30 20 10 0 --10 --20 --30 --60
Max. limit for model S Max. limit for model L MALE DRIVE

FEMALE DRIVE

R717
C

--50

--40

(T250842_0)

--30 --20 --10 0 10 Evaporating temperature

20

Operating limits R22

SAB202S SAB202L
C 60 50 40 Condensing temperature 30 20 10 0 --10 --20 --30 --60
Max. limit for model S Max. limit for model L MALE DRIVE

FEMALE DRIVE

R22

--50

--40

(T250841_0)

--30 --20 --10 0 10 Evaporating temperature

20

22

0178-250-EN

SAB 202S/L VMY 447H/M

Operating limits R134a

C 70 60

Max. limit for model S/H

Max. limit for model L/M MALE DRIVE

SAB 202: FEMALE DRIVE

Condensing temperature

50 40 30 20 10 0 --10 --20 --50

VMY 447: Below curve full flow oil pump required HLI + ECO

HLI

SAB 202: no HLI operation

R134a

--40

(T250821_1)

--30 --20 --10 0 10 Evaporating temperature

20

30

Operating limits R404A - R507

SAB202S/L VMY447H/M
C 50 40 Condensing temperature 30 20 10 0 --10 --20 --30
VMY 447: Below curve full flow oil pump reguired HLI + ECO SAB 202: FEMALE DRIVE Max. limit for model S/H Max. limit for model L/M MALE DRIVE HLI

SAB 202: no HLI operation

R404A-R507
0 10 C

--70 --60 --50 --40 --30 --20 --10

(T250830_2)

Evaporating temperature

0178-250-EN

23

Operating limits R407C

TC C 60 50 Condensing temperature 40

SAB 202 S/L, VMY 447 H/M VMY 436 MB/B, VMY 536 H/M/B
Max. limit for model S/H, SAB 110L Max. limit for model M, SAB 202L MALE DRIVE

HLI FEMALE DRIVE

30 20 10 0 --10 --20 --30 ---70 --60 --50

HLI + econ SAB 202: NO HLI operation

Limit - model MB/B

SAB 110 standard units not for Booster opr. VMY 447: Below curve full flow oil pump required

R407C
--40 --30 --20 --10 0 10 20 TE C

(T250133_1)

Evaporating temperature

24

0178-250-EN

Compressor and unit operation SAB 128 Mk3, SAB 163 Mk3 and SAB 202

During operation of the compressor, the below points should be observed. These are described in detail in the following sections. 1. Preparations before starting up. 2. Initial start. 3. Current control requirements at normal operation. 4. Normal stop.
01.05

d) Connect the vacuum pump to valve pos. 24 and empty unit to a vacuum of approx. 4-5 mm Hg. If necessary, use a thermostatic vacuum gauge for measuring of pressure and fill up with dry air or nitrogen until the pressure reaches 1 bar. Then empty again to 4-5 mm Hg. e) Charging of oil Charging of oil is carried out by means of a portable oil charging pump, see Fig. 1.1. The charging of oil is carried out in the following way: The high-pressure hose pos. 7, see Fig. 1.1, is connected to the charge valve pos. 24 on the unit via the non-return valve pos. 12 and the correct reduction nipple. See also Fig. 1.2. The free end of the suction hose from the pump pos. 1 is placed together with the by-pass hose pos. 2 in the oil barrel. The ball valve pos. 9 and the charge valve pos. 24 will open whereupon the pump pos. 5 will start. The oil will now circulate until the system is free from air bubbles whereupon the ball valve pos. 9 will close. The oil will now be charged to the unit. When the desired amount of oil has been charged, the pump will stop and the charge valve pos. 24 will close. Open the ball valve pos. 9 carefully so that the pressure is equalized. The hoses can now be dismounted. Loosen the non-return valve carefully so that the remaining pressure is equalized. Remember to mount the cap nut on the charge valve and to seal the oil barrel if there is any oil left.

5. Preparations before a lengthy standstill period. 6. Pressure testing. 7. Evacuation. 8. Operating log.

0178-255-EN

1. Preparations before starting up

After the compressor unit has been installed in its final place and all connections for refrigerant, water and electricity, instruments and safety switches have been established, carry out the following: a) Check that the rotating direction is correct with the coupling dismounted. The rotating direction is marked by an arrow on the suction cover of the compressor. b) Check the rotating direction of the oil pump. c) Mount coupling and check that tolerances and alignment are in accordance with the coupling instruction.

0178-250-EN

25

Fig. 1.1
1 DETAIL A 1/4 RG 20 3/8 RG

1/2 RG

7/8 RG

9 7

(RG = PIPETHREAD) LENGTH: 460 DETAIL A HEIGHT: 350 WIDTH: 340 WEIGHT: 22

Fig. 1.2 Piping Diagram for Oil Charging

A 24 COMPRESSOR UNIT

20 12

5 1 2

26

0178-250-EN

Oil charging, weight and shipping volume SAB 128/163 Mk3 and SAB 202
Oil Charging (oil level at the middle of upper sight glass during operation)
Oil cooler Type OOSI 1614 OOSI 2114 OOSI 2714 OOSI 3214 OOSI 4114 OWSG 1615 OWSG 1619 OWSG 2115 OWSG 2119 OWSG 2719 OWSG 3219 OWSG 4119 HLI Litres SAB 128 11 20 SAB 163 11 20 31 48 SAB 202 11 20 31 48 86 25 39 63 78 119 0 Oilseparator Litres SAB 128 SAB 163 SAB 202 Compressor + Pipes Litres SAB 128 SAB 163 SAB 202 SAB 128 80 89 Total unit, Litres SAB 163 103 112 123 140 SAB 202 216 225 236 253 291 230 244 278 283 324 205

25 39

25 39 63

87 60 80 180 9 12 25 97

117 131 155

69

92

f) Open all internal valves. g) Slowly open the suction and discharge stop valves and fill up the plant with refrigerant according to the instruction manual for this plant.

f) Check the position of the Vi-slide and make sure that the capacity slide is in its minimum position. g) Start compressor as described in the UNISAB II manual. h) Watch out for abnormal sounds and check that the compressor works up a differential pressure. If nothing abnormal has been observed, allow the compressor to work at normal operating pressure, and adjust the capacity regulation to its immediate requirement or to automatic operation. Currently check pressure, temperatures and power consumption. Important Pay attention to the procedures for running down of the evaporating pressure as indicated in the instruction on refrigeration plants. i) Do not leave the compressor for the first 60 mins.

2. Initial start-up
a) Check that the compressor is easy to turn by hand. b) Check oil level in the oil separator. c) Open suction and discharge stop valves completely. Open the remaining internal valves. Check that all external valves on the refrigeration plant are open or closed in accordance with the piping diagram. d) Check the free access of the cooling water to the oil cooler, if any. e) Check the supply of power to the compressor.

0178-250-EN

27

3. Current control at normal operation

The following should be noted daily:

Suction pressure (bar). Suction temperature (C). Discharge pressure (bar). Discharge pipe temperature (C) Oil temperature (C). Power consumption (amp.). Number of hours The position of the Vi slide

Important Do not use the plant compressors for pressurizing the plant. Water or any other liquid must not be used in connection with pressure testing. In case nitrogen is used it is important to place a reduction valve with pressure gauge between the nitrogen cylinder and the plant. During pressure testing it is important that pressure transducers and other control equipment are not exposed to the test pressure. Similarly, the compressor stop valves must be closed during testing. Normally, the plant safety valves should be blanked off during the pressure testing as their opening pressure is lower than the test pressure. Important During this pressure testing no persons are allowed in the rooms with plant components or in the vicinity of the plant outside the rooms. S The entire plant is strength tested according to the local rules for pressure testing. S Usually, the test pressure must not be allowed to exceed the design pressure. However, also in this case the local rules and regulation apply. S In case there is a request for the compressor to be pressure tested together with the unit, the test pressure on the compressor must not exceed 24 bar. S Hereafter, lower the pressure to 10 bar for 24 hours - as a first leak testing - as a tight plant will maintain this pressure during the entire period. During leak testing, it is permitted to enter the rooms and approach the plant.

4. Normal stop
Regulate the compressor down to min. capacity. Set the change-over switch on stop.

5. Preparations before a lenghty standstill period

Once the compressor has been pressure equalized, close the stop valves of the compressor unit as well as all other valves connecting the unit to the plant, e.g. those of oil coolers or economizers. Switch off and safeguard the compressor main switch.

6. Pressure testing
Before charging the plant with refrigerant, it must be pressure tested and emptied. Pressure test the plant using: S Dry air - Pressurized cylinders containing dry atmospheric air may be used - never use oxygen cylinders. S Air compressor for high pressure. S Nitrogen.

28

0178-250-EN

S As a second leak testing search all weldings, flange joints etc. for leaks by applying soapy water, while at the same time maintaining the 10 bar pressure. During the pressure testing set up a pressure test report containing the following:

For evacuation, use a vacuum pump which empties the plant of both air and water vapour. The vacuum pump must be able to lower the pressure to approx. 0.1 mm Hg (mercury column), and it must be equipped with a gas ballast valve. Use this valve to the greatest extent possible in order to prevent condensation of water vapour in the vacuum pump. Important Never use the refrigeration compressor for emptying of the plant. In order for an evacuation to be satisfactorily carried out the final pressure must be below 5 mm Hg. Attention should be paid to the fact that there is a risk that the water still present in the refrigeration plant may freeze in case the ambient temperatures are below 10C. In that case it is necessary to heat up the surroundings of the components as ice only evaporates slowly. Evacuation is recommended carried out as follows: S Carry out an evacuation to a pressure below 5 mm Hg. S Next blow in dry air or nitrogen in the system to a pressure equal to atmospheric. S Evacuate again to a pressure below 5 mm Hg. S Shut off the vacuum pump from the refrigeration plant and check that the pressure does not rise within the next few hours. If there is still water in the system, it will evaporate and cause a pressure increase. This means that the evacuation has not been satisfactorily carried out and has to be repeated.

Date of pressure testing. Who carried out the testing. Test pressure Comments.

7. Evacuation
After pressure testing the refrigeration plant must be evacuated in order to remove atmospheric air and moisture. Evacuation must be carried out on all types of refrigeration plants regardless of the type of refrigerant to be filled into the plant. Note that HCFC, HFC and CFC refrigerants hardly mix with water. Consequently, it is important to make a particularly thorough evacuation of these plants. The boiling point of a liquid is defined as the temperature by which the steam pressure is equal to atmospheric pressure. The boiling point of water is 100C. If the pressure is lowered, so is the boiling point of water. The following table indicates the boiling point of water at very low pressures:
Boiling point of water C At pressure mm HG

5 10 15 20

6,63 9,14 12,73 17,80

0178-250-EN

29

8. Operating log
To be in control of the operating conditions of the plant it is recommended to keep an operating log in order to be able to keep an eye on any changes that may occur in the operatPower consump. Electric motor Fact.: No.: CV/kW: COS : n: rpm

ing conditions. Below table is an example of such an operating log. The information in this log is needed in order to make a satisfactory diagnosis.
Temperature
Machine room

Compressor
Suction pipe temperature Disch. man. Number of revolutions Suct. man. Discharge pipe temp.

Condenser 1
Air
Inlet

Time

2
Suction pipe

Cooling water
Inlet Outlet

Air

Suction pipe

Temp. of ambient air C

kW

C C

rpm C

lh

Outlet

Pres.

Temp.

C C

Inlet Outlet Pres.

Temp.

30

0178-250-EN

Service Schedules for screw compressors SAB 110, 128/163 Mk3, 202 & VMY
Good and careful servicing of the compressor and the unit is of great importance for their proper functioning and service life. It is therefore recommended that these service instructions be followed; based on the number of operating hours, they indicate the service tasks to be carried out. S Remove main fuses for the compressor motor in order to prevent it from starting inadvertently. Compressor and unit are now ready for inspection and dismantling, if required.

Replacement of oil filter

In case only the oil filter has to be replaced, follow below procedure depending on the the type of your compressor: SAB 110, SAB/163 and SAB 202 Above-mentioned compressors all have builtin oil filters. Follow the procedure described in the previous passage: Preparations before compressor 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 oil filters (mounted in parallel) apply procedures A or B. A: Units with one oil filter only Bring compressor to minimum capacity, and stop it. When pressure in unit is equalized to suction pressure, close stop valves before and after oil filter. Any over pressure in filter housing is equalized to atmospheric pressure through the evacuation valve on filter housing. Cover on filter housing can now be dismantled, as described in section Oil filter.

Preparations before compressor inspection

99.05

0178-028-EN

Before dismantling any part of the compressor or unit for inspection or repair, the pressure must be reduced to atmospheric pressure. This is done as follows: S Regulate the compressor down to its lowest capacity stage and stop it. S Now close all stop valves in the pipe connections to the unit except for the suction stop valve pos. 20, which remains open until the pressure in the unit has been equalized to the suction pressure. This is described in the passage called The nonreturn valve. S Close suction stop valve pos. 20. S Any excess pressure in the unit is equalized to atmospheric through stop valve pos. 24. See the Key to Piping Diagrams and the chapter on: Protecting the Environment. The heating element in the oil separator must remain connected until the pressure is completely equalized, thus boiling the refrigerant out of the oil.

0178-250-EN

31

B: Units with two parallel oil filters While the compressor is operating, the stop valves before and after one of the oil filters must be closed. Over pressure in filter housing is equalized to atmospheric pressure through evacuation valve on filter housing. Cover on filter housing can now be dismantled, as described in section Oil filter.

en to the lubricating system of the unit and absorbed by the oil filter. These impurities may result in a need to change the oil filter cartridge shortly after initial start-up. It is equally important to check the oil at regular intervals as specified in the sections Checking the oil and Assessing the oil. Purification of the oil may be done by means of a 3 micron filter in a closed system. During this process, the oil must not come into contact with the oxygen and moisture in the air. In addition, it is important that all pressures and temperatures be kept within the specified values and that filters be kept clean; provided inspection is carried out to the schedules prescribed below, compressor and unit will work efficiently and achieve a long service life. The following charts indicate the schedules for checking the oil in the compressor unit and a more detailed description of the operations to be performed during scheduled service inspections.

Cleansing of oil in the unit

The most critical time for an oil filter is, however, right after initial start-up of compressor. Although an effort should be made to keep the plant free of any impurities when assembled, experience shows that it may be difficult to avoid impurities in tubes and vessels. These impurities will be conveyed by the suction gas to the suction filter, where largesized impurities are intercepted. Smaller impurities will pass through the filter and be conveyed to the oil separator, where they are suspended in the oil. From here they are tak-

32

0178-250-EN

Checking the oil

Operating hours between main inspections See chart for main inspections 20000h 30000h 40000h * R717 * R717 * R717 Number of operating hours from initial startup and after each main inspection (see footnote) 50 200 1000 2500 5000 10000 15000 20000 25000 30000 35000 40000

Service schedules

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. Serviceterminer efter frste igangstning oil. The oil charge must be replaced with fresh af kompressoren. Serviceterminer efter hvert hovedeftersyn. Service schedules after initial start-up of compressor. Service schedules after each main inspection.

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

0178-250-EN

33

Activities during a service inspection

Periodic service 1 Daily 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.

2 3

After 50 hours operation After 200 hours operation

2.1 Clean the suction filter. 3.1 Clean the compressor suction filter. 3.2 Take an oil sample from the oil separator and appraise it visually, or send the sample to a laboratory for anlysis. Both methods are described in the section entitled Assessing the oil. 3.3 Replace the filter cartridge in the oil filter, unless it has been replaced earlier. 3.4 Clean all other oil filters and connections to and from the compressor. 3.5 Check the coupling and its alignment (SAB 110*) 3.6 Check that all screws and nuts have the correct torque. 4.1 Clean the compressor suction filter. 4.2 Take an oil sample from the oil separator and appraise it visually, or send the sample to a laboratory for analysis. Both methods are described in the section entitled Assessing the oil. 5.1 Clean the compressor suction filter. 5.2 Take an oil sample from the oil separator and send it to a laboratory for analysis, as described in Assessing the oil. 5.3 Fit a new oil filter cartridge. 5.4 Clean all other oil filters and connections to and from the compressor. 5.5 Check the coupling and its alignment (SAB 110*) 5.6 Check that the pressure switches and thermostats function correctly (refer to the set values in the instruction book). If UNISAB II computerized control is fitted, check the transducers (see the instruction manual for UNISAB II )

After 1000 hours operation

After 2500 hours operation

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.

34

0178-250-EN

Periodic service 6 After 5000 hours. operation This service should be repeated after every 5000 hours of operation

Activity
6.1 Clean the compressor suction filter. 6.2 Fit a new oil filter cartridge. 6.3 Clean all other oil filters and connections to and from the compressor. 6.4 Check the coupling and its alignment (SAB 110*) 6.5 Check that the pressure switches and thermostats function correctly (refer to the set values in the instruction manual). If UNISAB II computerized control is fitted, check the transducers (see the instruction manual for UNISAB II) 6.6 Take an oil sample from the oil separator and send the sample to a laboratory for analysis, as descri bed in the section entitled Assessing the oil. Please also refer to the table entitled Checking the oil.

Major service Carried out as specified for the individual screw compressor type. (See the diagram for major service)

7.1 Total overhaul of the compressor, including fitting new 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 by the motor manufacturer. 7.3 Fit a new oil filter cartridge. 7.4 Drain off the compressor oil and charge with new, fresh oil. 7.5 Check the coupling and its alignment (SAB 110*) 7.6 Check that the pressure switches and thermostats function correctly (refer to the set values in the instruction book). If UNISAB II computerized control is fitted, check the transducers (see the instruction manual for UNISAB II)

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.

0178-250-EN

35

Assessing the oil

Oil in refrigeration plants is a vital part of the compressor, as it not only lubricates and cools the movable parts of the compressor, it also prevents abrasive particles from entering the bearings. An analysis of the oil can give important information on how the compressor is running. We would, therefore, advise that the oil analyses be carried out at the intervals prescribed. An oil sample must be drawn off while the compressor is in operation, which gives a representative sample. Before taking the sample, clean the drain valve and tap a little oil off, to prevent any impurities which may have accumulated in the valve or the piping from mixing with the sample.
Warning If the oil sample is poured into a glass bottle, this must not be hermetically sealed until all the refrigerant in the oil sample has evaporated. Refrigerant in the oil may produce excess pressure in the bottle with subsequent risks of explosion. Never fill a bottle up completely. Do not send glass bottles through the postal service - use purpose-made plastic bottles. Please see below.

Analytical evaluation
Naturally, the oil sample can be analysed by the oil company which supplies the oil. As a special offer to our customers YORK Refrigeration has developed an analytical concept, which is able to analyse all oil makes. This will mean a uniform reporting of the results. The analysis allows the following to be determined: S Whether or not the oil is still usable, if necessary after filtering. S Whether solid particles possibly present in the oil originate from the bearings or other components exposed to wear and tear in which case the compressor must be inspected. S Each report will include the corresponding measuring results from the previous 3 oil analyses. In this way you will be able to follow up on the state of both the oil and the compressor from one analysis to the next.

Visual assessment
If you pour the sample into a clean, transparent glass bottle or a test-tube and hold it up to a clear light source, it will be easy to assess the quality. You can also compare the sample with the fresh oil of the same make and grade. An oil which you approve on the grounds of a visual assessment must: S be clear and shiny S not contain any visible particles S feel viscous, smooth and greasy when a drop is rubbed between two fingers. If you dont feel that you can approve the oil by visual assessment, charge with new oil or send a sample to a laboratory for analysis.

36

0178-250-EN

Procedure
S A form set with a plastic sampling bottle and a dispatching envelope can be requested from the local YORK Refrigeration representative. S The oil sample must be drained from the cleaned oil drain valve into the sample bottle. Screw the lid loosely on and let the bottle stand for a few hours to enable refrigerant contained in the oil sample to evaporate before sending it to the laboratory. Do not fill the bottle completely.

S Please follow the Sampling and Shipping Instructions enclosed in the form set in which the address of the laboratory in Holland are also mentioned.

Analysing the oil

The following table states some average values that can be applied in practice. However, you should be on the alert whenever the results of the analyses approach these values. In some cases the water content of 100 ppm in HCFC plants may be too much and thus lead to Cu-plating in the shaft seal.

Limiting values
Sabroe Olie PAO 68 Sabroe Olie AP 68 Spec. Vrdi 64 0,01 Max. 74 0,2 0 100
rapport rapport

Sabroe Olie A 100 Min. 51 Spec. Vrdi 100 0,05 Max. 115 0,2 0 100
rapport rapport

Parameter
Viskositet @ 40C TAN *1) SAN * 2) Vand Udseende Farve Uoplseligt Pentan Oxidering Nitrering Kvlstofforbindelser

Unit
cSt mg KOH/g mg KOH/g ppm W% abs/cm abs/cm abs/cm

Metode
ASTM D 445 ASTM D 664 ASTM D 665 Karl Fisher ASTM D 1500 MM 490 (5m) IR,1700-1720 /cm IR,1627-1637 /cm IR,1547-1557 /cm

Spec. Vrdi 66 0,03 -

Max. 76 0,2 0 100

rapport rapport

Min. 53 -

Min. 80 -

0,05 5 5 0,5 -

0,05 5 5 0,5

0,05 5 5 0,5

Max. vrdier for metalindhold i olien Bly Kobber Silicium Jern Krom Aluminium Tin ppm ppm ppm ppm ppm ppm ppm ICP ICP ICP ICP ICP ICP ICP 10 10 25 100 5 10 10 10 10 25 100 5 10 10 10 10 25 100 5 10 10 -

1): TAN (Total Acid Number/ Total Syretal) rapporteres kun for 2): SAN (Strong Acid Number/Strk Syretal) rapporteres kun

for anlg, hvor ammoniak ikke anvendes anlg, hvor ammoniak ikke anvendes

0178-250-EN

37

A report is drawn up for every sample received. This report concludes: S Whether the oil can still be used - without taking any further action. S Whether the oil can be used after it has been filtered through a very fine filter. If this is necessary, the oil must be pumped directly from the compressor unit through a 3 micron filter and back to the unit. The

system must be completely closed, to prevent the oil being affected by moisture in the air.

Whether the oil is no longer fit for use.

The report will always be sent to the address stated on the sample label included in the form set. A copy will be sent to YORK Refrigeration so that we are in a position to advise you, if required.

38

0178-250-EN

Major Service Intervals SAB 110, SAB 128/163 Mk3, SAB 202
Condensing temp.

TC(Bar,a) TC (C)
23.1 20.3 17.8 50 55

Extreme operating conditions 20000 hour interval

Normal operat. cond. 30000 hour interval

15.5

45

13.5 11.7 10
95.10

40 35 30 25 20 15 10 5 0 -5 -10 -20 -30 -50

8.6 7.3

0178-030-EN

6.2 5.2 4.3 3.5 2.9 2.4 1.9 1.2 0.7 0.4

Booster conditions 40000 hour interval

R717 R717

(C)

(Bar,a)

Evaporating temp.
-50 -30 -20 -10 -5 0 5 10 15 20 25

TE (C) TE (Bar,a)
T0177068_0

0.4 0.7 1.2 1.9 2.4 2.9 3.5

4.3

5.2

6.2

7.3

8.6

10.0

0178-250-EN

39

Oil charging, weight and shipping volume SAB 128/163 Mk3 and SAB 202
Oil charging (oil level at the middle of upper sight glass during operation)
Oil cooler Type SAB 128 OOSI OOSI OOSI OOSI OOSI OWSG OWSG OWSG OWSG OWSG OWSG OWSG HLI 1614 2114 2714 3214 4114 1615 1619 2115 2119 2719 3219 4119 11 20 Litres SAB 163 11 20 31 48 25 39 63 0 SAB 202 11 20 31 48 86 25 39 63 78 119 0 60 80 180 9 12 25 Oil separator Litres SAB SAB SAB 128 163 202 Compressor + pipes Litres SAB SAB SAB 128 163 202 Total, unit Litres SAB SAB SAB 128 163 202 80 89 103 112 123 140 117 131 155 92 216 225 236 253 291 230 244 278 283 324 205
96.02

25 39

87 97

69

Weight (excl. motor, refrigerant, oil and water)

Oil cooler Type SAB 128 OOSI OOSI OOSI OOSI OOSI OWSG OWSG OWSG OWSG OWSG OWSG OWSG HLI 1614 2114 2714 3214 4114 1615 1619 2115 2119 2719 3219 4119 78 130 Kg SAB 163 78 130 180 215 130 210 310 20 SAB 202 78 130 98 180 215 380 210 310 440 740 20 700 950 2100 230 500 1040 Basic Unit Kg SAB SAB SAB 128 163 202 Compressor block Kg SAB SAB SAB 128 163 202 Total, unit Kg SAB SAB SAB 128 163 202 1008 1060 1528 1580 1630 1665 1580 1660 1760 1470 3218 3270 3320 3355 3520 3270 3350 3450 3580 3880 3160

120 185

1050 1115

20

950

Shipping volume (excl. motor)

Oil cooler Type Compressor type m3 SAB SAB SAB 128 163 202 5 6 4 8 11 9 7 12 10

OOSI OOSI OOSI OWSG OWSG OWSG HLI

2114 3214 4114 2115 2719 4119

40

0178-250-EN

0178-256-EN

Temperature and pressure settings SAB 202

The setting of pressures and temperatures must be made in accordance with tables 1 and 2, supplemented by the numbered notes. Any deviation from the factory settings can, in view of the current operating conditions, be written down in the column Current plant.

Table 1 - Screw compressors - Measured and calculated pressures Measuring Suction pressure [bar] High alarm High warning Low warning Low alarm High alarm High warning Low warning Low alarm Low warning Low alarm Settings Current plant Factory 5,0 1,5 1,0 16,0 15,0 -1,0 4,0 2,5 Notes 3 3 3 1 1 1 2+4 2+4

96.12

Discharge pressure [bar]

0178-275-EN

Oil press. [bar] Calculated value

SAB Mk 1 compressors

Oil press. [bar] Calculated value

SAB Mk 2 compressors

Low warning Low alarm

0,0 0,0

2+6 2+6

Oil press. [bar] Calculated value

SAB Mk 3 compressors SAB 202 compressor Stop/start of oil pump

Low warning Low alarm Set point 1 Set point 2 Low warning Low alarm Low warning Low alarm Set point 1 Set point 2 High alarm High warning

1,0 0,5 2,5 4,0 2,0 1,5 4,0 3,0 5,5 7,0 1,0 0,7

2+6 2+6

Oil press. [bar] Calculated value

VMY Mk 2-2,5 compressor

2+6+10 2+6+10 2+6 2+6

Oil press. [bar] Calculated value

VMY Mk 3 compressors Stop/start of full flow pump

Diff. pressure across oil filter [bar] Calculated value

2+7 2+7

0178-250-EN

41

Table 2 Screw compressors - Measured and calculated temperatures Measuring Discharge temp. [C] High alarm High warning Low warning Low alarm High alarm High warning Low warning Low alarm High alarm High warning Low warning Low alarm High alarm High warning Low warning Low alarm Low warning Low alarm Settings Factory 100,0 90,0 -65,0 60,0 55,0 25,0 20,0 60,0 50,0 4,0 2,0 110,0 100,0 2,0 0,0 10,0 0,0 Current plant Notes 1 1

Oil temperature [C]

2+4 2+4 2+4 2+4 1 1 1 1 2+4 2+4 2+4 2+4 2+4 2+4

Brine temperature [C]

Suction gas superheat [C] Calculated value Disch. gas superheat [C] Calculated value

42

0178-250-EN

Notes:
Note 1 Note 2 Note 3 Note 4 Note 5 Note 6 Note 7 Note 8 Note 9 Note 10 The alarm cannot be switched off until the cause has been removed. The alarm can be switched off immediately The alarm is switched off automatically. Alarm monitoring 300 sec delayed after compressor start. (not defined for screws) Alarm monitoring 45 sec delayed after compressor start. A delay of 30 sec, no matter when the limits are exceeded. (not defined for screws) (not defined for screws) For VMY Mk 2-2.5 calculate the following: Oil pressure = oil pressure (after oil filter) - discharge pressure. For all other compressor types calculate: Oil pressure = oil pressure (after oil filter) - suction pressure -

0178-250-EN

43

Servicing the Refrigeration Plant

Both during start-up and operation it must be made sure that the plant is working correctly. Compressor and condenser must be able to work satisfactorily, safety devices must be intact and the evaporator must function under load. i.e.: S the desired temperatures are observed, S the oil pressure and discharge pipe temperature on the compressor are correct,

S the condenser pressure is not excessively high and S the plant works as it is supposed to. The service instructions outline some general guidelines for servicing the refrigeration plant with some references to the instruction manual. The service instructions should therefore be read and followed carefully.
97.07

Check
Condensing pressure

Interval

Activity
Excessively high pressure may be due to: reduced cooling effect air in the condenser. Too low condensing pressure implies a risk of restricting the refrigerant supply to the evaporator. Normal discharge pipe temperature according to instructions. Accumulated dirt causes reduced refrigerant supply to the evaporator. If a filter has a hot inflow and cold discharge, this may be due to clogging of the component. Some installations are provided with a sight-glass featuring moisture indicator. If the indicator colour switches from green to yellow, there is moisture in the refrigerant. Change the drying filter regularly.
0171-470-EN

Pressure and temp.

Daily

Discharge pipe temperature

Filters

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

Clean when required

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

Dehumidifier

When required

44

0178-250-EN

Check Refrigerant charge

Interval

Activity Inadequate charge results in reduced plant capacity and often leads to an excessively high discharge pipe temperature.

Refrigerant Leak detection Periodically

The plant must be searched regularly for leaks. Flanges and joints settle during the initial operation period of the plant. They must therefore be tightened and checked. Adjust operating point and check the function. Replace switch system if sticking. Clean and lubricate according to suppliers instructions. At temperatures lower than -25C, use special lubricant.

Automatic controls

Safety pressure controls Automatic operating controls Alarms Lubrication of electric motors

Periodically

Electric motor

Periodically Alignment of coupling V-belt drive

Check in accordance with the instructions of the instruction manual. Tighten loose V-belts, if any, or replace with new ones. Marine condensers are normally protected against galvanic corrosion by the mounting of corrosion plugs in the condenser covers. Metallic contact between corrosion plug and cover is essential to proper functioning. Unproblematic operation is conditional on the evaporator being kept free of ice. Defrost as and when required. Check evaporator, intermediate cooler, receiver, etc. for oil accumulation. Exercise caution; use a gas mask

Condenser

Corrision

Periodically - normally min. 4 times a year

Frosting-up Evaporator Oil draining (ammonia plant)

When required

Periodically

0178-250-EN

45

Maintenance of compressor SAB 202 Dismantling and assembly

Service work on the SAB 202 compressor must be carried out of by professional and well-trainied staff who are familiar with the compressor. This instruction is a description of the complete dismantling and assembly of the compressor, although this will not always be required. When dismantling, parts should be marked to ensure that they can be remounted in the same position as before. Torque moments for screws and bolts as stated in the table on Torque moments should be strictly observed. As O-ring gaskets have a tendency to expand beyond their size when exposed to oil and refrigerant, it is useful to have an extra set of gaskets ready before starting work. See the list of spare part sets in this instruction manual.

Tools
Apart from having the necessary tools at hand (see the tool list in the instruction manual), it is an advantage to place the compressor on an iron plate when dismantling completely. This will allow for easy removal of oil leaking from the compressor during disassembly. It is also recommended to position the compressor in a room with plenty of surrounding space and to ensure that the room is clean and dustfree. Evacuation of refrigerant gas Shut off suction and discharge stop valves and evacuate the refrigerant gas as described in the section Protecting the environment. Removal of various accessories When working on the compressor, the power to the compressor motor must be cut off and it must be ensured that the compressor cannot be inadvertently started (if needed, remove the main fuses). During an overhaul of the compressor or if the compressor is removed from the unit, dismantle the following parts: 1. Coupling between compressor and motor. 2 Flanges connecting the suction and discharge side of the compressor to the

Preparations before dismantling

The following is a description of a complete dismantling, inspection and assembly of the compressor. Partial dismantling and inspection can be undertaken while the compressor is secured to the base frame. To allow a complete dismantling, however, the compressor must be lifted off the baseframe. For further details, see the section below entitled Sequence for dismantling the compressor. It is important that dismantling and handling of the various parts be done as described in this instruction in order to avoid damage when restarting the compressor. Therefore, read the instructions carefully before commencing the work. Before disassembly of the compressor or dismantling of its pipe connections, the pressure must be equalized to atmospheric.

46

0178-250-EN

0178-260-EN

00.12

plant and oil separator (in case of total dismantling). 3. Oil pipes connected to the compressor. Note: There may be oil in these pipes. They should therefore be loosened carefully in order to allow for collection of this oil. When the oil pipes have been removed, they should be stored to prevent them from being bent or damaged. 4. Electrical connections to the compressor block In the following section the pos. numbers refer to the spare parts dwg. 0661-850 for SAB 202. Draining oil from the compressor: Following dismantling of the oil pipes, some oil may still be left in the compressor. Most of it can be removed by unscrewing the threaded plug pos. 24 on the bottom side of the compressor while still suspended, for example, in the crane. (see weights under Compressor Data SAB 202) Note: For cleaning or wiping of compressor parts, never use twist or any other fluffy material.

Dismantling the compressor Sequence for dismantling of the compressor:

Parts to be dismantled Oil filter Suction filter and compr.protect.system Non-return valve Shaft seal, balance piston and cap cover Thrust cover/regulating cylinder Regulating slide Slide stop for Vi-regulation Suction cover and bearings in compressor shaft end Rotors and bearings at compressor discharge end Capacity indicator Sequence 1 2 3 4 5 6 7 8 9 10

Each point is described in the following sections, in connection with the stated numbers.

Reassembling the compressor

Clean all parts carefully before reassembly. Examine the parts for damage and wear. Replace damaged or worn parts with new ones. Examine all gasket to see if they can be reused. If in doubt, replace with new parts. Before remounting, lubricate all parts, including screws, with clean fresh refrigerant oil.

0178-250-EN

47

1. Oil filter
Oil filter pos. 470 is a replaceable filter cartridge, mounted in the compressor block as shown on the spare parts drawing. As the filter capacity of the filter cartridge is being used the pressure loss across the filter will increase. This is registered by the two pressure transducers pos. 752 and pos. 753. Make sure that a new filter cartridge is at hand as the replaced oil filter cannot be cleaned. Before removing the filter cartridge from the compressor block, stop the compressor and the pressure will be equalized to atmospheric pressure. Further, empty the oil filter housing of oil, which is done by using drainage valve pos. 48 - see piping diagram as well as fig. 1.1. This drainage is most easily carried out while there is still some excess pressure left in the compressor.
Fig. 1.1

drained off the oil filter housing, the oil filter can be removed in the following way: 1.1.1. Remove the four screws, pos. 476, while keeping the flange for the oil pipe fixed to the cover, pos. 450. 1.1.2. Dismantle wiring connections on pressure transducer pos. 753. 1.1.3. Remove the four screws, pos. 456, and cover, pos. 450, and oil filter cartridge, pos. 470, can now be extracted manually as one entity. Pay attention to O-rings, pos. 475 and pos. 452. 1.1.4. By dismantling nut pos. 455 the filter cartridge pos. 470 can be pulled out across stay bolt pos. 458. Pay attention to O-ring pos. 453. As it is not possible to clean the filter cartridge, replace it by a new one. 1.1.5. Solenoid filters pos. 459/460 are not dismantled but are wiped clean of any magnetic particles with a clean and fluff-free piece of material. 1.2 Fitting of oil filter 1.2.1. After cleaning cover pos. 450 on the inside, mount filter cartridge pos. 470 and O-ring pos. 453. Fasten these parts with nut pos. 455. 1.2.2. Position the complete cover, pos. 450, together with O-ring, pos. 452, in the compressor and fasten with screws, pos. 456. Make sure that the O-ring, pos. 475, has been fitted. 1.2.3. Mount and fasten screws, pos. 476. 1.2.4. Mount the electric connection to pressure transducer, pos. 753.

48 Cutting ring connection

Pipe dia.OD = 10 mm ID = 8 mm

1.1

Replacement of oil filter

Once the pressures in the compressors has been equalized to atmospheric and oil

48

0178-250-EN

2. Suction filter and compressor protecting valve

2.1 Suction filter The suction filter is built into the compressor housing above the rotors. The purpose of the filter is to collect the impurities conveyed from the evaporator system with the suction gas. Experience shows that a good deal of impurities is collected in the filter during the initial period following start-up of a new refrigeration plant. It is important, therefore, to clean the suction filter when the compressor has operated for 200 hours after the initial start-up. If the suction filter is not taken out and cleaned, there is a risk of it bursting as a result of too high a differential pressure across the filter. Removal and cleaning 2.1.1. When the pressure in the compressor has been equalized to atmospheric,
C

remove the cover, pos. 705, as follows: 2.1.2. Remove the screws, pos. 721, that keep the pipe connection, pos. 720, fixed to the manifold, pos. 710. 2.1.3. Before removing screws, pos. 706, it is a good idea to support the cover, pos. 705, by suspending it in eye bolt no 28 from the tools kit. Fit the eye bolt in the threaded hole in the outer diameter of the cover. Total weight of the cover is approx. 45 kg. 2.1.4. After the screws, pos. 706, have been dismantled, lift the cover a few millimetres and carerully pull it out of the compressor block. Take care that the long valve, pos. 704, does not do any damage to the suction filter, and pay attention to the O-rings, pos. 707 and 722. 2.1.5. The suction filter, pos. 170, is available in an old and a new construction of which the new suction filter is fitted with a collar as illustrated in the drawing:

0178-250-EN

49

The two different filters can be mounted on the compressor randomly. Remove the suction filter manually or pull it out using the two extraction fittings in the old construction, or the two 7 mm diameter holes, pos D, as illustrated in the drawing. Make sure that filth does not get into the compressor when dismantling the suction filter. 2.1.6. Cleanse the suction filter in oil solvent and blow clean it with compressed air. Mounting 2.1.7. Before mounting check that the filter mesh in the suction filter is undamaged. Further, the filter housing in the compressor and cover pos. 705 together with valve pos. 704 must be completely clean without any further dismantling taking place. Make sure that non-return valve pos. 259 moves easily back and forth. 2.1.8. Mount the suction filter in the filter housing manually so that the abovementioned two extraction fittings or the flange, pos. A, front the flange,

pos. 705. Additionally, the new suction filter must be turned for the notch, pos. C, to point slantwise to the right as shown in the drawing in section 2.1.5. The two holes, pos. D, must be positioned horizontally. 2.1.9. Position the cover, pos. 705, and make sure that the valve does not damage the suction filter during mounting. It is a good idea to use eye bolt no 28. Remember the O-rings, pos. 707 and 722. 2.1.10.Mount and fasten the screws, pos. 706 and 721, by first giving them a light turn so that the cover fits in with the two plant surfaces. Then fasten the screws with the prescribed torque, in accordance with the table on Torque moments. 2.2 Compressor protecting system To protect the compressor against inadmissible high pressures the compressor has a built-in protecting valve type POV, pos. 704, controlled by pilot valve type BSV8, pos. 700. The protecting system is described below:

50

0178-250-EN

Fig. 1

Pilot valve, BSV8, pos. 700

Main valve, POV, pos. 704

Evaporator Oil separator, condenser Condensing pressure Evaporating pressure Compressor

Functional description The pilot valve, shown in fig. 1, is actuated by the high pressure P1. The valve is supplied with a stainless metal bellow . The reference pressure in the bellow is the atmospheric pressure. The effective area of the bellow is exactly equivalent to the area of the valve seating, which means that the back pressure P2 does not affect the opening pressure of the valve. The main valve is a normal closed valve. The high pressure P1 is affecting the lower side of the valve cone propagating up through the piston rod to the upper chamber of the valve, producing a pressure on the piston . The area of the piston is larger than the area of the valve seating. Together with the power of the spring this will keep the valve closed. When the pressure P1 reaches the set pressure of the pilot valve, it will start opening. The pressure P2 of the pilot line and of the lower chamber of the main valve will

increase. The pressure of the lower chamber is limited by flow through the nozzle . When the flow through the pilot valve exceeds the capacity of the nozzle, the pressure of the chamber will increase, providing the opening of the main valve. When the pressure P1 is reduced, the pilot valve will close, and the pressure P2 is equalized through the nozzle . The spring will then close the main valve. The closing time is < 30 seconds, depending on the size of the nozzle. The spring is dimensioned to the effect that the difference pressure (P1-P2) of 7 bar will make the valve open completely. The pilot valve BSV 8 is designed to a max. opening pressure < the set pressure +10% and the closing pressure > the set pressure -10% in the pressure area 10-25 bar.

0178-250-EN

51

Dismantling and assembly Usually, it is not necessary to dismantle the compressor protecting system from flange pos. 705, and it is not advisable to dismantle the individual components. Any checking of the correct opening pressure, which is stamped on the nameplate on the pilot valve, should be done on the entire system. Test pressure is added through a flange mounted on the manifold pos. 710. That is where the pipe connection pos. 720 is usually fitted. Once the opening pressure has been reached, the BSV8 pilot valve opens and the compressed air flows out through the lateral connecting piece on the POV main valve, which opens modulating, thus equalizing the pressure. At the same time pipe connection pos. 1 in fig. 2 should be leak tested. This is done as follows: a: Shut the flange just mentioned on the manifold pos. 710 tightly and jam in flange pos. 2 with the lateral connecting piece on the POV valve, as shown in fig. 2.
Fig. 3

b: Put a pressure of approx. 7 bar on the system and apply soap water to the pipe connection pos. 1 right to the pilot valve.
Fig. 2
1
POV main valve

7 bar BSV 8 pilot valve

Pipe connection pos. 720 As it appears from fig. 3 the pipe connection, pos. 720, has a bigger cross-section for HFC and HCFC compressors than for R717 compressors. However, the two models have one thing in common: they follow the same procedure for cleaning the suction filter as described in section 2.1. with main valve POV 80

with main valve POV 50

705

705 710B

710A 721A 722A 721B 722B

720

720B

715

52

0178-250-EN

3. Non-return valve
The non-return valve is mounted on the intermediate flange pos. 253 and positioned in the suction chamber. While the compressor is idle the non-return valve is closed by means of spring pos. 261. See sectional drawing. After start-up of the compressor the non-return valve opens and the compressor is able to suck in refrigerant gas. When the compressor stops, the non-return valve shuts off immediately and hereby prevents the compressor from running backwards. In valve cone pos. 259 a hole of dia. 6 mm has been bored which slowly equalises the pressure in compressor and oil separator to suction pressure at compressor standstill. Dismantling S Dismantle the compressor protection valve and the suction filter as described in section 2. S Seal the opening to the rotors with a cloth free of flocks in order to prevent foreign particles from falling down to the rotors. Do never use twisted yarn, paper or several small cloths. S Now the suction non-return valve can be dismantled by means of the screw pos. 258. S Dismantle the valve cone pos. 259 by removing the countersunk screw pos. 265.

S Dismantle the valve spindle pos. 260 by pushing the spindle guide pos. 256 so that the locking ring pos. 268 is clear of the spindle guide. Dismandle the locking ring and extract the spindle from the spindle guide. Note that the spindle is springloaded. S Tape bearings, pos. 262 and pos. 263, usually remain in the groove of the intermediate flange, pos. 253, and must normally not be replaced. However, replacement should take place in case the tape of the bearing bushing is removed. The tape must then be positioned with its perforated side against the spindle for non-return valve. Mounting Assemble the non-return valve in the reverse order from described above. Note the following, however: S The bearing tapes, pos. 262 and pos. 263, must be undamaged and correctly fitted in the grooves in the spindle guide, pos. 256. The perforated side of the tape must face the spindle, pos. 260. S The O-ring, pos. 707, must be in one piece and mounted on the flange, pos. 705, before it is fitted on the compressor housing with the screws, pos. 706. After the mounting has been completed, check that the non-return valve is easy to push into the suction filter and that the spring forces the valve cone back correctly.

0178-250-EN

53

4. Shaft seal and lip seal arrangement

Fig. 4.1
156I 156B 160E 113 112 111 21

325 166 156A 156K 160A C 156F 156C 110

B A 156G 156D 156E 156H 139 163

Fig. 4.1a

Pos. No. Designation 156AA 156AB 156B 156C 156D 156EA 156EB 156F 156G 156H 156I 156K Shaft seal cover SM/LM Shaft seal cover SF/LF Balance piston Slide ring Sealing ring Retaining ring for 156 D, SM/LM Retaining ring for 156 D, SM/LF O-ring, dia. 88.49 x O-ring, dia. 107.54 x O-ring, dia. 142.47 x Countersunk screw Cylinder screw

Quantity 1 1 1 1 1 1 1 1 1 1 4 2

The shaft seal pos. 160 as illustrated in fig. 4.1 is mounted at the compressor shaft. The shaft seal must ensure that refrigerant and oil from the inside of the compressor do not escape into the atmosphere both when the shaft is rotating and when it is standing still. The shaft seal has therefore two sealing systems, the primary shaft seal and the lip seal arrangement as described in the following. Primary shaft seal The shaft seal is of the slide ring type. It consists of a slide ring made of special carbon and mounted in the rotating part of the shaft seal pos. 160A. It rotates together with the shaft and slides against a steel ring pos. B, which is inserted in the shaft seal cover pos. 156A. The sliding surfaces of the two rings are surface-ground and lapped together, thus

54

0178-250-EN

ensuring the desired tightness both when the compressor is and is not in operation. It is therefore important to be very careful with the lapped sliding surfaces as even the smallest scratch will reduce the tightness of the shaft seal. The shaft seal is mounted and dismounted as described in the following. The rotating part pos. 160A is secured to the compressor shaft by means of three pointed screws pos. 160E. The outer and inner O-ring pos. C and D ensure tightness between the shaft seal and the shaft seal cover pos. 156A and the compressor shaft respectively. Lip seal arrangement When the compressor has not been in operation for a long period of time, the oil in the shaft seal chamber, which helps to keep the shaft seal gas-tight, will drain away from the chamber, making it possible for small amounts of refrigerant to leak from the shaft seal. To avoid this situation, a sealing ring pos. 156D must be used. This ring ensures that the oil stays in the shaft seal chamber. In this way there will always be a thin oil film between the two sliding surfaces of the shaft seal and thus complete gas-tightness between the inside of the compressor and the atmosphere. The sealing ring pos. 156D is mounted in the shaft seal cover pos. 156A and seals against the sliding ring pos. 156C, as illustrated in fig. 4.1. Dismounting of shaft seal and lip seal arrangement S Take the pressure off the compressor - as described in the instruction manual - and dismantle the coupling.

S Remove the screws pos. 167 and pull out the shaft seal cover. If the cover sticks, it can be pushed out by mounting two of the screws pos. 167 in the two threaded holes of the cover. S The steel slide ring pos. A and the sealing ring pos. 156D will come out with the cover and can then with great care be pressed out of the cover. The oil splash ring pos. 162 will also come out with the cover and can then be removed manually. By dismounting the screws pos. 156K, the retaining ring pos. 156E can be removed from the shaft seal cover and the O-ring pos. 156H can be dismounted. Now push the sealing ring pos. 156D out of the retaining ring. S Dismount the four countersunk screws pos 156I, Allen key size 4 mm. S Pull out the slide ring 156C by means of two long M6 screws, which are mounted in the two threaded holes in the flange. The O-ring pos. 156G can now be removed manually. S Now there is enough space to loosen the three pointed screws pos. 160E a couple of turns by means of the shortened Allen key - size 3 mm - which is included in the shaft seal set. S When the three pointed screws have been loosened, the rotating part - with the carbon ring - can be pulled out over the shaft. Tools will usually not be necessary. S Dismount the screws pos. 113 by means of Allen key - size 4 mm. S By fitting the above-mentioned two long screws (M6) in the threaded holes of the balance piston pos. 156B, the piston can now be pulled out manually. The O-ring pos. 156F will come out with the piston.

0178-250-EN

55

Mounting of shaft seal and internal oil seal After cleaning the shaft seal parts and the compressor shaft and checking them for scratches and marks, oil all surfaces with the same type of oil which is used in the compressor. Now the shaft seal and the oil seal are ready to be mounted. S First place the balance piston pos. 156B (see fig. 4.1) on the compressor shaft and turn it so that it is possible to mount the screws pos. 113. Tighten the screws to the torques indicated in the instruction manual. Make sure that the O-ring pos. 156F has been fitted in the balance piston before the piston is mounted. S Mount the rotating part of the shaft seal pos. 160A and tighten it by means of the pointed screws pos. 160E. Make sure that the O-ring has been mounted in the rotating part. S Mount the slide ring pos. 156C and tighten it by means of four countersunk screws pos. 156I. Make sure that the O-ring pos. 156G has been mounted.

Fig. 4.2
Plant 156E 156D

S Fit the retaining ring pos. 156 E in the shaft seal cover pos. 156A. Turn it so that the two screws pos. 156K can be mounted and tightened. Make sure that the O-ring pos. 156H has been mounted in the retaining ring. Note that there are two types of shaft seal covers and retaining rings, one type for compressors driven by male rotor and one type for compressors driven by female rotor. The many bored holes in the retaining ring must be placed above the centre line of the compressor shaft when the shaft seal cover has been fitted on the compressor. S Mount the steel ring pos. B and the Oring pos. C in the shaft seal cover. Make sure that the pin pos. 161 catches the key groove of the cast iron seat. S Mount the O-ring pos. 166.

Before mounting the shaft seal cover pos. 156A on the compressor block, carry out the following: S Press the sealing ring pos. 156D into the retaining ring pos. 156E. It must be turned as shown in the drawing fig. 4.2 and must only be pressed so far into the retaining ring that the two surfaces are flush with each other as illustrated in fig. 4.2.

S Place the shaft seal cover on the shaft and move it carefully forward until it touches the rotating part. Before the screws pos. 167 are tightened, there must be a gap of 3-4 mm between the two flanges as shown in fig. 4.3. It is recommended to cross-tighten the screws pos. 167 so that the shaft seal is not damaged due to uneven tightening. Tighten the screws to the torques indicated in the instruction manual.

56

0178-250-EN

S Mount the oil splash ring pos. 162. Fit the coupling for the motor as described in the instruction manual. Turn the compressor shaft manually to check that it is able to rotate freely.

Cap cover After dismantling the screws pos. 167, dismount the cap cover pos. 163 by fitting two of the screws in the free threaded holes in the flange of the cap cover. Thus the cap cover can be pushed out. Remounting of the cap cover is carried out in the same way as the shaft seal cover.

Fig. 4.3

3-4 mm

0178-250-EN

57

5. Thrust cover and regulating cylinder

The purpose of the regulating cylinder in thrust cover, pos. 40, the built-in piston system and the capacity slide, pos. 200, is to adapt the capacity of the compressor to the immediate cooling requirements of the plant. The system works by letting the piston consisting of parts pos. 201, 202, 203 and 204 move the capacity slide pos. 200 back and forth hydraulically. This opens modulatingly for an internal by-pass channel which - when the position of the piston is to the extreme right on the drawing - is most open. The compressor now runs at its lowest capacity. Dismantling S First, dismantle the pipe connections to the cover, pos. 60. S During manual Vi regulation it is an advantage to unscrew the Vi slide as far as possible by turning the spindle, pos. 180 , clockwise. This slackens the spring, pos. 191, as much as possible. S Next, dismantle the complete capacity indicator by unscrewing two diagonally positioned screws, pos. 62. Mount two threaded spindles no. 22 in their place as well as nuts no. 9.2 from the tools kit as shown in fig. 5.1.
Fig. 5.1
60 62

large spring, pos. 191, will, via capacity slide ,pos. 200, and the piston, loosen the cover, pos. 60. The cover is now pulled straight out in order to avoid damaging the spindle, pos. 210. Watch out, there may be oil behind the cover, pos. 60. S It is now possible to pull the complete capacity slide with piston, pos. 201 and 202, out of the cylinder. Please note that the Vi slide, pos. 190, can also be extracted from here if necessary. First dismantle the blank-off screw and the gasket, pos. 24/25, however and push the Vi slide slightly forward so that screw, pos. 192 ,can be removed through the side hole. S The thrust cover, pos. 40, weighs approx. 80 kg and must therefore be suspended in a crane before the screws, pos. 41 are removed. S Now mount the two pointed screws no. 45 from the tools kit in the holes A, see fig. 5.2, and insert them by turning them only 3 to 4 turns into the thread. Next, fit the two screws no. 16.1 in the thread of the thrust cover on top of the two pointed screws in holes A. S By tightening screws no 16.1 alternately, the thrust cover is pulled free of the two guide bushings, pos. 22, that guide the thrust cover towards the compressor block. The bushings are positioned in holes B.
Fig. 5.2 B A B A

9.2

22

T0177135_14

Now remove the remaining screws, pos. 62 ,and by loosening nuts no. 9.2 alternately the

A description of the mounting of the thrust cover, pos. 40, and the capacity indicator

58

0178-250-EN

with cover, pos. 60, can be found in section 6: Regulating slide.

6. Regulating slide
Dismantle the complete capacity slide with piston, pos. 201 og 202, as described in section 5: Thrust cover and regulating cylinder. Any dismantling of the piston rod, pos. 207A, and the slide, pos. 200, can be done by removing the set screw, pos. 311, as well as the locking device, pos. 312. The circlip, pos. 207D, and the steel ball, pos. 207E, act as a kind of non-return valve. At an emergency stop this non-return valve ensures the quick movement of the capacity regulating slide to its minimum position as the oil is emptied through the non-return valve. In case the sealing ring, pos. 204, has been damaged it must be replaced. This is done be removing the groove nut, pos. 206, and the locking plate, pos. 208, whereby the outer and inner rings of the piston can be dismantled. Pay attention to the O-ring, pos. 203. Antifriction tapes, pos. 209, have been fitted on the end surface of the capacity slide. Their length is adapted so that they can be placed loosely in the groove of the capacity slide. Mounting Mounting of the thrust cover, capacity slide and capacity indicator is done in the following order: S Mount the two guide bushings, pos. 22, in holes B of the compressor block, see fig. 5.2.

S Position the thrust cover with the O-rings, pos. 43 and 49, against the compressor block and guide it into its place by means of the guide bushings which are pulled towards each other with the screws, pos. 41. Remember to place washers, pos. 23 ,under the screws fitted in holes A and B cf. fig. 5.2 - and to tighten all screws, pos. 41, with the prescribed torque moment. S In case the Vi slide has been removed it must be refitted. Fit and tighten the screws, pos. 192 and 24/25. S Assemble the complete capacity slide on the work bench while paying special attention to the following: - that the screw, pos. 311, with locking device, pos. 312, has been tightened correctly. - that the two antifriction tapes, pos. 209, are fitted correctly in the capacity slide, pos. 200. - that the steel ball, pos. 207E, and the circlip, pos. 207D, have been fitted. - that the piston parts, pos. 201 and 202 ,have been mounted on the piston rod, pos. 207A, fastened with the groove nut, pos. 206, and secured with the locking plate, pos. 208. Remember that the opening of the sealing ring, pos. 204, must be facing the capacity slide. Do not forget the O-ring, pos. 203. S Mount the spring, pos. 191, and insert the complete capacity slide in the thrust cover while guiding it carefully into place until the spring starts resisting. S Mount the two threaded spindles no. 22 in the end surface of the cylinder and position the cover, pos. 60 on the threaded spindles, while first letting the spindle, pos. 210, catch the pin, pos. 207C.

0178-250-EN

59

By an alternate tightening of nuts no. 9.2 the cover is pressed against the capacity slide and the entire system is pressed against the spring. Take special care not to damage the sealing ring, pos. 204, while inserting it in the cylinder. S Tighten two of the screws, pos. 62. Next, dismantle the two threaded spindles and nuts which are replaced by the two other screws, pos. 62. S Mount pipe connections. Dismantling

7. Slide stop for Vi regulation

The purpose of the Vi-regulating system is to regulate the built-in volume ratio of the compressor so that the compression ratio of the compressor is equal to the pressure ratio between the condensing pressure and the evaporating pressure in the refrigeration plant. The system works by displacing the slide stop, pos. 190, hereby - via the regulating slide, pos. 200 - changing the size of the discharge port of the compressor. This change of the size of the discharge port increases or diminishes - the compression chamber and consequently the compression ratio. As described in the following, the Vi-regulation can be done in two ways: A: Manual Vi-regulation B: Automatic Vi-regulation The two systems cannot be mounted simultaneously, however. A: Manual Vi-regulation Manual adjustment of the Vi slide stop position is described in a separate section in this instruction manual. Please refer to table of contents and fig 7.1.

S After dismantling the screws, pos. 198, the entire unit with the slide stop cover, pos. 181, and the bearing retainer, pos.185, can be unscrewed by turning the spindle, pos.180, anti-clockwise. When the spindle has been unscrewed completely from the thread in the threaded washer, pos. 189, the unit can be removed manually. S By dismantling the screws pos. 196, the cover, pos. 181, is dismantled from the bearing retainer, pos. 185, and the sealing washer, pos. 182, the sealing ring, pos. 183, and the O-ring, pos. 184, can be removed manually. S The spindle, pos. 180, and the ball bearings, pos. 186, can now be pushed out of the bearing retainer, pos. 185. S The slide stop, pos. 190, and the slide guide, in which the spring has been fitted, are pressed together and should normally not be disassembled. The whole unit cannot be extracted from the compressor until the suction cover, pos. 20, has been dismantled. Cf. section 8 or the description found in section 5.

60

0178-250-EN

S The screw, pos. 192, acts as a slide stop and should normally not be dismantled. Cf. section 5. Mounting When mounting - which is done in reverse order - attention must be paid to the following: S Insert the ball bearings, which must be well lubricated with ball-bearing grease, in the bearing retainer, pos. 185, with the collar of the spindle, pos. 180, in between. Avoid knocking on the bearings. S Before clamping together the slide stop cover, pos. 181, and the bearing retainer, pos. 185, position the sealing washer, pos. 182, the sealing ring, pos. 183, and the O-ring, pos. 184, as shown in drawing. The open side of the sealing ring, pos. 183, must face the ball bearing. The
Fig. 7.2

clamping is done by means of screws, pos. 196. Check that the spindle is easy to turn. S Mount the whole unit in position by screwing the spindle into the thread washer, pos. 189, until the slide stop cover, pos. 181, bears against the suction cover, pos. 20. Pay attention to the O-ring, pos. 197. S Secure with screws, pos. 198. B: Automatic Vi-regulation By automatic Vi regulation, the slide stop is moved by oil pressure controlled by solenoid valves and a position transmitter pos. 410. Adjustment of the system is described in the following chapter: System for regulating the capacity and the Vi-ratio of SAB 202 of this instruction manual.

T0177135_1

0178-250-EN

61

Dismantling of the Vi-regulating system S First dismantle the electrical connection to the position transmitter pos. 410. S Dismantle the pipe connection to the cover, pos. 380. S After dismantling the screws, pos. 382, it is possible to extract the cover, pos. 380 including its parts as one unit, but care must be taken not to damage the spindle, pos. 390, and the sealing ring, pos. 371. S Dismantle the magnetic coupling, pos. 405, by removing screws, pos. 403. This makes it possible to remove the position transmitter, pos. 410, with the flange, pos. 402. S Dismantle the driving disk, pos. 395, and the screw, pos. 396, while holding it back by means of a screwdriver of a suitable size inserted in the slot of the driving disk. S By removing the screws, pos. 401, it is possible to dismantle the housing, pos. 400, and the magnetic coupling, pos. 405, can be dismantled from the flange, pos. 380 and be taken apart. See Dismantling of magnetic coupling in the following section. S Dismantle the piston in the flange, pos. 380, by removing screws, pos. 387, whereby the flange, pos. 384, the sealing ring, pos. 371, and the ball bearing, pos. 393, can be dismantled. S Slide guide and slide stop, pos. 190, cannot be extracted before the suction cover,

pos. 20, has been removed. See section 8 or the description found in section 5. Mounting When mounting - which is done in reverse order from dismantling - attention must be paid to the following: S On mounting the sealing ring, pos. 371, the open side must be facing the flange, pos. 384. S Mount the flange, pos. 380, and tighten with screws, pos. 382. Remember the Oring, pos. 381. S Position the complete magnetic coupling, pos. 405, with spindle, pos. 390 and seal with O-ring, pos. 406. See Assembly of magnetic coupling in the following section. S On fastening the driving disk, pos. 395, with the screw, pos. 396, the slot in the driving disk must be facing vertically down as shown on drawing and be held back by means of a screwdriver of a suitable size inserted in the slot.

395

S On mounting the position transmitter, the retaining pin, pos. 413, must engage in the slot in driving disk, pos. 395.

62

0178-250-EN

Position transmitter
S In case arm no. 4 has been dismantled from the transmitter, it must be fitted correctly as follows: S Find the 4mA point of the transmitter by turning the shaft as described in the Instruction manual for UNISAB II. S Mount arm no. 4 so that pin no. 3 is positioned as shown on the sketch. S Tighten the pointed screw no. 5. S Mount the transmitter, pos. 410, as shown in fig. 7.2 with the connection facing downwards.

5 4 3

Magnetic coupling for Vi-indication

The rotating movement from the spindle, pos. 390 - see fig. 7.2 - is transferred to the transmitter, pos. 410, through a magnetic coupling, pos. 405, which is completely tight so that neither oil nor refrigerant can pass through the coupling.
Fig. 7.3
9 A-A
N S N S

Usually, it is not necessary to dismantle the magnetic coupling, but on dismounting spindle, pos. 390, proceed as follows:

3 5 4 A 390

10 11
N S N S NS S

N S N S

N S

N S N S

1 6 7 2 406
from T4161061_0

Dismantling: S After the magnetic coupling has been dismounted from the compressor as already described, dismantle circlip no. 1. The

magnet retainer no. 2 and bearing no. 3 can now be pulled out against the magnetic force which is rather strong.

0178-250-EN

63

S After removing screw no. 4 spindle pos. 390 can be dismantled. S Bearing no. 3 can be released once circlip no. 5 has been removed. S Should it be necessary to dismantle the magnetic coupling, screw no. 6 can be loosened by inserting a 2.5 mm Allen key in the hole in the magnet retainer no. 7. Pay attention to washer no. 11. Magnet retainer no. 7 and flange no. 8 an now be pulled apart. S After removing circlip no. 9, ball bearing no. 10 can be pulled out. Assembly of magnetic coupling Assembly is done in the reverse order to the dismantling. Note the following, however: S We recommend not to insert magnet retainer no. 2 in the coupling until the spindle, pos. 390, has been fitted as the magnetic force makes it very difficult to dismantle the parts again.

Dismantling S Dismantle the screws, pos. 113, at the balance pistons, pos. 134 and 137. S Pull out the balance pistons, pos. 134 and 137 as well as the spacer rings, pos. 135 and 138 manually. S Suspend the bearing cover in a crane with shackle and wire. (Weight 101 kg) S Dismantle the screws, pos. 26, 27 og 28. S Mount the pointed screws no. 45 from the tools kit in the two threaded holes at the top of the bearing cover as shown in fig. 8.1 and fig. 8.2. Screw the pointed screws completely into the compressor housing. S Mount the stay bolts no. 11 from the tools kit in the two top holes, in which the bolt, pos. 28, has been mounted. The stay bolts must guide the suction cover while it is being pulled across the shaft pins. See fig. 8.2. S Mount the screws no. 17.1 in the same holes as the pointed screws. By tightening the screws the bearing cover will come loose. See fig. 8.1.
Fig. 8.1
17.1 20 45

8. Suction cover and bearings at compressor shaft end

Before the bearing cover at the suction end, pos. 20, can be dismantled, the following parts must be removed as described earlier: - Shaft seal cover, pos. 165, and shaft seal - Cap cover, pos. 163. - Slide stop cover, pos. 181, for man. Vi and 380 for auto. Vi.

T0177135_2

64

0178-250-EN

S Carefully pull out the bearing cover across the shaft pins and the slide bearings, pos. 111, will follow.

Fig. 8.3
4 9.2 2 1 3 20 111 112

Fig. 8.2
Holes for pointed screws

Holes for stay bolts

T0177135_6

Mounting To mount the slide bearings, pos. 111, carry out the following procedure: S Before the slide bearing, pos. 111, is pushed into place on the cover, pos. 20, the guide pin, pos. 112, should be mounted as illustrated in fig. 8.4.a. The guide pin is knocked just 5 mm into the hole in the slide bearing and is straightened up to stand at a right angle to the end plate.
Fig. 8.4.a
40

T0177135_3

S With an arrangement as shown in fig. 8.3 the slide bearings can be pulled out of the bearing cover. Screw the threaded pins no. 3 into the threaded holes of the slide bearing. Puller no. 2 is pushed against the threaded pins and kept in place by nuts no. 9.2. S Position the thrust plate for puller no. 1 at a right angle to the first plate. By tightening screw no. 4 the slide bearing will be pulled out.

111

112

0178-250-EN

65

S When the slide bearing, pos. 111, is placed on the cover the bearing should be positioned for the guide pin to reach the 6 mm hole in the cover - as illustrated in fig. 8.4.b.

S The guide pin, pos. 112, will at the same time be pushed into the slide bearing, pos. 111, and this guarantees that the slide bearing is positioned correctly. S The suction cover, pos. 20, is mounted on the compressor housing, pos. 10, when the rotors have been mounted. Cf. chapter 9.

Fig. 8.4.b
111 20 112

9. Rotors and bearings at compressor discharge end

Before the rotors can be removed from the compressor, the parts mentioned in section 7 must be disassembled. Then proceed as follows: Dismantling
T0177135_7

S The thrust cover, pos. 40, must be dismantled as described in section 5. S Loosen the four locking screws pos. 45, next loosen adjusting screws pos. 44 3-4 turns. Dismantle cross bar pos. 46 by removing screws pos. 47. S Remove inner covers pos. 153 by mounting tools no. 26 and 27 in the threaded holes in the cover which is now carefully pulled out. Take care not to lose the two cylindrical steel rolls pos. 155. S Next dismantle screws, pos. 115, and the thrust washer pos. 114 can be removed. During their dismantling the rotors should be locked in order to prevent them from rotating. For this purpose use arrangement in fig. 9.1 at the shaft end of the rotors.

S The slide bearing is pushed into the cover, pos. 20. The tools arrangement in fig. 8.4.c should be used for this purpose.

Fig. 8.4.c
111 20 112

9.1

T0177135_7

66

0178-250-EN

Fig. 9.1
13 17.2

thread hole at the end of the rotor to protect the centre hole. S Then mount the plate no. 14 with the screws 17.3 and the bushes no. 15. Screw no. 16.1 is mounted hereafter.
110

17.2

S By tightening the screw no. 16.1 the rotor is automatically pushed out of the ball bearing, pos. 132. S When plate no. 14 is dismantled again, the outer ring and the shim, pos. 133, can be dismantled manually. The innermost inner ring of the ball bearings can later on be dismantled from the rotors with tool no. 49 when the rotors have been removed from the compressor block. S Both rotors should be pushed as far out of the block to allow a soft lifting sling to be placed around them. Since the weight of a set of rotors amounts to approx. 170 kg, a crane or another approved lifting device should be used to lift the rotor set off the block. S Pull out the main bearings, pos. 111, using the tools shown in fig. 9.3. The bearings should normally not be reused.
Fig. 9.3
141 111 10 133 132 18 16.2 3 1 2 4.2 4

12

T0177135_0 V13

Remember to dismantle the tools again before pressing out the rotors. S It is now possible to push out the rotors, pos. 110, - one at a time - by means of the tools shown in fig. 9.2.
Fig. 9.2
17.3 14 16.1 17.3

15

17.3

14

16.1

17.3

15

S Screw no. 16.2 and washer no. 18 from the tool set should be mounted in the

T0177135_8

0178-250-EN

67

S The discharge ports, pos. 140 and 141, are dismantled in the following way: S Dismantle the screws, pos. 142 and the sealing plates, pos. 143, as shown in fig. 9.4.
Fig. 9.4
141 140 10 143 142

the adjusting screw, pos. 145, is loosened 2 turns with the same Allen key.
Fig. 9.4.b
10

145 146

140 141 T0177135_15

T0177135_15

S Design 2 (after January 1999) This design is easier to use as the adjustment is made from the outside as illustrated in fig. 9.4. c.
Fig. 9.4.c
141 140

S Dismantle the screw, pos. 144, in each discharge port as shown in fig. 9.4.a.
Fig. 9.4.a
A A-A

148

147

10

149B 149A

144 A

S An adjustment device fitted at each discharge port must be loosened before the discharge ports can be dismantled. The adjustment device exists in two different designs dependent on whether the compressor was delivered before or after January 1999. S Design 1 (before January 1999) As shown in fig. 9.4.b., the locking screw, pos. 146, is first dismantled by means of an NV5 Allen key, and then

First, the blank off screw, pos.149A, and the gasket, pos. 149B, are dismantled. Then the locking screw, pos. 147, is dismantled with the Allen key no. 27-1. Loosen the adjusting screw, pos. 148, two turns with the same Allen key. S The discharge ports, pos. 140 and 141, can now be pulled out carefully using a wooden stick or the wooden handle of a hammer. Mounting Before positioning discharge ports pos. 140 and 141 in the rotor housing, check that they are free of burrs and marks, especially on the

68

0178-250-EN

surfaces that are going to adjoin the rotor housing. Likewise, check the rotor housing for similar defects on the corresponding contact surfaces. Push the discharge ports into place in the rotor housing and fasten with screws pos. 142 and new steel gaskets, pos. 143. S Tighten the screws, pos. 142, with half the torque moment required (cf. the torque table) to ensure that the discharge ports stay close to the end plate in the rotor housing. Now loosen the screws and tighten them slightly again to facilitate the following adjustment - which is the same for both designs. Cf. the section Dismantling. Mount the capacity slide, pos. 200, and tighten the adjusting screw, pos. 148 (145) slightly. S While the capacity slide is pushed back and forth, tighten the screws, pos. 148 (145) alternately until the capacity slides can be moved back and forth easily. S Then mount the locking screw, pos. 147 (146), and tighten well. S In the case of design 2 the blank off screws, pos. 149A, and the gaskets, pos. 149B, should be mounted and tightened. S The screws, pos. 142, must be tightened with the prescribed torque moment. Please remember that the used steel gaskets, pos. 143, must not be reused. They must be replaced by new ones to ensure tightness.

S Finally, the screws, pos. 144, should be mounted in the two discharge ports - cf. fig. 9.4.a - and tightened with the prescribed torque moment. S Before the slide bearings, pos. 111, are fitted the guide pins, pos. 112, should be mounted as illustrated in fig. 9.5.a.

Fig. 9.5.a
40

112

111

The guide pin is only knocked 5 mm into the hole in the slide bearing and it is straightened up to stand at a right angle to the end plate. When placing the slide bearing on the compressor block, turn the bearing for the guide pin to reach the 6 mm hole in the discharge port - as illustrated in fig. 9.5.b.

Fig. 9.5.b

140 141

112

10

111

Press the slide bearing into place against the discharge port, pos. 140/141, using the tools arrangement shown in fig. 9.5.c.

0178-250-EN

69

Fig. 9.5.c

141 140

10

housing as indicated on the spare parts drawing and cast on the end cover pos. 20. Mounting of covers and bearings After fitting the rotors in the compressor block, mount the following: 1. Tighten the suction cover, pos. 20, with the screws, pos. 26. Mounting must be done using the staybolts no. 11 mounted as as in fig. 8.2. The suction cover must be fastened with the screws, pos. 26, 27, and 28. Remember the O-ring, pos. 21. Check that the slide stop, pos. 190, moves easily back and forth. 2. Lock the rotors as shown in fig. 9.1. 3. Lubricate the rotor shaft with Molykote grease. Press the inner ring of the ball bearing into place by using the tools arrangement shown in fig. 9.7.
Fig. 9.7
Inner ring for pos. 132 110 10 25.2 14

The guide pin, pos. 112, will at the same time be pressed into the slide bearing, pos. 111, and it is thereby ensured that the slide bearing is positioned correctly. Mounting of the rotors Before the rotors, pos. 110, are mounted in the rotor housing it is recommended that the Vi-slide, pos. 190, is fitted in the rotor housing to support the rotors.
Fig. 9.6

8 8 8 Female Male

The rotors are marked with a number on the end surface that faces the suction end of the compressor. The marking must have the same number on both rotors and the catching between the rotors must, on mounting, be as shown in fig. 9.6. The number 8 is given as an example. It is also extremely important that the male and female rotors are positioned in the rotor

T0177135_10

4. As shown in fig. 9.8, the thinnest spacing washer, pos. 133, from the set of adjustment washers is fitted, i.e. the washer which is 5.6 mm thick. 5. The ball bearing, pos. 132, is fitted. The outermost inner ring is not yet to be mounted.

70

0178-250-EN

6. Fit the inner covers, pos. 153, without the O-rings, pos. 154. 7. Mount the cross bar, pos. 46, with the screws, pos. 47. The adjustment screw, pos. 44, should be mounted but not tightened. 8. Dismantle the locking tools mentioned in item 2. 9. Mount the balance pistons, pos. 134/137, in the suction side and tighten with the screws, pos. 113. Push the spacer rings,

pos. 135/138, into place. They should reach the retaining pins, pos. 136/139.
Fig. 9.8
10 110 141 111 133 132 153 46 44 45

T0177135_12

0178-250-EN

71

Adjusting the axial play of the rotors

After mounting of the bearings, as described in the previous section, the axial play of the rotors can be adjusted with the tools arrangeFig. 9.9
22 25.1 20 21 50

ment shown in fig. 9.8. The dial meter measures on balance piston pos. 134 for the female rotor and on pos. 137 for the male rotor. Start by adjusting the female rotor.
20 134/137 111 110

Female

Male

19

23

24

T0177135_9

Adjustment 9.1 Use the tools arrangement in fig. 9.8. By tightening nuts no. 25.1 until cover no. 20 touches pipe pieces no. 21 the spring will push the rotor up against the discharge port at the other end of the compressor frame. Leave adjusting screw pos. 44 loose. Position dial meter on 0. Now screw in adjusting screw pos. 44 at the female rotor and tighten with 32 Nm.Read the dial meter and note the difference that indicates how much the rotor can be moved axially. This movement may, f.inst., be 0.430 mm. As the correct movement must be between 0,13 and 0,22 mm the medium figure to be used is 0,175 mm, which is deducted from the measured value that in example point a amounts to: 0,430 - 0,175 = 0,255 mm

9.3

9.2

From the set of adjusting shims select the shim that is 0,255 mm thicker than the one that was first mounted and which in the example pt. 3 was 5,600 mm. The thickness is stamped on the shims. In the example given this means: 5,600 + 0,255 = 5,855. The shim that measures 5.85 is then chosen in accordance with this example. By inserting the new shim as shown in fig. 9.7 (pos. 133) and repeat the adjustment mentioned in point 9.2 it is made sure that that the movement keeps within the tolerances mentioned in point 9.2 (0.13 and 0.22 mm), and the exact measure is noted for later application - (see section 9.10). The exact measure for the female rotor may, f.inst., be 0,171 mm after the adjustment mentioned in sections 9.3 and 9.4. In order to be able to insert the shims, proceed as follows: - Loosen adjusting screw pos. 44. -

9.4

a: b:

72

0178-250-EN

- Dismantle toggle pos. 46. - Remove inner cover pos. 153. - Remove by hand the outer ring of the ball bearing with the balls. Do not dismantle the remaining parts in the tools arrangement. 9.5 The adjustment completed, loosen adjusting screw pos. 44 and toggle pos. 46 and dismantle inner cover pos. 153. With tools as shown in fig. 9.5 mount the outermost inner ring, and fasten the thrust washer, pos. 114, by means of the screw, pos. 115. Tighten screw with 70 Nm. Insert the cylindrical steel roll, pos. 155, in the groove of the outer ring of the ball bearing turning it so that it the groove faces upwards. Position the O-ring, pos. 154, on the inner cover, pos. 153, and mount tools no 26 and 27 on the cover. Replace the inner cover and turn it with tools until the groove in the cover catches steel roll pos. 155. This is felt as the cover during the turning is carefully pressed inwards and then can be pressed in a little further when the steel roll is caught by the groove in the cover. 9.9 Mount toggle and tighten the adjusting screw with 32 Nm. Check the movement of the dial meter once more. It must now be within 0.13-0.22 mm. Should the measure, against all expectations, not be within the stated limits, the entire adjusting procedure must be repeated right from pt. 9.1.

Adjust the male rotor in the same way as described in points 9.1 to 9.9, but mount the adjusting tools laterally reversed to the arrangement in fig. 9.8. Tool no. 12 must be mounted on the male rotor so that it gets the same length as the female rotor. Final adjustment When both rotors have been adjusted and the exact measures noted, we are ready for the final adjustment of the rotors. First check that the two adjusting screws, pos. 44, are loose. 9.10 The final adjusting measure must be 0,02 mm less than the exact measure. If, for inst., the exact measure is 0,171 mm for the female rotor as indicated in example pt. 9.4, the final adjusting measure must be: 0,171 - 0,02 = 0,151 mm With the adjusting tools mounted on the female rotor as shown in fig. 9.8 and the dial meter set on 0, tighten adjusting screw pos. 44, while reading the dial meter. The indicator of the dial meter must move the final adjusting measure. 9.11 After the final adjustment lock the adjusting screw pos. 44 with pointed screws pos. 45, and the adjustment of the female rotor has been completed. 9.12 Next mount adjusting tools at the male rotor as indicated in pt. 9.9.The adjustment described in sections 9.10 and 9.11 is now repeated for the male rotor. 9.13 Check that the rotors are easy to turn by hand.

9.6

9.7

9.8

0178-250-EN

73

10. Capacity indicator

The SAB 202 compressor is equipped with a standard position transmitter which registers the compressor capacity and transmits it to the regulating system.

Function: On moving the capacity slide pos. 200 the spindle, pos. 210, is turned by means of the helical key groove in the spindle. The spindle turns the transmitter, pos. 350, via the magnetic coupling, pos. 216, which is completely tight so that neither oil nor refrigerant can pass through it.

Fig. 10.1 Magnetic coupling pos. 216

50

70

71 216 221 223 350

75 74

210

218

217

61

60

219

224

72

73

Dismantling After cover, pos. 60, has been dismantled from cylinder, pos. 50, remove the following parts: S By removing screws, pos. 73, the following parts are dismantled: - Flange pos. 72 - Sight glass, pos. 75 - O-ring pos. 74 - Supporting ring pos. 224 -

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

S Dismantle indicator dial, pos. 221, by loosening screw, pos. 223.

S By removing screws, pos. 219, the entire magnetic coupling, pos. 216, can be pressed out of the flange, pos. 60, by hand.

74

0178-250-EN

Fig. 10.2 Magnetic coupling for capacity indication pos. 216

60 217 210 A 1
S N S N S N S N S

A-A
N S N S N S

N S

SN

NS

218 A

219

from T4161067_2

S By dismantling circlip no. 1, as illustrated by fig. 10.2, the inner magnet retainer no. 2 and spindle, pos. 210, can be pulled out against the magnetic force. S Dismantle spindle, pos. 210, by loosening screw, pos. 218. A further dismantling of the magnetic coupling is usually not necessary. Reference is made to section 7, however. Note: We recommend not to insert magnet retainer no. 2 in the coupling until spindle, pos. 390, has been fitted as the magnetic force makes it very difficult to dismantle the parts again. Assembly Assembly of the complete unit is carried out in reverse order to the dismantling. Pay attention to the following, however: S On mounting of the magnetic coupling in cover, pos. 60, O-ring, pos. 217, must be fitted.

S Before fastening indicator dial, pos. 221, with screw, pos. 223, it should be positioned so that the slot points to the left and 40 below horizontal. See sketch.

40

S On mounting of sight glass, pos. 75, it should be positioned so that the 0 mark is right above the slot in the indicator dial, pos. 221. S Transmitter, pos. 350, must be fitted on the sight glass, pos. 75, so that the electric socket faces downwards when the 0 mark of the sight glass stands right above the slot in the indicator dial as described above. S The retaining pin no. 3 of the transmitter must engage in the slot in indicator washer, pos. 221, on mounting sight glass, pos. 75.

0178-250-EN

75

Transmitter
Usage: The position transmitter is used for remote indication of compressor capacity. By integrating electronic limit switches into the control, max. and min. compressor capacity can be signalled, for instance. Assembly The following drawing shows a position transmitter for capacity signalling and indication. The transmitter is fitted in the sight glass with the plug facing vertically down. The transmitter arm is turned by the indicator dial by means of pin no. 3 engaging in the slot of the dial, pos. 221.

Slide position Volume ratio

4.5 4.

3.5 3. 100% 2.5 2 3

SPAN + ZERO

No. 3
0% 2.

T0177063_0

Connect the position transmitter to the control system according to the following table:
Terminal
1 2 3

S Turn the sight glass until the 0% mark aligns with the indicator dial with the capacity slide in its minimum position. S With the Zero screw adjust to the desired minimum signal. With controls supplied by SABROE, adjust to 4mA signal. One turn with the ZERO screw changes the signal to 2mA. S With the capacity slide in maximum position, adjust the output signal to 20mA on the SPAN screw. One turn changes the signal to 1mA. Note: The adjustment of the slide will affect the max. position of the capacity slide. The max. signal of the position transmitter must therefore be adjusted on the SPAN screw after adjustment of the Vi slide.

Used for
Signal 0--20 mA Power supply 24 V DC +/--20% Earth connection 0V Not used

Adjustment: S Turn the transmitter shaft until the output signal is approx. 4mA. On UNISAB II the display shows 0%. Secure the arm opposite the 0% mark on the sight glass. Fit sight glass with transmitter on the compressor. Make sure that the pin no. 3 catches the slot in the indicator dial!

76

0178-250-EN

System for regulating the capacity and the Vi-ratio of SAB 202
This chapter comprises the following three systems: 1. Regulating of compressor capacity. 2. Automatic regulation of the Vi-slide. 3. Manual regulation of the Vi-slide. Please, refer to page 1 to see the system of your compressor. from the capacity cylinder through branch A. Branch C is connected to the capacity cylinder. The system has built in two throttle valves pos. 72, by which the oil flow and thus the velocity of the capacity slide can be regulated. The throttle valves are meant to create a regular movement of the capacity slide, adapted according to the operating conditions. Turning the spindle clockwise reduces the oil flow. Solenoid valves: Pos. 70 is a normal closed valve. Pos. 71 is normal open meaning that with a dead coil it is open for passage.

98.05

1. Regulating of compressor capacity

The regulating system is a complete assembly as shown in fig. 1. It regulates the compressor capacity by supplying or draining oil from the capacity cylinder pos. 50 (see spare parts drawing). The system is connected to the oil pressure at connecting branch B and the oil returns

0178-258-EN

0178-250-EN

77

Fig. 1 C A B

72

72

NO

NC

71

74

70

73

Function
1. At a constant capacity both solenoid valves are closed so that pos. 70 is dead whereas pos. 71 is supplied with current. 2. On regulating to a higher capacity power is supplied to coil pos. 70 so that both coils are now supplied with current. Hereby, pos. 70 opens and puts oil pressure on the capacity cylinder, and pos. 71 remains closed.

3. On regulating to a lower capacity the current is cut to both coils. Hereby, pos. 70 closes and cuts the oil pressure to the capacity cylinder. Pos. 71 opens and lets oil flow away from the capacity cylinder through the force of spring pos. 191. 4. By standstill of the compressor the current to both solenoid valve coils is interrupted. Hereby, the capacity piston is moved to its 0% position - as described in pt. 3, and the compressor is unloaded at the next start-up.

78

0178-250-EN

2. Automatic regulation of the Vi-slide

For regulation of the Vi-slide position use the same type of regulating system that is used for regulating the compressor capacity. This system has been described in the previous section. In the following functional description the solenoid valve in the Vi-regulating system designated as indicated in the dash-and-dot line frames on drawing in fig. 1. Pos. 73 is a normal closed solenoid valve. Pos. 74 is a normal open solenoid valve. The regulating systems can be controlled by a UNISAB II, and they work as follows:

70 and pos. 71 will receive opening and closing signals without it leading to changes in the compressor capacity.

2.2 At reduced compressor capacity

When compressor capacity is reduced from 100%, the following happens: S With the UNISAB II regulating system the capacity slide is moved away from the Vi-slide, creating a gap between the two slides. The solenoid valves in question are hereafter controlled by UNISAB II so that the capacity requirement and the Vi-slide position are controlled by the pressure ratio above the compressor. When the compressor capacity increases to 100% and pos. 200 reaches pos.190, the regulating systems will return to the function described in section 2.1.

2.1 At 100% compressor capacity:

S Pos. 73 is open and maintains the oil pressure on the Vi-slide piston so that the Vi-slide pos. 190 is permanently pressed against capacity slide pos. 200. (See spare parts dwg.). Pos. 74 remains closed. S The Vi-regulating is controlled by the capacity regulating system which, by minor corrections of pos. 200, adapts the Vi-ratio to the suction- and discharge pressures on the compressor. By this regulation pos.

2.3 When the compressor stops

When the compressor stops, the current is cut to all four solenoid valves. Hereby, pos. 74 and pos. 71 open and allow the two regulating slides to move to their minimum position as the slides are pressed away from each other by the force of spring pos. 191.

0178-250-EN

79

3. Manual regulation of the Vi-slide

Instead pf the automatic regulation of the Vi-side, as described in section 2, regulation may be done manually. However, bitg systems are not found in the compressor at the same time.

vement of the capacity slide. If, therefore, the Vi-slide is adjusted to max. or min. position, the spindle must be loosened by turning it 1/2 to 1 turn in the opposite direction from its extreme position. For correct adjustment of the Vi-slide position use the shown doagrams which are applied as follows: For the current refrigerant, type of compressor and the evaporating temperature TE follow the horizontal line to the intersection with the curve for the current condensing temperature TC. From this intersection two readings can be made by following the line up or down: S Vertically up, reading of the Vi-ratio referring to the scale on the compressor capacity indicator. Note, whether or not your compressor is connected to an economizer S Vertically down, reading of the number of revolutions the spindle pos. 180 must be turned anti-clockwise - from tis extreme position - in order to obtain the optimum efficiency at the given temperature conditions TE and TC. Note, wether or not your compressor is connected to an economizer.

Function
The Vi- slide pos. 190 works as a movable stop for the capacity slide, thus regulating the size of the discharge port (pos. 140/141) and consequently the built-in Vi volume ratio of the compressor. The Vi-slide is moved by turning the spindle pos. 180 a preditermined number of revolutions. S By turning the spindle clockwise a lower Vi is obtained. S By turning the spindle anti-clockwise a higher Vi is obtained. Important S Adjustment must only take place while the compressor is at standstill. S On regulating the Vi-slide to max. or min. position it must not be tightened against the end stops. This could impede the mo-

80

0178-250-EN

Evaporating temperature

0 --10 --20 --30 --40 --50 --60 C 0 40 40 --25 --20 60 62 --10

TC C 55 50 40 30 20 10 0 Single stage Turns on the adjusting screw

Adjusting of Vi T250824

Economizer 0 20 60 62

Evaporating temperature

--10 --20 --30 --40 --50 --60 C 0 40 0 20 --25 --20 60 40 67 60 --10

TC C 55 50 40 30 20 10 0 Single stage Turns on the adjusting screw

Adjusting of Vi T250825

Economizer 67

0178-250-EN

81

Condensing temperature

Adjustment of the Vi-slide position SAB 202L R22 R134a R404A/R507 R407C

2 2.5 Volume ratio Vi TE 20 10 2 3 3.5

3 4

3.5 4.5

4 Vi Single stage

4.5

Vi Economizer

SAB 202L

R22 R134a R404A/R507 R407C

Condensing temperature

Adjustment of the Vi-slide position SAB 202S R22 R134a R404A/R507 R407C

2 2.5 Volume ratio Vi TE 20 10 2 3 3.5

3 4

3.5 4.5

4 Vi Single stage

4.5

Vi Economizer

SAB 202S

R22 R134a R404A/R507 R407C

Adjustment of the Vi-slide position SAB 202S R717

2 2.5 Volume ratio Vi TE 20 Evaporating temperature 10 0 --10 --20 --30 --40 --50 --60 C 020 40 2 2.5 3

3.5 3.5 4

4 4.5 Vi Single stage

4.5 Vi Economizer SAB 202S

R717 Condensing temperature Condensing temperature

TC C 55 50 40 30 20 10 0 --25 --20 --10 Single stage 60 62 Turns on the adjusting screw

T250826

Adjusting of Vi 0 20

Economizer 40 60 62

Adjusting of the Vi-slide position SAB 202L R717

2 2.5 Volume ratio Vi TE 20 Evaporating temperature 10 0 --10 --20 --30 --40 --50 --60 C 0 20 40 2 2.5 3

3.5 3.5 4

4 4.5 Vi Single stage

4.5 Vi Economizer SAB 202L

R717

TC C 55 50 40 30 20 10 0 --25 60 60 --20 --10 Single stage 67 Turns on the adjusting screw

T250827

Adjusting of Vi

Economizer 0 20 40 67

82

0178-250-EN

Torque moments for screws and bolts

Metric thread (ISO 8.8)

M Kpm ft.lbf. Nm 4 5 6 8 2.2 16 22 10 4.1 30 40 12 7.0 50 14 11 16 15 18 23 20 30 22 38 24 52 27 68 490 670 0.28 0.53 0.94 2.1 2.7 3.9 5.2 6.8 9.2

80 110

170 220 270 370 225 295 375 510

69 108 147

00.10

Metric thread (ISO 12.9)

M 4 5 6 1.4 10 14 8 3.2 23 31 10 6.1 44 60 12 10 14 16 16 23 18 34 20 44 22 55 24 76 27 100 720 980 Kpm ft.lbf. Nm 0.42 0.78 3.0 4.1 5.7 7.6

0171-465-EN

75 120 160 98 157 225

240 320 400 550 335 430 540 745

Connecting rods with UNF thread

HPO/CMO UNF Kpm ft.lbf.
T0177082_0

HPC/SMC 100 3/8 4.4 32 43

SMC 180 5/8 17 130 167

5/16 2.1 15 20

Nm

Bolts for top-, side- and end covers

Compressor
Location

T/CMO
Top/side covers End covers Top/side covers

HPO
End covers

T/SMC 100
Top/side and end covers

HPC
Top/side and end covers

T/SMC 180
Top/side and end covers

M Kpm ft.lbf. Nm

M12 8.6 63 85

M14 13.7 100 135

M12 13.2 95 130

M14 20.3 147 200

M14 13.7 100 135

M14 20.3 147 200

M20 42.7 310 420

0178-250-EN

83

Bolt on discharge valve

HPO/CMO Kpm ft.lbf. Nm 3.2 23 32 HPC/SMC 100 10.2 75 101 SMC 180 35 255 344

AMR

B
Compressor Type Coupling Type AMR225 Thread Kpm. B D 3.5 5.6 13 28 13 20 20 13

Torque ft.lbf. B D 25 40 95 200 96

Nm B D 34 130 200

HPO/CMO/TCMO

5/16 7/16 1/2 11/16 Thread 5/16 3/8 7/16 5/16 5/16 3/8 7/16 1/2 9/16 5/8 11/16

104-108 AMR312S HPC/ SMC/ TSMC 112-116 AMR350S

147 55

147 128 200 96 275 130

186-188 AMR450S Coupling Type 225 262 312 200 225 262 Serie 52

Compressor Type 128 Serie 52

Torque (B) Kpm. 3.5 4.2 5.6 3.5 3.5 4.2 5.6 13 18 25 28 ft.lbf. 25 30 40 25 25 30 40 95 130 175 200 Nm 34 41 55 34 34 41 55 128 177 245 275

SAB

163 202

Depends VMY on the size of the motor

Serie 52

312 350 375 425 450

84

0178-250-EN

Oil separator

Fig. 1 27A 27B

31
98.05

30 34

30

0178-259-EN

Design and operating mode

As illustrated in fig. 1 the oil separator system consists of two vessels, of which the upper one is the oil separator. Here the oil is separated from the discharge gas and led down into the bottom vessel which serves as the oil reservoir. Both vessels are firmly connected to pipes that cannot be cut off one from the other.

Fig. 2

From the compressor 27A

Demister

27B

To oil vessel Fine oil separator elements, pos. 55

Oil separator
As illustrated in fig. 2, the discharge gas and the oil from the compressor first pass the demisters in which the main part of the oil is separated from the discharge gas and drained into the oil vessel.

However, the discharge gas still contains a certain amount of fine oil drops that are separated as the discharge gas passes the fine oil separator elements (the fine filters) This oil is returned to the compressor in separate pipe systems as described further on in this section. As the velocity and specific weight of the gas influences the efficiency of the fine oil separator elements, the units are available in two executions according to the following guidelines:

0178-250-EN

85

1: Refrigerants HFC and HCFC All units types SM-LM-SFand LF are delivered with two built-in fine filters and both connecting branches, 27A and 27B, are connected to the refrigeration plant. 2: Refrigerant R717 S All units types LM-SF og LF are delivered with two built-in fine filters and both connecting branches, 27A and 27B, are connected to the refrigeration plant. S Unit type SM is delivered with one fine filter and only the open connecting branch, 27A/27B, is connected to the refrigeration plant.

Normally, the fine oil separator elements need not be inspected, but if it is considered necessary - e.g. in case an increasing oil consumption has been observed in the unit they can be removed through the ends of the oil separator. In the case of units with two fine filters it is essential that the pressure loss through the oil separator and the piping system is the same in both passes. This requires that the pipe connections from the oil separator to the refrigeration plant are of equal length and as symmetrical as possible as shown in fig. 1 and 2, whereas the asymmetrical principle sketch shown in fig. 3 should be avoided.

Fig. 1

to condenser x x

Fig. 2

to condenser

Fig. 3

Oil return system for fine filter element

Whether the unit is delivered with one or two discharge stop valves, thus with one or two fine oil separator elements, two oil return pipes will be fitted on the unit. This may be seen from the piping diagram at the end of this book.

Throttle valves pos. 52 are used for adjustment of the oil flow through the oil return systems. Their adjustment is just enough to make the pipelines feel warm during operation. In general, it is recommended not to open the throttle valves more than 4 turns. At the same time gas bubbles should be visible in sight glass pos. 53.

86

0178-250-EN

Oil vessel
As already mentioned, the lubricating oil is collected in the oil vessel. The oil level in the vessel must always be visible in sight glasses pos. 31. The correct amount of oil in the unit is stated in a table in a previous chapter of this book. The oil vessel contains 2 heating elements, pos. 30, which must be on whenever the unit

is not operating, and off when the compressor is started. Remember to switch off the heating elements when oil is drained off the oil vessel before an oil renewal. Also remember that if the unit has been idle for a lenghty period without the heating elements being switched on, these must be connected at least 8 hours before the unit is set into operation.

0178-250-EN

87

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

1
T0177037_0

No 1 2 3 4 5 6

Used for Hot oil inlet Cooled oil outlet Water inlet Water outlet Type plate Air purging from water side

For cooling of the oil with water a welded shell and tube heat exchanger can be delivered of the OWSG/OWRG type.

which significantly improves the heat transmission from the oil to the cooling water. The end covers on the cooler are formed to guide the water back and forth a number of times in order to ensure an adequate water velocity. Oil cooler type OWRG is made of stainless steel in two versions for fresh water and sea water, respectively. The type is indicated on the type plate of the cooler. Futher, the oil cooler can be manufactured with corrosion plugs on the end covers. To maintain the corrosion resistance of the two types of oil cooler, it is a condition that the pipes never become overheated. Consequently, they must not be uncovered. To avoid this, it is important that:

Design
The oil cooler consists, in principle, of a cylindrical jacket with a steel tube insert. The cooler has oil inlet and outlet sockets in the jacket, whereas the inlet and outlet for water are placed in one of the end covers. The covers are made of cast iron. The tube insert consists of two tube plates, each with a number of tubes welded in. Baffle plates are placed between the tubes to extend the oils passage through the cooler, thus causing the oil to flow across the tubes,

88

0178-250-EN

0171-561-EN

95.10

S there are no air pockets on the water side of the oil cooler. Therefore, the oil cooler must be supplied with a purge valve on top of the cover without connections. This valve may be left out if the water discharge pipe points upwards, so that air can escape together with the water. S the water velocity through the oil cooler should never be below 1.5 m/sec. Furthermore, this high water velocity prevents fouling in the oil cooler. In the fresh water versions, the content of chloride (Cl-) in the water must not exceed 400 ppm. In the case of a chlorine treatment, if any, of water for the sea water version, the amount of chlorine must not exceed 0.5 mg Cl2 per litre water for 30 min. once every 24 hrs. Besides, the oil cooler must be drained of water for longer standstill periods (more than 1 - 2 weeks).

When operating with a cooling tower, rust inhibitors, algicides and anti-fouling must be added to the water according to normal practice in connection with cooling tower systems. The OWRG oil cooler type is used where the quality of the water cannot be guaranteed satisfactory and constant.

Cleaning
Fouling or soiling of the water side of the cooler will reduce the heat transfer, and hence the capacity of the cooler. The cooler must therefore be checked and cleaned at regular intervals, depending on the degree of purity of the cooling water. The internal pipe diameter is 8 mm. The OWSG/OWRG oil cooler can be cleaned by removing the end cover with no connection branches and scrubbing the piping clean with a bronze brush. Give the tubing a final rinse with fresh water. Alternatively, ready-mixed inhibitive scouring acids can be used, with subsequent neutralization. Such agents must be designed for untreated steel tube heat exchangers. The chemical manufacturers instructions should be followed precisely.

Application
The OWSG type oil cooler is designed for connection to a fresh-water system incorporating anti-corrosion and anti-scaling measures.

0178-250-EN

89

Regulating the oil temperature

Open system: If the oil cooler is connected in an open system, i.e. it cools by means of cooling tower water, other fresh water or sea water, the oil temperature must not be regulated by altering the water flow through the cooler. A decreasing water flow will result in fouling and perhaps in clogged-up tubes which would lead to corrosion on the tubes. Instead, the following is prescribed: S If necessary, use a temperature-regulated three-way valve to regulate the oil flow through the cooler. On SAB 202 the oil temperatur regulation is based on a two-way valve incl. pilot valve. See piping diagram.

S Or use a temperature-regulated three-way valve on the water side in connection with a water pump to maintain the prescribed water flow through the oil cooler. Closed system: OWSG If this oil cooler is connected in a closed system, such as a heat recovery system, the water flow can still be regulated. OWRG Only use the mentioned oil coolers for the prescribed water flow in order to minimize the risk of corrosion as a result of the combination of high temperature and Cl content in the cooling water. Therefore, we recommend the use of the same regulating system as prescribed under Open system.

90

0178-250-EN

Refrigerant-cooled Oil Cooler type OOSI SAB 202

4 1 pass 5 1 6 3 4 2 pass 2 1 6
97.03

3
T0177101_0/1

0178-261-EN

1 2 3

Oil inlet Oil outlet Refrigerant inlet

4 Refrigerant outlet 5 Oil draining (oil side) 6 Oil draining (refrigerant side R717)

For cooling of the oil with refrigerant a closed, welded tubular heat exchanger of the OOSI type can be used.

refrigerant. The draft on the following page is an example of a common pipe layout. Ex. 1: The receiver is placed above the oil cooler. Ex. 2: In case the inlet height (H1) is insufficient a small priority vessel can be placed between condenser and receiver as shown in the example. If it proves quite impossible to obtain a satisfying inlet height, a pump could possibly be mounted for the refrigerant supply. Normally, the inlet height (H1) will be sufficient when constituting min. 75% of the return height (H2), provided that the horizontal length of the return pipe is less than 50% of the vertical pipe length or if executed min. 1 pipe dimension larger. For detailed calculations and choice of velocity, please see Capacities.

Description
The OOSI oil cooler is an all-welded tubular heat exchanger manufactured in steel. On the inside the pipes are equipped with a special insert in order to improve the heat transfer. The oil flows through the pipes, while the refrigerant evaporates outside the pipes. It is a flooded system, which is to say that the refrigerant leaves the oil cooler as partly evaporated (mixture of liquid and vapour). This ensures that, under normal conditions, no oil is accumulated on the refrigerant side.

Mounting
In order for the condenser to function correctly it has to be mounted higher than the oil cooler to ensure a natural circulation of the

0178-250-EN

91

Ex. 1
From the compressor D B C Receiver Decrease 1:300

Ex. 2

Condenser

Alternative arrangement From the condenser

B H1 E to the evaporator or main receiver A Oil cooler R Increase 1:300 R Oil cooler

H2

to the receiver A

The oil temperature, typically within the range of 35-60C, depends on the actual operating conditions and size of oil cooler. The choice of size of oil cooler also depends on the chosen oil type. The design oil temperatures for the various oil types may be seen from YORK Refrigerations Oil Recommendation. The set points of the safety equipment are adjusted accordingly. Normally, the alarm limit is 10K above the design oil temperature for the oil type in question. As to its control, see instruction manual.

reopens once the compressor is working again and the oil temperature has reached min. 20C. Before the compressor is started, the oil in the pipe system must have a temperature of at least 10C. In machine rooms without any heating it may be necessary to mount a heating rod. Normally, oil separators are standard mounted with heating rods in order to ensure a sufficiently high oil temperature in the oil separator. In case several oil coolers are mounted in parallel with a considerably different flow resistance due to the pipe lengths etc, a throttle valve (R) (see Ex. 1) can be fitted in the liquid supply line (A), so that the flow can be equalized between the oil coolers and thus ensure the full function of all oil coolers. Do not throttle so much that the oil cooler does not remain flooded. Do not throttle the oil temperature by throttling on the liquid supply line (A) or the return line (B). In that case the oil cooler does not remain flooded, and the return line will only contain refrigerant gas. Hereby, oil will accumulate on the refrigerant side in the oil cooler, causing malfunction and a heavy thermal loading of the oil cooler. This increases the risk of its break-down.

Oil temperature regulation

Most units are fitted with an oil temperature regulating system as described in the following section. This system is of special importance if, f.inst. during cold periods, the condensing temperature at times drops below 20C during operation or below 10C during standstill. Should this oil temperature regulating system not be fitted and the condensing temperature drops below 10C at standstill, the liquid supply line to the oil cooler must be closed. For this purpose, a solenoid valve with a low pressure drop, closing whenever the compressor stops, can be mounted. The valve

92

0178-250-EN

Water-cooled oil cooler, type B SAB 110, SAB 128/163 Mk3, SAB 202

No. 1 2 3 4

Used for Hot oil inlet Cooled oil outlet Water inlet Water outlet

95.10

4
T0177038_1

0171-562-EN

Construction
The B-type oil cooler is a stainless steel plate heat exchanger. A V-pattern is moulded into each plate together with the inlet and outlet holes. The plate heat exchanger is assembled by turning the V-pattern upwards and downwards, alternately. All points of contact between the V-patterns are copperwelded. A supporting plate is soldered onto either side. Between the support plate fitted with connecting branches and the first heatexchanger plate, a row of channels is visible. By means of a welding rod, for instance, check that the V-pattern faces up-wards, preventing water from accumulating here. Owing to the principle of its design, the heat exchanger cannot be stripped down and must not be used in R717 plants.

For water-cooling of oil in units with HFC/ HCFC a B-type soldered plate heat exchanger can be used. Refer to page 1 to see the type of oil cooler used for this unit.

Cleaning
Since the oil cooler cannot be dismantled, mechanical cleaning is not possible. It is therefore recommended that the water filter be fitted before the oil cooler. Cleaning can only be done with a cleaning fluid. The cleaning intervals for the cooling water side of the heat exchanger should be determined on the basis of the waters hardness and tendency to deposit scale. For cleaning purposes a weak acid can be used as e.g. a 5% phosphoric acid or, if the heat exchanger is cleaned often, a 5% oxalic acid solution. Rinsing with plenty of pure water is then required to remove any remaining acid and dirt.

Application
The B-type oil cooler can only be used with freshwater as cooling agent.

0178-250-EN

93

Oil temperature regulation

Open system If the oil cooler is connected in an open system, ie that it is cooled by means of water from a cooling tower, other fresh water or sea water, the oil temperature must not be regulated by altering the water flow through the cooler. A decreasing water flow could lead to fouling and perhaps clogged-up cooling pipes which would lead to corrosion on the pipes. Instead, the following is prescribed: S Adjust the oil flow through the cooler by means of the temperature regulated threeway valve.

S Or use a temperature-regulated three-way valve on the water side in connection with a water pump to maintain the prescribed water flow through the oil cooler. Closed system Only use the B-type oil coolers for the prescribed water flow in order to minimize the risk of corrosion as a result of the combination of high temperature and Cl content in the cooling water. Therefore, we recommend the use of the same regulation system as prescribed under Open system.

94

0178-250-EN

Oil temperature regulating system SAB 110, 128, 163, 202 and VMY 536
In above screw compressor units, in which the oil system is cooled by means of either a refrigerant-cooled oil cooler type OOSI or a water-cooled oil cooler type OWSG, the oil temperature is usually regulated by a thermostatic three-way valve as illustrated in fig. 1.
Fig.1

The valve dimension can be read from the nameplate on the valve cover. Function Valve pos. 46 is fitted in a bypass piping system as shown in fig. 2:

Fig. 2 To the compressor Three-way valve

98.05

Oil cooler

0178-277-EN

From oil receiver

This thermostatic three-way valve is used in the following dimensions for above-mentioned compressor units: Compressor unit
SAB 110 SAB 128 SAB 163 SAB 202 SAB 330 VMY 536

As shown in fig. 3 and 4, it works by letting a built-in thermo element, pos. 1, regulate a cone, pos. 2, so that cold and warm oil is mixed to the set temperature. In fig. 3 the thermo element is shown in its cold position, i.e. the flow of cold oil has been shut off whereas the flow of warm oil is completely unobstructed. Fig. 4 illustrates the opposite situation in which the thermo element is in its warm position, hereby shutting off the flow of warm oil.

Valve dimension
RT3 RT3 RT5 RT6 RT6 RT6

Welded connection
DN 25 DN 25 DN 40 DN 50 DN 50 DN 50

0178-250-EN

95

During operation the thermo element will adjust the regulating cone modulatingly so that the two oil flows are mixed to the set oil temFig. 3

perature, leaving the valve through connecting branch A.

Fig. 4

B Varm oil from oil separator C

B Varm oil from oil receiver Cooled oil from oil cooler
2 1

Cooled oil from oil cooler C

A Thermo element in cold position

Oil with correct mixed temp.

Thermo element in warm position

The thermo element is factory set to maintain a mixed oil temperature of 48C, allowing for a few degrees deviation and it cannot be readjusted. Service: As a rule, it is not necessary to dismantle a well-functioning three-way valve as it does not contain any gaskets or wearing parts that must be replaced at fixed intervals. Dismantling: During dismantling, if any, apply the following procedure: S After the pressure in the piping system has been equalized to atmospheric, unscrew the four Allen screws that keep the cover fixed to the valve housing. S The cover which reaches down into the valve housing in order to keep the thermo element in a fixed position, is most easily dismantlled by turning it slightly and then

lift it up by means of a big screwdriver. Watch out ! There may still be oil in the system. S The thermo element can now be extracted from the valve housing by hand. Assembling: Assembling the valve is done in the reverse order and attention should be paid to the following: S The O-ring, fitted in the cover, should be replaced by a new one. See section Spare Parts Survey in this manual. S No sealing ring should be fitted between the inner guideway of the cover and the valve cone. S In case the three-way valve does not regulate the oil temperature correctly, the thermo element and cone can be replaced as one entire unit. See section Spare Parts Survey in this manual.

96

0178-250-EN

Heating rods, pos. 30

In order to keep the lubricating oil in the compressor warm during a period of standstill, the oil reservoir has one or two heating rods built in. Before start-up, the heating rod (s) must have been activated for 6-8 hours in order to ensure that there is only a minimum of refrigerant in the oil. When containing much refrigerant, the oil will lose its lubricating property and the following operational interruptions may occur: In reciprocating compressors there is a serious danger of vigorous oil foaming when the compressor starts as a result of a falling suction pressure. For screw compressors starting with much refrigerant dissolved in the oil, there is a risk of the compressor being stopped by the Flow Switch as the oil will be foaming owing to the fall in pressure through oil pipe and oil filter.
NV 50 G 1 1/4

As illustrated on the drawing the heating rod consists of an electric heating element, incorporated in a dia. 30 mm pipe. The entire heating cartridge is screwed on tight at the G 1 1/4 thread. Note: The heating rod must not be energized if the oil level in the reservoir is below the minimum mark in the sight glass, and it should generally be switched off during compressor operation. Remember to turn off the heating rod whenever the crankcase of the reciprocating compressor is opened for inspection. The following table indicates which heating rods are used for the various compressor types. In the spare parts lists for compressor or unit you will find the current part numbers.
Marking: Prod. nr. Watt Volt Manu. date 30 L1

0170-017-EN

98.05

50

30

80

L2

Heating rods Power Watt

270 270 270 460 460 460

Voltage V
250 230 115* 250 230 115*

L1 mm

L2 mm

Used for:

CMO - TCMO - SMC 100 - TSMC 100

158

175

HPO - HPC, SMC 180 - TSMC 180 VMY 347 /447 - 536 SAB 110 - 128 - 163 - 202 - 330 -

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

0178-250-EN

97

External oil filter

The compressor unit may be executed with an external oil filter, pos. 106, mounted in the oil pipe between the oil separator/the oil cooler and the compressor. In case of an external oil filter, no oil filter will be mounted in the compressor block. Concerning the construction of the compressor unit, please see page 1. The external oil filter may be designed with either one or two parallel filters. The filter housing may be either cast or welded, but the filter insert is the same for both. Stopping the compressor at too high a differential pressure happens with a 30 second delay as the pressure difference may momentarily exceed 1.0 bar if the compressor is started up with cold oil.

Opening the oil filter

Before the filter is opened, new O-rings pos. 2 and 5 should be available in case the existing ones cannot be reused. The filter cartridge pos. 6 cannot be cleaned and reused but has to be replaced. 1. Stop the compressor after regulating it down to minimum capacity. 2. Close the valves on both sides of the oil filter.
97.12 0178-266-EN

2 1

3. Open the ventilating valve/plug at the top of the oil filter carefully in order to equalize the pressure in the oil filter to atmospheric pressure. 4. Take off the cover at the top of the oil filter. The filter insert can now be removed without the use of tools. The oil charge in the filter housing may be drained through the drain valve/plug at the bottom of the filter housing and the filter housing can be wiped clean.

T0177149_9 v5

Replacement of the filter cartridge

When the filter insert has been removed, it is dismounted by dismantling the hexagon nut at the end of the filter. Throw away the filter cartridge (it cannot be reused). Clean the magnetic rod with compressed air. Position the new filter cartridge by fastening it in the fixture.

The filter is a vertical filter in which the oil must pass the filter cartridge from the inside and out. In this way dirt will accumulate on the inside of the filter cartridge and thus not fall into the filter housing during a replacement of the filter cartridge. The filter is protected against bursting because UNISAB ll stops the compressor if the pressure drop across the filter exceeds 1 bar.

98

0178-250-EN

Top up the filter housing with clean refrigerant oil after positioning the whole filter cartridge. The interval for changing the filter cartridge very much depends on how carefully the refrigerating plant has been cleaned at the assembly. The first replacement of the filter cartridge can be expected after a few hours operation. Note: Remember to open the stop valves before and after the oil filter before restarting the compressor.

Unit with double oil filter

If the unit has two parallel filters only, one filter should be used at a time. The filter which is not being used can be cleaned while the compressor is working. By cleaning the oil filter while the compressor is working it is important to be aware of the higher pressure when the ventilating valve/ plug is opened. There may be a lot of oil foam, especially in the case of (H)CFC plants. Note: While the compressor is working, both discharge valves should be open to avoid that a hydraulic pressure arises in the filter housing.

0178-250-EN

99

Oil pump pos. 63

The pump principle 1 2 3

The oil pump, pos. 63, is an internally toothed gear pump with built-in pressure relief valve and slide ring shaft sealing. The pump is fitted with suction inlet facing downwards and discharge connection and outlet from pressure relief valve facing upwards. The pump is fitted on an intermediate piece which again is mounted on the electric motor. The electric motor is fastened to the oil separator by means of a small frame.

Start-up
In consideration of bearings and shaft sealing, the pump may only run without an oil flow for brief periods. On charging of oil to a completely empty oil separator it must be made sure that the pump is filled with oil in accordance with the instruction: Preparations before Start-up.

2. Dismantle the screws between the intermediate piece and the oil pump. Dismantle the screws that keep the motor fixed to the oil separator, at the same time supporting the motor. The motor with the intermediate piece can now be pulled away from the oil pump. It may be necessary to dismantle the wires leading to the electric motor in order to remove it sufficiently. Now carry out the replacement of the shaft seal with the pump still mounted in the pipe system.

Service
The oil pump is designed as one unit and should not be separated. However, the shaft seal is regarded as a wearing part which can be replaced in case of leakage. If the shaft seal is going to be replaced, you can do one of two things:

Replacement of shaft seal

The easiest way to replace the shaft seal is to follow below procedure: S Remove the half section of coupling and the key fitted in the oil pump shaft. S Dismantle the 3 screws keeping the shaft seal housing fixed to the oil pump.

100

0178-250-EN

0178-265-EN

97.12

Description

1. Drain the oil from the oil separator and dismantle all pipe connections to the pump. Dismantle the 2 screws that keep the intermediate piece and the oil pump together. The oil pump can now be pulled out of the intermediate piece and the shaft seal replacement can be carried out on a workshop table.

S Screw in the 3 threaded rods no. 3 in the threaded holes in the shaft seal housing.

Fasten puller no. 1 with thrust screw no. 2 on the threaded rods with nuts no. 4.

T0177149_0 V3

S Pull off the shaft seal housing by turning thrust screw no. 2. Replace the O-ring pos. 6, which seals the shaft seal housing, if damaged. S Loosen the 3 pointed screws in the rotating part of the shaft seal pos. 9, and pull if off the pump shaft. In order to remove the fixed part of the shaft seal, bearing pos. 10 must first be pressed out with punch no. 5. Remember to dismantle locking ring pos. 11. The fixed part of the shaft seal can now be pushed into the shaft seal housing. S Tape over the key way in order to protect the O-ring of the shaft seal and lubricate the shaft in refrigerating machine oil. Take care not to damage the lapped surfaces on the shaft seal parts. S Press the rotating part of the shaft seal over the shaft. On mounting of the shaft seal, press it against the oil pump housing with a 0.05 mm feeler gauge in between. Tighten the 3 pointed screws in turns. S Mount the fixed part of the shaft seal inside the shaft seal housing. Make sure

that the retaining pin in the shaft seal housing engages in the shaft seal. S Carefully pull the shaft seal housing over the shaft and tighten it by means of the 3 screws. Remember to mount O-ring pos. 6. S Carefully mount bearing pos. 10, using the hollow punch no. 6, then mount circlip pos. 11. S Remount key and half-section of coupling. Leave an opening of 3 mm between coupling and shaft seal housing. S Mount oil pump on the intermediate piece of the motor, while making sure that the half-sections of coupling engage correctly. Remount pipe connections and motor.

Checking the rotating direction of the motor

Before the initial start-up of the oil pump remember to check that the oil pump has the correct rotating direction. This is done by looking through the fan shield mounted at the end of the motor away from the oil pump. Seen through this shield the motor must rotate clockwise.

0178-250-EN

101

Spare Parts drawings

Pos. 1 2 3 4 5. 6 8 9 10 11 12 13 14

Designation Pump cover Pump shaft O-ring Pump wheel Housing O-ring Shaft seal housing Shaft seal Bearing Circlip Rotor shaft Shim Shim

Tools
4

1 3 T0177149_0 V4 2 5 6

No. 1 2 3 4 5 6

Designation Puller Screw M10 x 75 Threaded rod M8 x 150 Nut M8 Punch, solid Punch, hollow

102

0178-250-EN

The oil pump filter

5 2 3

94.05

0178-264-EN

6
T0177149_0/1

The filter consists of a filter housing, pos. 1, a flange for the end cover, pos. 2, an insert for the end cover, pos. 3, a filter element, pos. 4, an O-ring for the cover, pos. 5, O-rings for the filter element, pos. 6, and screws for the cover, pos. 7. The purpose of the filter is to protect the oil pump against dirt in the oil. In order to clean the filter element, close the valves pos. 60 and 65. Hereafter, open the filter and take out the filter element.

Note: Some oil will be present in both the filter and the oil pump. This oil may be drained off through valve pos. 62. The filter element can be cleaned in a cleaning fluid by means of a stiff brush and pressurized air. Hereafter, refit the filter element and close valves pos. 62 and 64. At the same time open valves pos. 60 and 65.

0178-250-EN

103

Safety and monitoring devices SAB 110, SAB 128/163 Mk3, SAB 202, SAB 283L/283E
Compressor units with relay control or terminal strip for remote control are normally equipped with the following instruments for safety and operating control, depending on the specific order. pressure cut-out is not equipped with a reset, so the compressor starts again when the pressure has risen above the difference between the setpoints of the pressure cut-out. Pos. PAZ2 High pressure cut-out KP5. The pressure cut-out is intended to safeguard the compressor against excessive discharge pressure. Note: On units to be approved by TV (Germany), the KP5 is replaced by a pressure cut-out KP 7ABS which has been approved by TV. This high pressure cut-out will stop the compressor in the event of damage to the cut-out bellow or excessively high discharge pressure.

Safety devices
Pos. 28 Safety valve on oil separator with exhaust to the atmosphere. The exhaust line must be routed from the engine room out into the open air. The SAB 110 compressor has a built-in by-pass safety valve which, in case of too high differential pressure across compressor, will lead gas from the oil separator to the compressor suction chamber. The opening pressure the of safety valve is indicated on its name plate. Pos. 43 Flow control in the oil distributor pipe. A spherical float with a permanent built-in magnet is able to actuate a reed switch in the float guide. The switch is wired up to a timing relay which will stop the compressor if the flow control chamber is not filled with oil within max. 50+10 sec. after start-up, or after 10 sec. without oil during normal operation.

Pos. PDAZ 11 Differential oil pressure cutout MP55. This pressure cut-out is designed to ensure sufficient lubricating pressure and oil pressure for capacity regulation. The pressure cut-out is equipped with a time lag of 45 secs. If the preset differential pressure has not been obtained by that time, the compressor will stop. The MP55 is equipped with manual reset. Pos. 0376-A12 Differential pressure cut-out for control of pressure drop across oil filter. If pressure drop across oil filter becomes excenssive

Pos. PAZ1 Pressure cut-out KP1, which stops the compressor in the event of the suction pressure falling below the set value. The

104

0178-250-EN

0171-566-EN

95.10

due to impurities, the pressure cut-out will stop the compressor and a pilot lamp will light. Futher, the differential pressure cutout contains a visual indication of presure drop represented by a green field for permissible pressure drop and a red field indicating excenssive a pressure drop across oil filter in which case the pressure cut-out will stop the compressor. Pos. TAZ12 Thermostat KP79 with sensor in oil flow control. Designed to safeguard against excessive oil temperature. Pos. TAZ13 Thermostat KP79 or KP81 with sensor in oil separator. Designed to safeguard against excessive discharge gas temperature. Pos. TC14 Thermostat KP77 with sensor in oil separator. Designed to safeguard against too low discharge

pipe temperature and hence too low oil temperature in connection with HLI oil cooling. Please see section on setting of safety devices for various values.

Monitoring devices
Pos. PI15 Pos. PI16 Pos. TI5 Pos. TI6 Pos. TI7 Suction pressure gauge (evaporator pressure) Discharge pressure gauge (condenser/intermediate pressure) Thermometer in oil separator (discharge gas temperature) Thermometer in oil flow control (oil temperature) Thermometer with sensor in suction pipe. Supplied as extra. Used to calculate superheat of the suction gas. Superheat is the temperature difference found by deducting the temperature read off the suction pressure gauge from the temperature read off the thermometer.

0178-250-EN

105

Refrigeration Plant Maintenance

Operational reliability
The prime causes of operating malfunctions to the plant are: 1. Incorrect control of liquid supply to the evaporator. 2. Moisture in the plant. 3. Air in the plant. 4. Anti-freezing liquid is missing. 5. Congestion due to metal shavings and dirt. 6. Congestion due to iron oxides. 7. Congestion due to copper oxides. 8. Inadequate refrigerant charge. Below, some information is given about ways of keeping contaminants out of the refrigerating system and at the same time facilitating day-to-day supervision of the refrigeration plant. bled of refrigerant. Adjust any constantpressure valves to bring evaporator pressure down to atmospheric. 3. Start up the compressor. Adjust regulating system to lower suction pressure. 4. Keep a close eye on the suction pressure gauge! When the suction pressure is equal to atmospheric, stop the compressor and quickly shut off the discharge stop valve. Shut off any stop valve in the oil return line. If the receiver has an extra stop valve in the feed line, this can be closed; practically the entire refrigerant charge will then remain shut off in the receiver. Note: The receiver must not be overfilled! There should be a minimum gas volume of 5%. 5. A slight overpressure should normally remain in the piping system - this safeguards the system against the penetration of air and moisture. 6. Before dismantling parts, the operator should put a gas mask on.

Pumping down the refrigeration plant

Before dismantling any parts of the refrigeration plant for inspection or repair, pump-down must be carried out. 1. Open suction and discharge stop valves on compressor. 2. Close liquid stop valve after condenser or receiver so that liquid refrigerant can be collected in the tank. Any solenoid valves in the liquid line should be opened by force, adjusting the thermostat to its lowest position so that the liquid line can be

Dismantling plant
In order to prevent moisture penetrating into the refrigeration plant during any repair work, it is advisable to follow the rules below: 1. No component should be opened unnecessarily. 2. When dismantling the system, the pressure in the system should be a little higher than atmospheric.

106

0178-250-EN

0171-464-EN

94.05

3. Note: If the piping system is colder than the surroundings, there is a considerable risk of damp precipitation (condensation) on cold plant parts. Plant components to be dismantled must be warmer than the ambient temperature. 4. No two points in the system should be opened at the same time. 5. Plug, close or at least cover opening with oiled paper or suchlike. 6. Be aware of the possibility of filters being very moist.

Tightness testing and pump-down of refrigeration plant

Before charging refrigerant into that part of the refrigeration plant which has been opened, this should be pressure-tested as described in the section entitled Pressure testing. Afterwards, pump down in order to eliminate air and moisture. In this regard, consult the section on Evacuation. Otherwise, follow the instructions given in the separate instruction manual on plant components. Note: If the oil in the crankcase of the piston compressor or the oil separator of the screw compressor has been in contact with the atmospheric air for any length of time, it must be replaced with fresh oil of the same grade and make.

0178-250-EN

107

Troubleshooting on the Screw Compressor Plant

Operating condition
Experience shows that pressure and temperature variations in a refrigerant system can provide information about the operating condition of the refrigeration plant. In particular, suction and condenser pressures as well as the temperatures of suction and discharge gases may provide important information as to the operating conditions of the plant. Considerable changes in operating conditions can often be produced by only very slight modifications to variable pressures and temperatures. Using the following troubleshooting chart, it is possible to ascertain the cause of and remedy for any operating disturbance. Fault Code
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21

Using the troubleshooting chart

In the following chart each individual error possibility is indicated by a code number in the left hand column, with the error briefly described in the second column. The third column states code numbers for the possible causes of the error. The code numbers refer to the subsequent chart. The section entitled Remedying malfunctions states how to remedy the observed error. See the following example for the correct procedure.

Example
Observed error: excessive suction pressure - error code 5. Cause codes: 2. (compressor lacks capacity) and 48. (safety valve leaky or opens prematurely).The entry keys to the subsequent section are therefore (5,2) and (5,48). Probable causes
2, 28, 48, 49. 31, 32. 1, 14, 27, 28, 29, 30, 33, 40, 42. 1, 14, 27, 28, 29, 30, 33, 39, 42, 49. 2, 48. 38, 41, 43, 44. 22, 23, 24, 26, 38, 41, 43, 44. 2, 22, 23, 24, 26. 5, 11, 25, 31, 32. 13, 18, 19, 20, 37, 48. 21, 50. 19. 3, 4, 12. 3, 4. 15, 16, 17. 31, 32. 47, 50. 5, 7,

Observed Fault
Excessive suction pressure Suction temperature is too low Suction pressure is too low Compressor starts and stops too frequently, at low-pressure cut-out Excessive suction pressure Compressor starts and stops too frequently, at high-pressure cut-out Excessive condensing pressure Condensing pressure too low Oil pressure too low Oil temperature too high Oil temperature too low Excessive pressure drop across oil filter Excessive capacity - aut. controls out of order Insufficient capacity - aut. controls out of order Oil level in the reservoir falls Oil foams vigorously during standstill Oil reservoir sweating during standstill Abnormal noise from compressor Compressor motor will not start Compressor runs continuously Liquid in the suction line

8,

9, 10, 31, 32, 48, 52. 47

6, 12, 13, 19, 34, 35, 36, 40, 41, 45, 46, 2, 3, 4, 42, 48, 49. 1, 31, 32.

108

0178-250-EN

0171-627-EN

95.01

Code 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25

Cause Compressor has excessive capacity Compressor lacks capacity Solenoid valve in regulating system fails to open Timer or other automatic control out of order Excessive capacity during decrease in temperature Capacity regulation not set to 0% Loose foundation bolts Misalignment of motor and compressor Friction between rotors and housing or defective bearings Loose bolts in coupling Oil pressure regulating valve set too low Oil pump out of order Oil too hot - oil thermostat cut out Too much oil circulating in system (evaporators) Filter in solenoid valve in oil-return line clogged Solenoid valve in oil return out of order During initial start-up, some of the oil will be led out into the plant A valve in the oil line is being throttled Oil filter clogged Insufficient water through oil cooler Excessive oil cooling - oil too cold Insufficient water or air through condenser Condenser tubing clogged by sludge or scale Cooling water too hot Too much water through condenser

Code 26 27 28 29 30

Cause Water filter clogged Filter before valve in liquid or suction line clogged Excessive suction gas superheating Freezing-up of thermostatic expansion valve Thermostatic expansion valve has lost its charge Excess flow through expansion valve (liquid in suction line) Loose or misplaced sensor Solenoid valve in liquid or suction line not opening Oil filter needs cleaning - pressure cut-out has cut Oil pressure too low - pressure cut-out has cut Oil too hot - oil thermostat has cut Oil thermostat set too high High-pressure cut-out set too low Low-pressure cut-out set too high Low-pressure cut-out shut off High-pressure cut-out shut off Insufficient charge in plant Too much charge in plant Air or non-condensable gases in system Fuses blown Thermal relay reset Main switch interrupted Safety valve leaky or opening prematurely Evaporator soiled or iced up Heating element blown Liquid in suction line

31 32 33 34 35

36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 52

0178-250-EN

109

Remedying Malfunctions
1. Excessive suction temperature
1.2 1.28 1.48 Inadequate capacity Excessive superheating of suction gas Safety valve leaky or opening prematurely Increase capacity Check and regulate thermostatic valves on evaporators Check condenser pressure and adjust or repair safety valve

2. Suction temperature too low

2.31 2.32 Liquid in suction line Loose or misplaced sensor Regulate expansion valves or float valves Check whether sensors are making good contact with suction pipe and whether correctly positioned

3. Suction pressure is too low

3.1 3.14 3.27 3.28 Excessive capacity Too much oil in evaporators Filter in liquid line clogged Excessive superheating of suction gas Freezing in thermostatic expansion valve Reduce compressor capacity Draw oil off evaporators Examine and clean filters in the liquid lines Regulate expansion valves

3.29

De-ice thermostatic expansion valve with hot wet cloths and run the liquid from the receiver through the drying filter Note: Never add methanol to the system to avoid freezing, as this will give rise to corrosion and chemical attacks in compressor, etc.

3.30

Thermostatic expansion valve has lost its charge Solenoid valve in liquid or suction line not opening Insufficient charge

Valve fails to open - change the valve

3.33

Coil may have blown - change the coil

3.42

Charge more refrigerant into the plant

110

0178-250-EN

4. Compressor starts and stops too frequently at low-pressure cut-out

4.1 4.14 4.27 4.28 4.29 4.30 4.33 4.39 4.42 4.49 See point 3.1 See point 3.14 See point 3.27 See point 3.28 See point 3.29 See point 3.30 See point 3.33 Low-pressure cut-out set too high See point 3.42 Evaporator soiled or iced up Clean or defrost evaporator Adjust pressure cut-out

5. Excessive suction pressure

5.2 5.48 Compressor lacks capacity Safety valve leaky or opening prematurely Regulate compressor capacity 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 through condenser Condenser tubing clogged by sludge or scale Cooling water too hot Regulate water supply or clean condenser

7.23 7.24

Clean condenser tubing Procure colder cooling water or reduce compressor capacity

0178-250-EN

111

7.26 7.38 7.43 7.44

Water filter clogged High-pressure cut-out set too low Too much charge in plant Air or non-condensable gases in system

Clean water filter Adjust pressure cut-out Draw fluid off into empty vessel Blow air out at condenser

8. Condensing pressure too low

8.2 Compressor lacks capacity Check whether compressor capacity corresponds to load on plant. Regulate water supply to condenser. Adjust water supply

8.25

Too much water through condenser

9. Oil pressure too low

9.5 Excessive capacity during decrease in temperature Excessive capacity during temperature decrase (run-down) may result in liquid being sucked along in suction line. This liquid may cause the oil in the oil reservoir to foam vigorously so that the oil pressure drops, thus stopping the machine. Before restarting, check whether there is liquid in the oil reservoir. This liquid must be boiled off using a heating element or by heating the oil reservoir with hot water or steam. The plant must therefore be rundown at reduced capacity. 9.11 Oil pressure regulator set too low The regulator is set to the 2.5 kp/cm prescribed by the manufacturer, but must be checked during operations. See comments under point 9.5 Loose sensor on expansion valve may cause liquid throughflow to suction line - see also comments under point 9.5.

9.31 9.32

Excess flow through expansion valve (liquid in suction line) Loose or misplaced sensor

112

0178-250-EN

10. Oil temperature too high

10.13 Thermostat cut out See section Pressure and temperature settings for setpoint.. The reason for the oil overheating must be found in the following points Check whether all valves are open Check whether valves are open or whether water filter or oil cooler need cleaning Adjust or repair valve

10.18 10.20 10.48

A valve in the oil line is being throttled Insufficient water or refrigerant through oil cooler Safety valve leaky or opening prematurely

11. Oil temperature too low

11.21 11.50 Excessive cooling of oil Heating element in oil reservoir out of order Regulate oil cooling 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 13.4 13.12 Solenoid valve in regulating system fails to open Timer or other automatic control out of order Auxiliary pump out of order Change valve or coil Change or fix When the compressor stops, the auxiliary pump must ensure capacity regulation is set to 0% capacity so that the compressor is ready for restarting. Check whether the pump is being energized or whether pump or motor is out of order.

14. Insufficient capacity - automatic controls out of order

14.3 14.4 See point 13.3 See point 13.4

0178-250-EN

113

15. Oil level in the reservoir falls

15.15 15.16 15.17 Filter for solenoid valve in oil-return line clogged Solenoid valve in oil return out of order During initial start-up, some of the oil will be let out into the plant Clean filter The oil return line must be hot during operation. On HCFC plants, particularly, some of the oil will circulate in the plant. When the system is balanced, top up with oil, if necessary.

16. Oil foaming vigorously during standstill

16.31 16.32 Excess flow through expansion valve (liquid in suction line) Loose or misplaced sensor Check expansion valve Check sensor positioning

17. Oil reservoir sweating during standstill

17.47 Main switch interrupted If the compressor is stopped and the current interrupted at the main switch, any refrigerant in the oil reservoir will evaporate. As the heating element in the oil reservoir has also been cut off, the heat needed for evaporation must be taken from the surroundings. The oil will therefore go very cold and will require heating up before restarting. See point 17.47

17.50

Heating element blown

114

0178-250-EN

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 during run-down Excessive capacity during run-down may result in liquid being sucked along into the compressor suction line. Therefore, operate at reduced capacity during run-down. Tighten bolts Adjust alignment Do not start the compressor. Open and repair.

18.7 18.8 18.9

Loose foundation bolts Misalignment of motor and compressor Friction between rotors. Friction between rotors and defective bearings Loose bolts in coupling Liquid in suction line Loose or misplaced sensor Safety valve opens

18.10 18.31 18.32 18.48

Stop compressor and tighten bolts Check and adjust the valves with excess throughflow Check sensor positioning Check opening pressure of safety valve

19. Compressor motor will not start

19.6 19.12 19.13 19.19 19.34 19.35 19.36 19.40 Capacity regulation not set to 0% Auxiliary pump out of order Excessive oil temperature Oil filter clogged Differential oil pressure cut-out has cut Oil pressure too low Oil too hot Low-pressure cut-out interrupted See under points 13.3-13.4 and 13.12 See under point 13.12 See under point 10 Clean oil filter. Reset pressure cut-out Clean oil filter. Reset pressure cut-out See under point 9 See under point 10 The compressor will restart after a rise in suction pressure sufficient to re-activate the pressure cut-out - see point 3 also. See under point 7 Check cause and change fuses Check cause of overloading Switch power on

19.41 19.45 19.46 19.47

High-pressure cut-out interrupted Fuses blown Thermal relay has interrupted Main switch interrupted

0178-250-EN

115

20. Compressor runs continuously

20.2 20.3 20.4 20.42 20.48 20.49 Compressor lacks capacity Solenoid valve in capacity regulating system fails to open Timer or other automatic control out of order Insufficient charge on plant Safety valve leaky or opening prematurely Evaporator soiled or iced up See under point 14 See under point 13.3 See under point 13.4 Top plant up with refrigerant See point 10.48 Clean or defrost evaporators

21. Liquid in suction line

21.1 21.31 21.32 Compressor has excessive capacity Excess flow through expansion valve Loose or misplaced sensor for expansion valve Reduce capacity Adjust expansion valve Check sensor positioning and rectify

116

0178-250-EN

Selecting Lubricating Oil for SABROE Compressors

During the past few years YORK Refrigeration has experienced a number of problems with mineral oils, particularly in R717 plants. The problems can be divided into two groups: a: The oil changes viscosity b: The oil decomposes (becomes very black) The problems have been seen with several mineral oil brands, often occuring within a few operating hours and resulting in severe consequences for both compressor and plants. Following the careful investigation undertaken by YORK Refrigeration during the past few years, it has been decided to introduce a range of synthetic oils which can fulfil the demands of modern refrigeration plants. Mineral oils may continue to be used in refrigeration plants, providing the lubricating quality is carefully monitored. For modern, high capacity refrigeration plants, where long lifetime for both lubricants and moving parts is expected, YORK Refrigeration recommends the choice of synthetic lubricating oils. The application areas and specifications for these synthetic oils can be found in the following pages. Installers and/or users are at liberty to choose either YORK Refrigerations own or alternative oil brands which fulfil the necessary specifications. General This recommendation only deals with the lubrication of the compressor. The performance of the lubricant in the plant (receiver, evaporator, etc.) must, however, also be taken into consideration. Lubricating oils with relatively high viscosities must be used to ensure satisfactory lubrication of refrigeration compressors. To obtain the best lubrication, the oil must: S Provide the required fluidity at the lowest evaporating temperature encountered in the plant and at the highest permissible temperatures in the compressors. S Provide acceptable fluidity at start-up. S Provide sufficient oxidation stability (the oil must be moisture-free when added to the system). S Provide sufficient chemical stability when used together with the particular refrigerant. In addition, the extent to which different refrigerants dissolve in the oil must be determined, so that the oil return systems, etc. can be designed to function properly. Stratification It should be noted that in certain plants, particularly with HFC and HCFC refrigerants, the oil may stratify into layers in the refrigerant receivers and evaporators at certain operating conditions and at particular oil concentrations. The Oil recommendation diagrams for SABROE compressors for HFC and HCFC will indicate the limits for Sabroe oils at which this stratification occurs. The oil concentrations stated in these diagrams must not be exceeded. This will enable suitable oil rectification/return systems to be designed to balance with the compressor oil carry-over so that the maximum concentration is not exceeded. For area A in the diagrams, the max oil concentration in liquid phase must not exceed

0170-151-EN

00.06

0178-250-EN

117

2%. For the other area, the max. oil concentration must not exceed 5%. For area B: please contact YORK Refrigeration. Plants with several different compressor types/makes In plants comprising several different interconnected compressor types and makes, it is strongly recommended that all compressors should use the same type of oil. This is essential where automatic oil return systems are employed. If it is intended to change the oil from one type to another, please refer to the Oil changing on SABROE compressors later in this publication. Selecting the lubricating oil There are a number of operating diagrams for the selection of lubricating oils for Sabroe compressors operating with various refrigerants. Once the general conditions concerning the lubrication of the compressor and oil type in the plant have been considered, the specific plant conditions must be taken into consideration. Use the Oil recommendation diagrams to select the appropriate oil code number. The oil code number consists of letters designating the oil type together with the Sabroe viscosity grade number.
Code design M A PAO AP E Oil types Mineral oil Synthetic oil based on Alkylbenzene Synthetic oils based on Polyalphaolefin Mixture of A and PAO-oils Synthetic ester-based lubricants

oil best suited to the operating conditions. With this code number, it is possible to select the correct Sabroe oil for the application. The marked area on each side of the separating line in the diagram shows the zone where both oils are useable. Oil types and oil companies As a result of the large number of oil companies world-wide that deals in oil for refrigeration plants, it is impossible for YORK Refrigeration to test the many different brands of oil on the market. It is our experience, however, that some oil brands during use can change character and thus no longer fit the specifications given by the companies at delivery. We have thus experienced changes in the specifications as well as in the formula and performance without having had any information about this from the oil company. This makes it very difficult for YORK Refrigeration to give a general approval of the various oil brands. For this reason YORK Refrigeration has, in cooperation with a large recognised oil company, developed a series of three oils which cover most purposes. YORK Refrigeration has however, also listed a limited number of oils which can be supplied through YORK Refrigeration. The typical data of these oils can be found in the Data Sheet for Sabroe Oils. We suggest you to use these Sabroe oils, which are delivered in 20 litre pails and 208 litre drums and can be ordered using the parts no. listed in the List of Oils. It is of course possible to use similar oils from other oil companies, and in this connection, the Data Sheet for Sabroe Oils may be helpful. Please note, however, that YORK Refrigeration has not tested any other oils than our own brand, and hence we cannot

In the oil recommendation diagrams for each refrigerant and compressor type, it is possible to determine the code number for the

118

0178-250-EN

answer for the quality, the stability or the suitability of other oils for any purposes. The oil company in question is thus solely responsible for the quality and suitability of the oil delivered, and if any problems are experienced with these oils in the compressors or in the refrigeration plant, the oil supplier should be contacted directly. When choosing oils from other oil companies, please pay particular attention to the oils effectiveness in the compressor and the refrigeration plant as a whole. Pay particular attention to the following aspects: 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 crankcase 50-60 C Max. permitted oil temperature = Setting point for alarm Min. permitted oil temperatures = setting point for alarm - if fitted

Screw compressors: The oil temperature before injection in the compressor, but after the oil cooler Max. permitted oil temperature = setting point for alarm Min. permitted oil temperature = setting point for alarm Condensing pressure Evaporating pressure S Oil viscosity in the compressor during operation and under the influence of: Refrigerant type and solubility of refrigerant in the oil Operating temperatures Vapour pressure in the oil reservoir Reciprocating compressor: Suction pressure and oil temperature in the crankcase. Screw compressor: Discharge pressure and gas temperature. S Compatibility with the neoprene O-rings: the aniline point gives an indication of how the O-ring material reacts to the oil. At an aniline point less than approximately 100C the material tends to swell, and at an aniline point higher than approximately 120C it tends to shrink. For this reason it is not recommended to change oil type from M oil to PAO oil as a leakage may occur if the O-rings are not changed. YORK Refrigeration therefore recommends using the Sabroe AP68 oil as it reduces the risk of leaks considerably in this case.

0178-250-EN

119

YORK Refrigeration can supply a calculation showing the operating data on request. Attention is drawn to the following viscosity limits 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 under cartain operating conditions: 7cSt) S Max. permissible viscosity during the starting of the compressor = 500 cSt Maximum refrigerant concentration in the oil at running condition: 25% - also if viscosity requirements are met. Use of mineral oil Lately we have experienced a number of problems with mineral oil, particularly in R717 plants. The problems can be divided into two groups: a: The oil changes viscosity within a few operating hours. b: The oil decomposes (becomes very black) within a few operating hours. The problems have been seen with several oil brands and have resulted in severe consequences for both compressors and plants. When using mineral oil, it is thus important that the plant is monitored very closely, that oil samples are taken regularly (every 1-2,000 hours) and that the condition/colour of the oil is checked on a weekly basis. YORK Refrigeration therefore recommends only to use M oil at moderate operating conditions - cf. the attached oil recommendation diagrams.

YORK Refrigeration is aware, however, that several customers have been using mineral oils for many years without problems. Those customers who wish to continue using mineral oils in existing, as well as new, compressors can do so, providing the compressor type and operating conditions are similar to the existing ones (excepting the HPC and HPO series compressors). YORK Refrigeration has therefore decided to market a brand of mineral oil which has been tested and found to be suitable for most general refrigerating purposes. If another brand of mineral oil is chosen, the specifications in the data sheet in this recommendation should be followed as a guideline. Mineral oil can be used in refrigerating plants, providing the lubricating quality is carefully monitored. For modern, high capacity refrigeration plants, in which a long lifetime for both lubricant and moving parts is expected, YORK Refrigeration recommends using synthetic lubricating oils. A benefit of using the synthetic lubricant oil is a much lower oil carry-over to the plant and longer intervals between oil changes. A better fluidity at lower temperatures also gives an easier drainage at the cold parts of the plant.

How to use the oil recommendation diagrams: To determine the code number, first refer to the Oil recommendation diagram for the refrigerant and compressor type and then plot the proposed operating conditions.

120

0178-250-EN

Example (recip. compressors): Refrigerant: R134a Condensing temp. TC +35C Evaporating temp. TE - 3C Please observe ! Plants may operate at different conditions from time to time, for example at different evaporating temperatures due to plant variations or at different condensing temperatures due to seasonal changes. By plotting TC and TE in the oil recommendation diagram, this example would require a No 1 oil. If, however, TE changes at certain times, e.g. from - to -3 +7C, a No 2 oil should be utilised. But, as +7C is inside the marked area, the No 1 oil can be utilised also at this TE.
R134a
TC F C 158 70 140 60 Condensing temperature 122 50 104 40 86 30 68 20 50 10 32 0 1 2

the example above, a oil code number E5 can be selected.

Code no Area no 1 E5 E9 Y Y 2

In plants which incorporate both screw and reciprocating compressors and where the recommendations indicate the use of different oil types, please contact YORK Refrigeration for advice. Changing oil on Sabroe compressors The oil should never be changed to another type without consulting the oil supplier. Nor is it advisable to top up compressors with an other oil than the one already used for the particular plant and compressor. Mixing different oils may result in operating problems in the refrigerant plant and damage to the compressors. Incompatibility between the different oil types may degrade the lubricating properties or may cause oil residues to form in the compressor or oil separator or in the plant. These oil residues can block filters and damage the moving parts in the compressor. Furthermore, changing the oil from one type or make to another should only be undertaken in connection with a careful procedure involving the drainage and thorough evacuation of the refrigeration plant. Information on a suitable procedure can be obtained from YORK Refrigeration as well as from a number of oil companies.

14 -10 -4 -20 -22 -30 -60 -50 -40 -30 -20 -10 0 10 20 30 C 68 86 F

-76 -58 -40 -22 -4 14 32 50 Evaporating temperature

TE

By referring to the Oil recommendation table placed at the bottom of each oil recommendation diagram, it is possible to select the code number for the appropriate oil type. In

0178-250-EN

121

It is imperative that oil is only used from the original container and that both the make and type complies with the specification for the plant. Ensure that the original container is sealed during storage to prevent moisture from the air being absorbed into the oil - many oils, particulary the polyolester oils, are extremely hygroscopic. Consequently, it is recommended that the oil is only purchased in containers corresponding to the amount to be used on each occasion. If the oil is only partially used, make sure that it is effectively re-sealed in the original container and that it is stored in a warm, dry place. Ideally with nitrogen blanking of the oil to keep the water content below 50 ppm.
Oil recommendation diagram symbols: Y : l : A : B : C : In case of a new plant. Very suitable. In case you wish to change from mineral oil Max oil concentration in liquid phase at: TE: 2% W

Oil drums should, ideally, be racked and mounted with a proper barrel tap to ensure an effective airtight seal. Oil changing intervals A list of the recommended intervals for changing the oil can be found in the compressor instruction manual. These are provided for guidance only. The actual interval between oil changes will often be determined by a variety of operating parameters within the plant. It is strongly recommended to monitor the quality of the oil by carrying out oil analyses with regular intervals. This will also give a good indication of the condition of the plant. The service can be supplied by YORK Refrigeration or the oil suppliers.

Max oil concentration in liquid phase: contact YORK Refrigeration Min suction temperature --50C: at TE< --50C superheating must be introduced. Dry expansion systems only. Flooded systems to be considered individually: contact YORK Refrigeration Suction gas superheat, K (Kelvin) Zone in which both oils are useable Calculation must be performed using COMP1

* :
SH : : :

122

0178-250-EN

Data Sheet for Listed Sabroe Oils

Typical data for lubricating oils for Sabroe compressors

Sabroe code M1 A3 AP1 PAO3 PAO5 PAO9 E3 E5 E9 E11

Viscosity cSt 40C 63 97 64 66 94 208 cSt 100C 6.4 8.1 9.3 10.1 13.7 25

Viscosity Index 14 13 121 136 147 149

Spec. grav. at 15C 0.91 0.86 0.858 0.835 0.838 0.846

Flash p. COC C 202 206 195 266 255 260

Pour p. C -36 -32 -51 <-45 <-45 <-39

Anilin C point 81 78 121 138 144 154

Acid no. mg KOH/g 0.02 0.05 0.04 0.03 0.03 0.03

Due to the big difference between polyolester-based lubricants from various suppliers it is suppliers, not p possible to present typical data for these oils. When using another oil brand than the one p yp g recommended by YORK Refrigeration, please contact the oil supplier to select the correct oil type. type

The listed data are typical values and are intended as a guideline only when selecting a similar oil from a different oil company. Data equivalence alone does not necessarily qualify the oil for use in YORK Refrigerations Sabroe compressors.

0178-250-EN

123

List of part numbers for available Sabroe oils

Oil brand
Mobil Gargoyle Arctic 300 Sabroe Oil A100 Sabroe Oil AP68 Sabroe Oil PAO68 Mobil Gargoyle Arctic SHC 228 Mobil Gargoyle Arctic SHC 230 Mobil EAL Arctic 68 Mobil EAL Arctic 100 Mobil EAL Arctic 220 Sabroe H oil
1)

Oil code no no. M 1 (M68) A 3 (A100) AP 1 (AP68) PAO 3 (P68) PAO 5 (P100) PAO 9 (P220) E 3 (E68) E 5 (E100) E 9 (E220) E11 (E370)

Part no. 20 litre pail 1231-264 1231-263 1231-257 1231-256 1231-282 1231-284 1231-272 1231-274 3914 1512 954 1) 208 litre pail 1231-296 1231-262 1231-260 1231-259 1231-283 1231-285 1231-273 1231-275 1231-279 9415 0008 000

18.9 litre pail (5 US gallons)

The oils recommended by the former Stal Refrigeration correspond to the following oils: Stal Refrigeration oil type A B C H
Mobil Gargoyle Arctic 300 Sabroe Oil PAO 68 Sabroe H oil

Sabroe oil
M1 (M68) PAO 3 (PAO 68) PAO 9 (PAO 220) E 11 (E 370)

Mobil Gargoyle Arctic SHC 230 -

124

0178-250-EN

R717
one-stage reciprocating compressors
Condensing temperature
F

TC
C

122 50 104 40 86 68 50 32 30 20 10 0

Code no PAO 3 AP 1 M1

Area no 1 Y l/Y See note

14 -10 -4 -20 -22 -30

-60 -76

-50 -58

-40 -40

-30 -22

-20 -4

-10 14

0 32

10 50

20 68

C F

TE

Evaporating temperature

Note: YORK Refrigeration recommends that the use of M oils is restricted to moderately loaded compressors and that the oil quality is monitored carefully via regular oil analyses. Y l : : In case of a new plant. Very suitable. In case you wish to change from mineral oil

0178-250-EN

125

R717
two-stage reciprocating compressors
Condensing temperature
F

TC
C

122 50 104 40 86 30 68 50 32 20 10 0

Code no

Area no 1

14 -10 -4 -20 -22 -30

PAO 3 AP 1 M1

Y l/Y See note

-60 -76

-50 -58

-40 -40

-30 -22

-20 -4

-10 14

0 32

10 50

20 68

C F

TE

Evaporating temperature

Note: YORK Refrigeration recommends that the use of M oils is restricted to moderately loaded compressors and that the oil quality is monitored carefully via regular oil analyses. Y l : : In case of a new plant. Very suitable. In case you wish to change from mineral oil

126

0178-250-EN

R717
HPO and HPC reciprocating compressors
Condensing temperature
F

TC
C

176 80 158 70 140 60 122 50 104 40 86 30 68 20 50 10 32 0 -30 -22 -20 -4 -10 14 0 32 10 50 20 68 30 86 40 104 50 122 C F

Code no PAO 5

Area no 1 Y

TE

Evaporating temperature

Please observe: PAO 5 oil is the only oil which can be used in the HPO and HPC compressors. Y : In case of a new plant. Very suitable.

0178-250-EN

127

R22
one-stage reciprocating compressors
Condensing temperature

TC
F 122 104 86 68 50 32 C 50 40 30 20 10 0 A

Contact YORK Refrigeration

14 -10 -4 -20

Code no Area no 1 A3 Y

-22 -30

-60 -76

-50 -58 C

-40 -40

-30 -22

-20 -4

-10 14

0 32

10 50

20 C 68 F

TE

Evaporating temperature

Y : In case of a new plant. Very suitable. A : Max oil concentration in liquid phase at: TE: 2% W C : Min suction temperature --50C: at TE< --50C superheating must be introduced.

128

0178-250-EN

R22
two-stage reciprocating compressors
Condensing temperature

TC
F C

122 50 104 40 86 30 A

68 20 50 10 32 0

14 -10 -4 -20 -22 -30

Code no Area no 1 A3 Y

-60 -76

-50 -58 C

-40 -40

-30 -22

-20 -4

-10 14

0 32

10 50

20 68

C F

TE

Evaporating temperature

Y : In case of a new plant. Very suitable. A : Max oil concentration in liquid phase at: TE: 2% W C : Min suction temperature --50C: at TE< --50C superheating must be introduced.

0178-250-EN

129

R134a
one-stage reciprocating compressors
Condensing temperature

TC
C 158 70 140 60 122 50 104 40 86 68 50 32 30 20 10 0 F

14 -10 -4 -20 -22 -30 -60 -50 -40 -30 -20 -10 -76 -58 -40 -22 -4 14 0 32 10 50 20 68 30 C 86 F

Code no

Area no 1 2 Y

E5 E9

TE

Evaporating temperature
Y: : In case of a new plant. Very suitable. Zone in which both oils are useable

130

0178-250-EN

R134a
two-stage reciprocating compressors
Condensing temperature
F

TC
C 158 70 140 60 122 50 104 40 86 68 50 32 30 20 10 0

14 -10 -4 -20

Code no Area no 1 E5 Y

-22 -30 -40 -40 -70 -60 -50 -40 -30 -20 -10 -94 -76 -58 -40 -22 -4 0 10 50 20 68 30 C 86 F

14 32

TE

Evaporating temperature

: In case of a new plant. Very suitable.

0178-250-EN

131

R407C
one-stage reciprocating compressors
Condensing temperature

TC
F C

122 50 104 40 86 30

68 20 50 10 32 0

14 -10 -4 -20 -22 -30

Code no Area no 1 E3 Y

-60 -76

-50 -58 C

-40 -40

-30 -22

-20 -4

-10 14

0 32

10 50

20 68

C F

TE

Evaporating temperature

Y: B : C :

In case of a new plant. Very suitable. Max oil concentration in liquid phase: contact YORK Refrigeration Min suction temperature --50C: at TE< --50C superheating must be introduced.

132

0178-250-EN

R407C
two-stage reciprocating compressors
Condensing temperature

TC
F C

122 50 104 40 86 30 B

68 20 50 10 32 0

14 -10 -4 -20 -22 -30

Code no Area no 1 E3 Y

-60 -76

-50 -58 C

-40 -40

-30 -22

-20 -4

-10 14

0 32

10 50

20 68

C F

TE

Evaporating temperature

Y: B : C :

In case of a new plant. Very suitable. Max oil concentration in liquid phase: contact YORK Refrigeration Min suction temperature --50C: at TE< --50C superheating must be introduced.

0178-250-EN

133

R404A
one-stage reciprocating compressors
Condensing temperature
F

TC
C

122 50 104 40 86 30

68 20 50 10 32 0

Code no

Area no 1 2

14 -10 -4 -20 -22 -30

E3 E5

Y Y -60 -76 -50 -58 C -40 -40 -30 -22 -20 -4 -10 14 0 32 10 50 20 68 C F

TE

Evaporating temperature

Y: C : :

In case of a new plant. Very suitable. Min suction temperature --50C: at TE< --50C superheating must be introduced. Zone in which both oils are useble

134

0178-250-EN

R404A
two-stage reciprocating compressors
Condensing temperature
F

TC
C

122 50 104 40 86 68 30 20

50 10 32 0

14 -10 -4 -20 -22 -30

Code no Area no 1 E3 Y

-60 -76

-50 -58 C

-40 -40

-30 -22

-20 -4

-10 14

0 32

10 50

20 68

C F

TE

Evaporating temperature

Y: C :

In case of a new plant. Very suitable. Min suction temperature --50C: at TE< --50C superheating must be introduced.

0178-250-EN

135

R410A
HPO og HPC reciprocating compressors

TC
F 122 104 C 60 50 40

Condensing temperature

86 68 50 32 14 -4

30 20 10 0 -10 -20 -30 A 1

Code no Area no 1 E5 Y

-22 -40 -60 -50 -40 -30 -20 -10 -76 -58 -40 -22 -4 0 10 50 20 68 30 40 50

TE
14 32 F

Evaporating temperature

Y: A :

In case of a new plant. Very suitable. Max oil concentration in liquid phase at: TE: 2%

136

0178-250-EN

R507
one-stage reciprocating compressors
Condensing temperature

TC
F C

122 50 104 40 86 30

68 20 50 10 32 0

14 -10 -4 -20 -22 -30

Code no Area no 1 E5 Y

-60 -76

-50 -58 C

-40 -40

-30 -22

-20 -4

-10 14

0 32

10 50

20 68

C F

TE

Evaporating temperature

Y: C : C

In case of a new plant. Very suitable. Min suction temperature --50C: at TE< --50C superheating most be introduced. must

0178-250-EN

137

R507
two-stage reciprocating compressors
Condensing temperature

TC
F C

122 50 104 40 86 30

68 20 50 10 32 0

14 -10 -4 -20 -22 -30

Code no Area no 1 E5 Y

-60 -76

-50 -58 C

-40 -40

-30 -22

-20 -4

-10 14

0 32

10 50

20 68

C F

TE

Evaporating temperature

Y: C :

In case of a new plant. Very suitable. Min suction temperature --50C: at TE< --50C superheating must be introduced.

138

0178-250-EN

R717
screw compressors
F

TC
C 50 40 30 20 10 0

122 104 86 68 50 32

Condensing temperature

Code no Area no 1 PAO 3 AP 1 M1 Y l/Y See note

14 -10 -4 -20

-22 -30 -60 -76 -50 -58 C -40 -40 -30 -22 -20 -4 -10 14 0 32 10 50 20 68 C F

TE

Evaporating temperature

Note: YORK Refrigeration recommends that the use of M oils is restricted to moderately loaded compressors and that the oil quality is monitored carefully via regular oil analyses. HLI: Y : l : C : : Calculation must be performed using COMP1 In case of a new plant. Very suitable. In case you wish to change from mineral oil Min suction temperature --50C: at TE< --50C superheating must be introduced. Calculation must be performed using COMP1.

0178-250-EN

139

R22
screw compressors with journal bearings or roller bearings

TC
F

SH10 SH20 SH25 SH5

SH10

122 50 104 40 86 30 SH5

Condensing temperature

68 20 50 10 32 0 A

Code no

Area no 1 2*

14 -10 -4 -20 -22 -30 SH20

A3 PAO 5

Y Y

-60 -76

-50 -58 C

-40 -40

-30 -22

-20 -4

-10 14

0 32

10 50

20 68

C F

TE

Evaporating temperature

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 of lubrication oils, please contact YORK Refrigeration for an update on the requirement for superheat. HLI: Calculation must be performed using COMP1. Y : A : C : In case of a new plant. Very suitable. Max oil concentration in liquid phase at: TE: 2% W Min suction temperature --50C: at TE< --50C superheating must be introduced. Dry expansion systems only. Flooded systems to be considered individually: contact YORK Refrigeration Suction gas superheat, K (Kelvin) Calculation must be performed using COMP1

* :
SH : :

140

0178-250-EN

R22
screw compressors with roller bearings only
Condensing temperature

TC
F

122 50 104 40 86 30 68 20 50 10 32 0 A

Code no

Area no 1 Y

14 -10 -4 -20 -22 -30 SH20

A3

-60 -76

-50 -58 C

-40 -40

-30 -22

-20 -4

-10 14

0 32

10 50

20 68

C F

TE

Evaporating temperature

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 of lubrication oils, please contact YORK Refrigeration for an update on the requirement for superheat. HLI: Calculation must be performed using COMP1. Y : A : C : In case of a new plant. Very suitable. Max oil concentration in liquid phase at: TE: 2% W Min suction temperature --50C: at TE< --50C superheating must be introduced. Dry expansion systems only. Flooded systems to be considered individually: contact YORK Refrigeration Suction gas superheat, K (Kelvin) Calculation must be performed using COMP1

* :
SH : :

0178-250-EN

141

R134a
screw compressors
F

TC
C 158 70 140 60 SH30

SH20

Condensing temperature

122 50 104 40 86 68 50 32 30 20 10 0 SH20 -40 -40 -30 -22 -20 -4 -10 14 0 32 10 50 20 68 30 C 86 F

2
SH5

SH10

Code no

(See note)

Area no 1 2 Y

14 -10 -4 -20 -50 -58

E5 E9

TE

Evaporating temperature

Note: For the compressors type S, Rotatune, SAB 81, SAB 83, and SAB 85 only Sabroe oil H is approved. 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 of lubrication oils, please contact YORK Refrigeration for an update on the requirement for superheat. HLI: Calculation must be performed using COMP1. Y : SH : : : In case of a new plant. Very suitable. Suction gas superheat, K (Kelvin) Zone in which both oils are useable Calculation must be performed using COMP1

142

0178-250-EN

R404A
screw compressors

TC
F C SH15

104 40

Condensing temperature

86 68 50 32

30 20 10

2 (3) (2)

SH10

1
B SH15

14 -10 -4 -20 -22 -30

Code no

Area no (See note) 1 2 3 Y Y Y

E3 E5 E9

-70 -94

-60 -76

-50 -58 C

-40 -40

-30 -22

-20 -4

-10 14

0 32

10 50

C F

TE

Evaporating temperature

Note: For the compressors type S, Rotatune, SAB 81, SAB 83, and SAB 85 only Sabroe oil H is approved. 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 of lubrication oils, please contact YORK Refrigeration for an update on the requirement for superheat. HLI: Calculation must be performed using COMP1. Y : B : C : SH : : : In case of a new plant. Very suitable. Max oil concentration in liquid phase: contact YORK Refrigeration Min suction temperature --50C: at TE< --50C superheating must be introduced. Suction gas superheat, K (Kelvin) Zone in which both oils are useable Calculation must be performed using COMP1

0178-250-EN

143

R407C
screw compressors
F

TC
C 50 40 30 20 10 0 SH10 SH5

122 104

Condensing temperature

86 68 50 32

14 -10 -4 -20 SH5 -70 -94 -60 -76 -50 -58 C -40 -40 -30 -22 -20 -4 -10 14 0 32 10 50 20 C 68 F

Code no

Area no (See note) 1 2 Y Y

E3 E9

-22 -30

TE

Evaporating temperature

Note: For the compressors type S, Rotatune, SAB 81, SAB 83, and SAB 85 only Sabroe oil H is approved. 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 of lubrication oils, please contact YORK Refrigeration for an update on the requirement for superheat. HLI: Calculation must be performed using COMP1. Y : B : C : SH : : : In case of a new plant. Very suitable. Max oil concentration in liquid phase: contact YORK Refrigeration Min suction temperature --50C: at TE< --50C superheating must be introduced. Suction gas superheat, K (Kelvin) Zone in which both oils are useable Calculation must be performed using COMP1

144

0178-250-EN

R507
screw compressors
F

TC
C

104 40

2
SH5

Condensing temperature

86 68 50 32

30 20 10 0

SH5

SH15

14 -10 -4 -20 -22 -30 -70 -94 -60 -76 -50 -58 C -40 -40 -30 -22 -20 -4 -10 14 0 32 10 50 C F

Code no E5 E9

Area no (See note) 1 2 Y Y

SH30

TE

Evaporating temperature

Note: For the compressors type S, Rotatune, SAB 81, SAB 83, and SAB 85 only Sabroe oil H is approved. 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 of lubrication oils, please contact YORK Refrigeration for an update on the requirement for superheat. HLI: Calculation must be performed using COMP1. Y : C : SH : : : In case of a new plant. Very suitable. Min suction temperature --50C: at TE< --50C superheating must be introduced. Suction gas superheat, K (Kelvin) Zone in which both oils are useable Calculation must be performed using COMP1

0178-250-EN

145

List of Major Oil Companies

The oil from the companies listed below are NOT tested by YORK Refrigeration and are therefore NOT approved by YORK Refrigeration either. The following list reflects the information provided by the companies themselves. The assessment of durability and suitability of specific oils for specific purposes are entirely at the companies own discretion. Oils tested and approved by YORK Refrigeration can be found in the List of part numbers for available Sabroe oils. Oil
Company 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 M A

Oil Types
PAO AP E

146

0178-250-EN

Alignment of VMY/SAB 202 unit and coupling

In order to ensure a long life for compressor and motor, the compressor unit and coupling need to be set up with care. Misalignment of compressor unit or coupling may produce stresses and vibrations which can be transmitted to the compressor bearings and thus cause major damages. Note: Before work on the coupling can proceed, it must be ensured that the compressor cannot be started inadvertently. If need be, remove the motor protection devices. Vibrations may be caused by the following:
0171-669-EN

Point a-1 Mounting unit straight onto foundation

When installing the unit straight onto a foundation, the foundation should be cast in accordance with the foundation drawing forwarded. When the foundation has been cast, with the holes marked out as shown, and has set, the unit should be positioned, allowing it to rest on sleepers, laid with a spirit level, at a suitable height so that the foundation plate is slightly recessed into the foundation. Check that the foundation plates are hard on the base frame - this is best done by tying them up to the base frame with steel wire. The concrete which is cast down around the foundation bolts should have only minimal water content to allow it to be rammed well down around the bolts and up under the foundation plates. Low water content does not cause the hardening concrete to shrink. 10-14 days should pass before tightening the foundation bolts. Remove the steel wire beforehand and check that there is no air space between the footplate of the base frame and the foundation plate. Otherwise, shims must be inserted between the plates before lashing them down.

00.01

a) Distortion between compressor unit and foundation. b) Distortion between compressor and base frame. c) Distortion between motor and base frame. d) Strains from pipe connections between compressor and plant. e) Incorrect alignment of coupling between compressor and motor. f) Untruth in compressor or motor shafts. g) Untruth in coupling. h) Imperfect balancing of coupling. i) Imbalance in compressor and motor. The fitter who sets up the unit is responsible for points a-b-c-d-e. The other points must be checked by the compressor or motor manufacturer prior to delivery. The following sections will deal with the individual points concerning the fitter.

Point a-2 Mounting vibration dampers

The units are invariably delivered without vibration dampers mounted. The vibration dampers supplied are marked with a code.

0178-250-EN

147

Matching codes are indicated in the drawing forwarded to the customer or dealer; these are valid for the unit in question only. It is important that the vibration dampers be

fitted correctly, as shown in the drawing forwarded, since the load on the foot-plates varies.

Standard type A A - 1 to 2 mm. -

Marine type

A - 3 to 5 mm. -

T0177040_0

Standard type The machine room or ship floor on which the unit is to be placed must possess the necessary bearing strength and be level enough for the difference in height between the foundation plates not to exceed the scope for adjustment on the vibration dampers, as stated in the positioning drawing. The vibration dampers are installed on the unit in their unstressed state while it is suspended from the crane; the unit is then placed in its final position. The unit is aligned with the aid of wedges placed in the vicinity of the vibration dampers. When the unit is horizontal, both longitudinally and laterally, the vibration dampers are tightened exactly enough to release the wedge.

The vibration dampers are intended to compress between 1.0 and 2.0 mm under the expected load at the corresponding point of support. To check that the vibration dampers are adjusted for the correct load, make a note of measurement A in the unloaded state for each individual damper. After mounting and adjustment, A should be reduced by 1 to 2 mm. When the adjustment is correct, tighten down the lock nut. Alignment of the unit against the foundation is now complete. Marine type Always fit the vibration dampers directly under the feet of the base frame. Measure the A-measure of the vibration dampers while unit is still suspended in the crane. Measure it again once the unit is back

148

0178-250-EN

in its position. The difference (compression) must be between 3 and 5 mm for all vibration dampers. In case this is not observed liner plates must be inserted under the vibration dampers until above compression is reached.

We recommend laying the piping as shown in the sketch with a free length of min. 1.5 m in two directions which are at right angles to each other.
Here a non-return valve may be fitted in the discharge pipe min. 1.5 m.

Point b) Alignment of compressor on base frame

Check that the compressor feet surfaces make full contact with the milled-off contact faces of the base frame. shiCheck with the fixing bolts loosened. If slip occurs at one or more resting surfaces, shim up before tightening the bolts. If not shimmed up, there is a risk that the compressor may be subjected to stresses which will damage the bearings.

min. 1.5 m.

Connection to compressor unit

Do not mount pipe hangers close to the compressor unit. On some elevated point on the compressor unit discharge pipe mount a non-return valve to prevent condensed refrigerant from returning to the oil separator. Note: Pipe systems that connect the compressor unit with the remaining refrigeration plant must be executed in a flexible way in order to prevent tensions in pipes and their connections.

Point c) Alignment of motor on base frame

Check the resting surfaces of the motor against the base frame in the same way as mentioned for the compressor.

Point d) Stress from pipe connections

To prevent transmission of stresses from pipe connections between unit and plant, care must be taken that the pipes are laid so as not to cause tensile or compression strains during expansion or contraction due to temperature changes. Steel pipes will expand approx. 1 mm per metre per 100C.

Point e) Mounting and alignment of coupling

hen all piping has been connected up to the unit, final alignment between compressor and motor can be undertaken. See the following section.

0178-250-EN

149

Auxiliary tools for coupling alignment

Four sets of liner plates are supplied, each consisting of one 3 mm, two 1 mm, three 0.25 mm, two 0.15 mm and two 0.1 mm plates to be placed under the motor feet. Four clamps are supplied with each unit, as shown in the sketch. These clamps can be used either to shift the motor sideways or to lift the motor with a view to inserting liners. In addition, an alignment gauge is supplied for the coupling, as shown in the drawing, together with a set of feeler gauges. Before mounting of coupling carefully clean motor and compressor shafts, half-sections of coupling, and bushing, if any. Then lubricate all parts in refrigerant machine oil. Do not use products containing any grease or molybdenumdisulfide.

T0177059_0

150

0178-250-EN

Mounting and alignment

Be careful when aligning the coupling. The better the initial alignment, the better the coupling will be able to absorb the small displacements which may arise during operations.

If the coupling discs are changed, the entire set must be replaced at a time. Note: When being dismantled, the coupling discs must be kept together in exactly the same position in which they are received.
1

Z 2 X a

C
T0177120_0/V1

Coupling alignment
The principle of the alignment procedure is to move the motor so that its shaft forms a continuation of the compressor shaft, but with the motor shaft 0.05 mm higher than the compressor shaft. In operation, the compressor shaft is lifted, owing to the fact that it rests in slide bearings.

tive to each other and relative to the flange. 2) Examine both compressor and motor shaft journals as well as the bores of the hubs to ensure that they are free of burrs. Check that the key fits the shaft and hub exactly. 3) Mount the hubs on the shafts. It is recommended to heat the hub in water, oil or over a gentle flame. Do not heat the hub in spots, as this may cause adverse stresses. When heated, the hub must immediately be placed on the shaft. On SAB 202 compressors a bushing must be applied between compressor shaft and coupling hub. On mounting adopt the following procedure:

Mounting
1) Dismantle the coupling. Note the placing of bolts, washers and nuts, as these must be mounted in the same order again. Tie a string or a piece of thread through one of the bolt holes in the coupling discs in order to avoid the plates being turned rela-

0178-250-EN

151

Position the coupling hub with the bushing on top of the shaft as shown in the following drawing.

Compressor
Bushing and shaft must be flush with each other

4) Position motor and compressor, and check the distance between the coupling flanges C. This distance is shown in the tables below. Motors with slide bearings or other equipment with end play in the shaft must be in neutral centre position. 5) Insert the intermediate piece of the coupling and the coupling discs and tighten the bolts. At the same time, fit the alignment gauge to the coupling flange of the compressor. The torque moment is given in the following tables. Avoid mounting the bolts between the coupling flange on the motor and the coupling discs until alignment has been completed. The following tables indicate the dimensional tolerances and torques to be observed.

Tighten the screws on the bushing crosswise, first to 18 Nm and then to the final torque of 35 Nm. The screws must be tightened cross-wise and a torque wrench must be used.

Table 1. Motor with ball bearings

Max. Variation at 180 Rotation
Coupling No. Diam. A mm 198 Distance C mm 140 Torque Nm 55 Horizontal mm 0 -- 0.10 Pos. 1 Vertical mm 0.10 -- 0.20 Pos. 2 mm 0 -- 0.10

312

Table 2. Motor with slide bearings

Max. Variation at 180 Rotation
Coupling No. Diam. A mm 198 Distance C mm 140 Torque Nm 55 Horizontal mm 0 -- 0.10 Pos. 1 Vertical mm 0 -- 0.10 Pos. 2 mm 0 -- 0.10

312

152

0178-250-EN

Obtaining parallel shafts on the horizontal plane

1. Turn the coupling so that the alignment gauge is in the upper position. 2. Guide the measuring pin (pos. 2) towards the coupling part using a 1 mm feeler gauge and fix the pin. 3. Turn the coupling 180. Measure by feeler gauges how much the distance from the measuring pin to the coupling part has changed. This change is called X. 4. Insert shims of thickness y either under both front feet or both rear feet, tilting the motor at the end desired. The shim thickness is calculated using the following formula:
y =X b 2a see the drawings

Obtaining parallel displacement for correct centre height

Remember that the centreline of the motor shaft must be 0.05 mm higher than the centreline of the compressor, as the rotors will lift during operations. 1. Turn the coupling so that the alignment gauge faces down. 2. Guide measuring pin (pos. 1) towards the coupling part using a 1 mm feeler gauge and fix the pin. 3. Turn the coupling 180 and measure the increase in distance by feeler gauges. This increase is called Z. Z = double the distance between the centreline of the two shafts in the horizontal plane. 4. Lift the motor by placing shims with thickness Z / 2 + 0.05 mm underneath all four feet. 5. After securing the motor, repeat the measurement and compare the results with the values in the table.

y b

Obtaining parallel shafts on the vertical plane

It only remains to push and turn the motor at the level on which it is now shimmed up. 1. Turn the coupling so that the alignment gauge faces horizontally out to one side. 2. guide both measuring pins towards the coupling using a 1 mm feeler gauge. 3. Turn the coupling 180 and measure the deviations using the feeler gauge. 4. Moving and turning the motor sideways with the adjusting screws, set the motor so that the deviations are in accordance with

2a = the diameter described by the measuring pin when rotated 180. b = length between the fastening bolts on the motor. The motor can be lifted using the abovementioned tools. 5. After fixing the motor bolts, repeat the measurement and compare the result with the values in the table.

0178-250-EN

153

the values in the table. Remember that the motor must be secured during each measurement.

Final check and assembly

1. Tighten the foundation bolts on the motor. 2. Check flange distance C. 3. Check the alignment of the coupling on the horizontal and vertical planes for pos. 1 and 2. 4. Fit the bolts between the coupling flange and coupling discs on the motor and check the tightening torque for all the bolts. 5. Fit the outer shell of the coupling guard on the adaptor plate which is secured on the compressor shaft seal cover. Push the inner shell, placed in-side the outer shell, so far towards the driving motor that access to the rotating parts is made impossible. See below drawing.
T0177045_0

6. Check the coupling alignment once more while still warm from operating and with pressure on the plant. It is strongly recommended that the alignment method described be used, as it measures the relative position of the shafts directly and eliminates all possible faults in the coupling flanges.

154

0178-250-EN

Key to Piping Diagrams/Component List

CS OS M EC 240 Screw compressor Oil separator Electric motor Electronic control system Coupling S _________________ PDAZ10 PDAZ11 TI6 TI7 TI5 Thermometer (discharge gas temperature) Thermometer (oil temperature) Thermometer (suction gas temperature) - only if specially ordered Oil pressure difference cut-out (oil pressure - discharge pressure) Oil pressure difference cut-out (oil pressure - suction pressure) for classified systems only Thermostat (oil temperature in manifold) Thermostat (discharge gas temperature) Thermostat (pilots solenoid valve pos. 82) Suction pressure manometer High-pressure manometer Oil difference manometer Level switch Double acting, four-way solenoid valve - unload capacity Double acting, four-way solenoid valve - load capacity Double acting, four-way solenoid valve - volume ratio/increase Double acting, four-way solenoid valve - volume ratio/decrease Throttle valve Throttle valve Throttle valve Throttle valve

_______________

PT1 PT2
01.03

Pressure transducer (suction pressure) Pressure transducer (discharge pressure) Pressure transducer (oil pressure after oil filter) Pressure transducer (oil pressure before oil filter) Pressure transducer (oil pressure after oil pump) Temperature transducer (discharge gas temperature) Temperature transducer (oil temperature in flow control) Temperature transducer (suction gas temperature) Position transmitter (capacity slide) Position transmitter (Vi slide) Safety pressure cut-out (for TV, SDM and SA only) Low-pressure cut-out (only for classified systems) High-pressure cut-out Differential pressure cut-out (pressure drop across oil filter)

PT3
0171-575-EN

TAZ12 TAZ13 TC14 PI15 PI16 PDI17 FT18 YY1 YY2 YY3 YY4 SC1 SC2 SC3 SC4

PT4 PT5 TT5 TT6 TT7 GT8 GT9 PAZ10 PAZ1 PAZ2 PDAZ3

0178-250-EN

155

BP LIT1 19 20 21 22 23 23a 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42

Throttle valve - by-pass Oil level transmitter Compressor safety valve Suction stop valve Non-return valve Flanged joint discharge pipe compressor Suction filter built into compressor External suction filter Service valve - air purge valve Oil separator Non-return valve in outlet pipe from oil separator Stop and non-return valve in outlet pipe from oil separator Safety valve - the unit Change-over valve for double safety valve Immersion heater in oil separator Oil level indicators (2 pieces) Oil cooler OOSI (refrigerantcooled) Oil cooler (water-cooled) Stop valve for oil purging (oil side) Stop valve for oil purging (refrigerant side) Oil outlet branch to oil cooler/filter Oil branch to pump suction end Stop valve before oil filter Oil filter Oil inlet from pump Non-return valve built into oil filter Stop valve after oil filter

43 44 45 46

Combined flow control and oil distributing manifold Check valve, rotor lubrication Nozzle in injection pipe for rotors Thermostatically-controlled 3-way valve for oil temperature regulation Service valve for oil drainage Oil purge valve on oil filter Thermostatic water valve for water-cooled oil cooler Stop valve Oil filter Nozzle/throttle valve Oil level indicator Stop valve Oil separation element (fine separation) Non-return valve Hand-regulated valve Temperature regulated main valve Oil receiver Stop valve Oil filter Oil charging valve Oil pump Stop valve for air purging of pump Stop valve Non-return valve for oil charging Solenoid valve (NC) - open during prelubrication Stop valve Non-return valve Solenoid valve (NC) - capacity regulation min. - 100% ->

47 48 49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 67 68 69 70

156

0178-250-EN

71 72 73 74 75 76 80 81 82 TC83 84 90 91 92 93 94 95 96 97 98 99 100 101 102 103

Solenoid valve (NO) - capacity regulation 100 -> min.% Throttle valve for regulation of slide velocity Solenoid valve (NC) - capacity regulation min. - 100% -> Solenoid valve (NO) Non-return valve Three-way non-return valve Stop valve Liquid refrigerant filter Solenoid valve (NC) Liquid injection valve TEAT Stop valve Oil supply to bearings at discharge end Oil supply to shaft seal and bearings at suction end Oil injection in compressor Oil return from capacity regulation Oil to and from regulating cylinder Liquid supply for HLI cooling Vi 4.0 Liquid supply for HLI cooling Vi 2.6 Economizer connection Oil connection from flow switch Oil to and from Vi regulation (only by auto-Vi) Oil return from fine oil separator Bypass throttle valve at suction stop valve Non-return valve Stop valve

104 105 106 107 108 110 TC111 112 113 114 115 116 120 122 123 124 125 126 127 128 129 130 131 132 PI139 140 141 142 143 144 145

Nozzle Flow switch External oil filter Oil filter for units with full flow oil pump Oil regulating valve Stop valve Thermostatic valve Solenoid valve (NC) Liquid filter Stop valve Stop valve for oil purge Economizer vessel Stop valve Main valve Solenoid valve (NC) Stop valve for oil drainage Safety valve Float valve Stop valve Stop valve Solenoid valve (NC) Stop valve Stop valve Liquid filter Oil pressure manometer Stop- and non-return valve Main valve Pilot valve Solenoid valve Stop valve Float valve

0178-250-EN

157

147 148 149 150 151 152 153 154 160 200 201 202 203 204 205 206 207 208 FT209 210

Liquid filter Stop valve for oil purge Non-return valve Stop valve Safety valve Solenoid valve Stop valve Stop valve Stop valve Gas-powered stop valve Solenoid valve (NC) Stop/non-return valve Non-return valve in discharge pipe Stop valve after oil separator Filter Nozzle Solenoid valve (NO) Solenoid valve (NC) Oil level switch in oil separator Non-return valve

211 212 213 214 215 220 221 222 223 224 225 226 227

Stop valve Service valve - air purge valve Non-return valve Filter Non-return valve (5 bar) Compressor protecting valve (main valve) Compressor protecting valve (pilot valve for pos. 220) Filter in economizer pipe connection Brake motor for capacity slide Three-way solenoid valve Oil return pump Solenoid valve for baby slide (NC) Quick closing oil drain valve

Note: On units supplied without valves the bracketed figures near the branches refer to the component numbers in this list. These components are to be fitted by the customer.

158

0178-250-EN

Ordering Spare Parts

When placing an order for spare parts, please state the following: 1. Shop No. ber. If you are in any doubt, add the spare part no. too. 3. Forwarding instructions

All compressors are fitted with an identification plate, which states the type and shop no. of the compressor and indicates what refrigerant is to be used. 2. Part No.

When ordering spares, please advise the forwarding address, and the address to which the invoice should be sent. If appropriate, please state the name of your local bank, the way in which you want the goods transported and required delivery date. 4. Classification certificate

Spare parts drawings and parts lists inserted in an instruction manual identify spare parts with the following: a) Spare part no. - which is a reference number to facilitate finding a part in the drawing and cross-referencing in the parts list or vice versa. b) Designation of the part. c) Part no. - a 7-digit number which refers to SABROEs stores. When you order spare parts, please always advise at least the designation and part num-

94.05

If you require a certificate from a Classification authority, please mark the order appropriately, as the inspection and issuing procedures take extra time and incur extra expenses. 5. Quotation No.

0171-466-EN

If a quotation no. has been given during earlier correspondence, please refer to this when placing your order - it will help us to identify and execute your order quickly.

0178-250-EN

159

Spare Part Sets for Screw Compressor and Unit Types: SAB 110 - 128 (HR) - 163 (HR) - 202 - VMY 347/447 and VMY 336-436-536
It is always an advantage to have a stock of spare parts for both compressor and unit. In this way the customer or a YORK Refrigeration service engineer is able to carry out the necessary replacements without wasting time waiting for new spare parts to arrive. On contacting YORK Refrigerations local representative, you may receive specifications for the following spare part sets for compressor and unit. Compressor Block: S Standard set of spares This set contains a representative selection of O-rings and gaskets. S Certificate set of spares Besides the parts from the standard set of spares this set also includes all bearings as well as shaft seal. Basic Unit: S Standard set of spares: This set includes the following spare parts for 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 standard set of spares, this set also includes spare parts for the below-mentioned components: - 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
01.05

160

0178-250-EN

0171-945-EN