Instruction Manual SAB 202

01.06

0178-250-EN 1

Instruction manualfor

SAB 202

The screw compressor and the unit maydiffer in equipment, depending on theirfunctions and requirements.

Part of these variants are treated in this

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

In the below table the x-mark indicateswhich variants are fitted on your particularunit with shop no stated below.

Male drive Female drive

R717

110.062 - 063 - 077

Transducers and manual regulation of Vi slide

Manual regulation of Vi slide

UNISAB II and automatic regulation of Vi slide

Internal

External Dobbelt

Water-cooled oil cooler Type B

Water-cooled oil cooler OWSG/OWRG

Refrigerant oil cooler OOSI

With 1 discharge valve

With 2 discharge valves

Thermostatisc oil valve

PM3 Main valve

Both compressor and unit are safeguarded

Instrumentation

Oil cooling

Type of drive

Refrigerant

Shop no

Oil separator

Oil temp.reg.

Designation

Oil filter

Ex-execution

R22 Other

SMLM

SFLF

0171-500-EN

00.07

2 0178-250-EN

Preface

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

S the function and maintenance of theindividual components;

S service schedules;

S procedure for dismantling andreassembling of the compressor.

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

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

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

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

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

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

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

0178-250-EN 3

Table of Contents

Instruction manual for SAB 202 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Preface 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Table of Contents 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

First Aid for Accidents with Ammonia 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

First Aid for Accidents with HFC/HCFC 6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Protecting the Operator as well as the Environment 7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Description of SAB 202 10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Handling of the compressor, areas of application, safety equipment etc. 12. . . . . . . . . . . . .

Sound data for reciprocating and screw compressor units -- all types of compressors 15. .

Vibration data for compressors - All Compressor Types 19. . . . . . . . . . . . . . . . . . . . . . . . . . .

Data for SAB 202 compressor & unit 21. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Compressor data SAB 202 22. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Compressor and unit operation SAB 128 Mk3, SAB 163 Mk3 and SAB 202 26. . . . . . . . . .

Service Schedules for screw compressors SAB 110, 128/163 Mk3, 202 & VMY 30. . . . . .

Assessing the oil 35. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Visual assessment 35. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Analytical evaluation 35. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Procedure 36. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Analysing the oil 36. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Limiting values 36. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Major Service Intervals SAB 110, SAB 128/163 Mk3, SAB 202 38. . . . . . . . . . . . . . . . . . . .

Oil charging, weight and shipping volume SAB 128/163 Mk3 and SAB 202 39. . . . . . . . . .

Temperature and pressure settings SAB 202 40. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Servicing the refrigeration plant 43. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Maintenance of compressor SAB 202 Dismantling and assembly 45. . . . . . . . . . . . . . . . . . .Magnetic coupling for Vi-indication 62. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Transmitter 75. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

System for regulating the capacity and the Vi-ratio of SAB 202 76. . . . . . . . . . . . . . . . . . . . .3. Manual regulation of the Vi-slide 79. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Adjustment of the Vi-slide position 80. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Torque moments for screws and bolts 82. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Oil separator 84. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Water-cooled oil cooler type OWSG/OWRG 87. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Refrigerant-cooled Oil Cooler type OOSI 90. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Water-cooled oil cooler, type B 92. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Oil temperature regulating system 94. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Heating rods, pos. 30 96. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

External oil filter 97. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4 0178-250-EN

Oil pump pos. 63 99. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .The oil pump filter 102. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Safety and monitoring devices 103. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Refrigeration Plant Maintenance 105. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Troubleshooting on the Screw Compressor Plant 107. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Remedying Malfunctions 109. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Selecting Lubricating Oil for SABROE Compressors 116. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Data Sheet for Listed Sabroe Oils 122. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

List of Major Oil Companies 145. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Alignment of VMY/SAB 202 unit and coupling 146. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Key to Piping Diagrams 154. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Ordering Spare Parts 158. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Spare Part Sets for screw compressor and unit 159. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Spare parts drawing 0661-855. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

List of parts for SAB 202 0661-856. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Spare parts survey for SAB 202 unit 0661-853. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Tools for compressor SAB 202 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 5

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

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 adistinctive, pungent odour that even at verylow, harmless concentrations is detectable bymost persons.

Since ammonia is self-alarming, it serves asits own warning agent so that no personremains voluntarily in concentrations whichare hazardous. Since ammonia is lighter thanair, adequate ventilation is the best means ofpreventing an accumulation.

Experience has shown that ammonia isextremely hard to ignite and under normalconditions a very stable compound. At ex-tremely high, though limited concentrations,ammonia can form ignitable mixtures with airand oxygen and should be treated with re-spect.

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 beavailable near all bulk installations withammonia.

4. When applying first aid, the personsassisting should be duly protected to avoidfurther injuries.

Inhalation

1. Move affected personnel into fresh airimmediately and loosen clothing restrictingbreathing.

2. Call a doctor/ambulance with oxygenequipment immediately.

3. Keep the patient still and warmly wrappedin blankets.

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

5. If the patient is conscious and the mouthis not burnt, feed the patient withsweetened tea or coffee (never feed anunconscious person).

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

7. If the patient’s breathing stops, applyartificial respiration.

Eye injuries from liquid splashes or con-centrated vapour

1. Force the eyelids open and rinse eyesimmediately for at least 30 minutes withthe salt water solution just mentioned.

2. Call a doctor immediately.

Skin burns from liquid splashes or con-centrated vapour

1. Wash immediately with large quantities ofwater and continue for at least 15 minutes,removing contaminated clothing carefullywhile washing.

2. Call a doctor immediately.3. After washing, apply wet compresses

(wetted with a sterile isotonic (0.9%) NaCl-solution (salt water) to affected areas untilmedical advice is available.

0170-008-DA

96.01

6 0178-250-EN

First Aid for Accidents with HFC/HCFCRefrigerant no.: R134a - R505A - R507 - R22, etc.

Warning!


General

HFC/HCFC form colourless and invisiblegasses which are heavier than air and smellfaintly of chloroform at high concentrations.They are non-toxic, non-inflammable, non-explosive and non-corrosive under normaloperating conditions. When heated to aboveapprox. 300�C, they break down into toxic,acid gas components, which are stronglyirritating and aggressive to nose, eyes andskin and generally corrosive. Besides theobvious risk of unnoticeable, heavy gasesdisplacing the atmospheric oxygen,inhalation of larger concentrations may havean accumulating, anaesthetic effect whichmay not be immediately apparent. 24 hoursmedical observation is therefore recom-mended.

Basic Rules for First Aid

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

2. Adrenaline or similar heart stimuli mustnot be used.

Inhalation

1. Move affected persons into fresh airimmediately. Keep the patients still andwarm and loosen clothing restrictingbreathing.

2. If the patient is unconscious, call a doctor/ambulance with oxygen equipmentimmediately.

3. Give artificial respiration until a doctorauthorizes other treatment.

Eye Injuries

1. Force the eyelids open and rinse with asterile isotonic (0.9%) NaCl-solution (saltwater) or pure running water continuouslyfor 30 minutes.

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

Skin Injuries - Freeze Burns

1. Wash immediately with large quantities oflukewarm water to reheat the skin.Continue for at least 15 minutes, removingcontaminated clothing carefully whilewashing.

2. Treat exactly like heat burns and seekmedical advice.

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

0170-009-EN

01.02

0178-250-EN 7

Protecting the Operator as well as the Environment

Warning!


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

To this end, many countries have passed le-gislation in an effort to reduce pollution andpreserve the environment. This legislationapplies to all fields of industry, including re-frigeration, and must be complied with.

Be especially careful with the following sub-stances:

S refrigerants

S cooling media (brine, etc)

S lubricating oils.

Refrigerants usually have a natural boilingpoint considerably below 0�C. This meansthat liquid refrigerants can be extremelyharmful if they come into contact with skin oreyes.

High concentrations of refrigerant vapoursare suffocating when they displace air. If high

concentrations of refrigerant vapours are in-haled, they will attack the human nervoussystem.

When halogenated gasses come into contactwith open flame or hot surfaces (over approx.300�C), they will decompose to produce poi-sonous chemicals, which have a very pun-gent odour, thus warning the personnel oftheir presence.

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

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

Usually the strong smell of ammonia willwarn the personnel before the concentra-tions become dangerous.

The following table shows the values for themax. permissible refrigerant content in airmeasured in volume %. Certain countriesmay, however, have an official limit whichdiffers from those stated.

Halogenated refrigerants Ammonia

R717

Unit

Time weighted ave-rage during a week

vol.% 0.1 0.005

Warning smell vol.% 0.2 0.002

TWA

R134a R404A R507 R22

0.10.10.1

R407C

0.1

HCFCHFC

R410A

0.1

8 0178-250-EN

Furthermore, it can be said aboutrefrigerants:S If released to the atmosphere, haloge-

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

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

S Ammonia is easily absorbed by water:At 15�C 1 litre of water can absorb approx.0.5 kg liquid ammonia (or approx. 700litres ammonia vapour).

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

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

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

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

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

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

S Refrigerants must not be released to theatmosphere.

S When purging an R717 plant, use an ap-proved air purger. The purged air mustpass through an open container of waterfor any remaining R717 to be absorbed.The water mixture must be sent to an au-thorized incineration plant.

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

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

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

In general, all brines must be considered asbeing harmful to nature and they must beused with caution. Be very careful whencharging or purging a refrigeration plant.

Never empty brines down a sewer or intothe environment.

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

0178-250-EN 9

Lubricating Oils

Warning!

When charging oil, avoid that your skincomes into direct contact with the oil. Directcontact with oils may in the long run developallergy attacks. Use therefore always protec-tive equipment - goggles and gloves - whencharging oil.

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

-- Mineral oil

-- Semi-synthetic oil

-- Alkyl benzene-based synthetic oil

-- Polyalphaolefine-based synthetic oil

-- Glycol-based synthetic oil.

-- Ester oil

When changing the oil in the compressor ordraining oil from the vessels of the refrigera-tion plant, always collect the used oil in con-tainers marked “waste oil” and send them toan approved incineration plant.

NOTE

This instruction only provides general information. The owner of the refrigeration plant isresponsible for ensuring that all codes, regulations and industry standards are compliedwith.

0178-253-EN

96.12

10 0178-250-EN

Description of SAB 202

The SAB 202 compressor is a capacityadjustable screw compressor with oilinjection.

The two rotors are equipped with 4 lobes(male rotor) and 6 lobes (female rotor),respectively, executed with asymmetricprofile according to SRM licence.

As indicated on the spare parts drawing atthe end of this manual, the rotors at thesuction end are fitted with slide bearings,whereas the bearing at the discharge endconsists of a combined bearing set with slidebearings, absorbing the radial load, and ballbearings, absorbing the axial forces. Theaxial forces are partly relieved by means ofthe rotating balance pistons mounted on therotors.

The rotors are designed for both male driveand female drive. The driving rotor is fittedwith a shaft.

The compressor is fitted with a large built-insuction filter, which effectively prevents dirtparticles from the refrigeration plant frombeing led with the suction gas into the com-pressor.

The suction filter housing also has a built-incompressor protection valve which - con-trolled by a pilot valve - safeguards the com-pressor against any unwanted highcompression pressures.

For efficient filtration of the oil that lubricatesthe bearings in the compressor, an oil filtercartridge has been inserted in the compres-sor block.

Furthermore, the compressor contains abuilt-in non-return valve, preventing the com-

pressor from running backwards wheneverthe power to the driving motor isdisconnected.

The driving shaft is fitted with a shaft seal ofthe slide ring type, consisting of a fixed castiron ring with an O-ring sealing against theshaft seal cover and a rotating springloadedcarbon ring with O-ring sealing against theshaft.

It is possible to regulate the compressor ca-pacity steplessly from approx. 10% to 100%by means of a regulating slide mountedunder the rotors. Once the slide has movedaway from the slide stop a gap is created sothat some of the sucked-in gas is returned tothe suction side. The bigger the gap, thelower the compressor capacity.

The regulating slide is moved hydraulically bya regulating piston and controlled by asolenoid valve system.

The compressor also features a regulatingsystem by which the built-in Vi volume ratiocan be adjusted.

The result hereof is that the compressorworks optimally at varying operationalpressures in the plant.

To optimize the compressor volume ratio theposition of the Vi regulating slide must bechanged whenever the compressor works atmax. capacity. This is done by changing theposition of the slide stop.

At partial load the Vi volume ratio will only beapproaching the optimum.

Regulating the built-in Vi volume ratio can bedone in the following two ways, depending onthe compressor type (as to your type of com-pressor, see page 1).

0178-250-EN 11

S Manual regulation of the Vi slide:By turning the spindle, pos. 180, inaccordance with the curves in theinstruction manual.

S Automatic regulation of the Vi slide:By means of the oil pressure and twosolenoid valves, controlled by a UNISAB IIcontrol system.

The type of screw compressor can bedetermined by means of the nameplate,placed on the compressor block.

SABROE

Shop noMax. speed

Test pressureWorking pressureSwept volume

Type Refrigerant

barbar

r.p.m.

T0177093_2

AARHUS DENMARK

m3/h

Year

Fig. 1

The name-plate indicates the compressor’sserial number as shown in fig. 1.

When contacting SABROE about the com-pressor, remember to state the serialnumber.

0170-120-EN

98.03

12 0178-250-EN

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

Direction of rotation

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

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

Seen towards shaft ends

Female Male

Handling of compressor and unit

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

Note:

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

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

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

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

Application

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

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

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

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

The compressor must NOT be used:

S For evacuating the refrigeration plant of airand moisture,

0178-250-EN 13

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

S As an air compressor.

Emergency device

The compressor control system must beequipped with an emergency device.

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

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

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

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

Other demands to the emergency device:

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

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

Combustion motors

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

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

Explosion-proof electricalexecution

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

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

T2516273_0

14 0178-250-EN

The temperature of tangible surfaces

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

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

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

0170-114--EN

99.02

0178-250-EN 15

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

In the following tables the noise data of thecompressors is stated in:

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

-- A-weighted sound pressure level LP(Sound Pressure level)

The values for LW constitute an average of alarge number of measurings on various units.The measurings have been carried out in ac-cordance with ISO 9614-2.

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

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

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

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

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

Dimensional tolerances are:

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

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

The dimensional values are stated for 100%capacity.

Fictional frame

Reflecting plane

Fig. 1

1 meter

Dimensional plane

1 meter

16 0178-250-EN

Note the following, however:

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

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

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

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

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

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

0178-250-EN 17

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

Compressor block LW LP

CMO 24 84 69

CMO 26 86 71

CMO 28 87 72

SMC 104 S 95 79

SMC 106 S 96 80

SMC 108 S 97 81

SMC 112 S 99 82

SMC 116 S 100 83

SMC 104 L 96 80

SMC 106 L 97 81

SMC 108 L 98 82

SMC 112 L 100 83

SMC 116 L 101 84

SMC 104 E 96 80

SMC 106 E 97 81

SMC 108 E 98 82

SMC 112 E 100 83

SMC 116 E 101 84

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


SMC 186 101 83

SMC 188 102 84

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

TCMO 28 81 66

TSMC 108 S 95 79

TSMC 116 S 97 81

TSMC 108 L 96 80

TSMC 116 L 98 82

TSMC 108 E 96 80

TSMC 116 E 98 82

LW LPCompressor block

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


TSMC 188 100 82

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

HPO 24 91 76

HPO 26 93 78

HPO 28 94 79

HPC 104 97 81

HPC 106 98 82

HPC 108 99 84


18 0178-250-EN

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

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

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

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

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

SV 17 100 83SV 19 101 84

FV 19* 101 86SV 24 103 85

FV 24* 104 86SV 26 103 85

FV 26* 107 85

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


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

Compressor unit LW LP

SAB 163 BM 106 88

SAB 163 BF 110 92

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


VMY 347 H 97 82

VMY 447 H 100 85

VMY 536 H 104 88

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


VMY 347 M 99 84

VMY 447 M 101 86

VMY 536 M 105 89

0170-115-EN

01.01

0178-250-EN 19

Vibration Data for Compressors - All Compressor Types

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

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

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

Pay attention to the following, however:

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

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

-- 85-95% for screw compressor units

-- 80% for recip. compressor units

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

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

-- For screw compressors, if the compres-sor runs at a wrong Vi-ratio.

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

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

20 0178-250-EN

Data for SAB 202 compressor & unit

IEC 355

UNISAB II

For removal of the fine separator element

700 700Height

WidthLenght

Compressor Oil coolingMax. dimensions Max. net

Compressortype Refrigerant Oil cooling

system 1) Widthmm

Lengthmm

Heightmm

Max. netweightKg 2)

R717R22

SAB 202 R134a OWSG, 1905 3234 1915 4000SAB 202R404A/R507

OWSG,OOSI

1905 3234 1915 4000

R407C

1) OWSG = Heat exchanger w/shell (water) 2) Excl. motor, oil, water and refrigerantOOSI = Heat exchanger w/shell (refrigerant)

Compressor and vessel data:

Max. operating

Test pressure

Type

Approvalno.

Serial no.

bar

bar

See their nameplates

AARHUS

DENMARK

T290927_0

Fig. 1

pressure

Type of compressor unitOn the base frame of the compressor unit aname plate has been fitted as shown in fig. 1.This name plate provides you with all rele-vant information in accordance with CE label-ling.

0178-254--EN

00.05

0178-250-EN 21

Compressor data SAB 202

Compressor Rotor Intern. Rotor L/D ∆P Motor at 2950 Motor at 3550type 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 male 202 2950 1229 3550 1479

SAB 202 S-F female 1.8-4.5 202 1.7 20 4425 1843 5325 2218

SAB 202 L-M male 202 2950 1590 3550 1914

SAB 202 L-F female 2.0-4.5 202 2.2 16 4425 2385 5325 2870

L = Rotor length D = Rotor diameter1) See permissible operating limits, however, in the Operating Limits Diagrams

Block weight Centre heightKg mm

SAB 202 S-M 950 315

SAB 202 S-F 950 315

SAB 202 L-M 1050 315

SAB 202 L-F 1050 315

Operating limits

The enclosed diagrams for R717, R22,R134a, R404A/507 and R407C indicate thelimits within which the compressor is per-mitted to work.

Please observe the following:

S The upper operating limits are for MaleDrive and Female Drive, respectively(see compressor type on p. 1).

S The use of an ecconomizer is allowedwithin the entire permissible operatingarea of the compressor.

22 0178-250-EN

Max. limit for model S

Evaporating temperature

Condensingtemperature

Operatinglimits

R717

(T250842_0)--60 --50 --40 --30

--30

--20

--10

0

10

--20 --10 0 10 20

20

30

40

50

60Max. limit for model L

SAB202S SAB202L

R717

MALE DRIVE

FEMALE DRIVE

C�

C�

Max. limit for model S

Max. limit for model L



Operatinglimits

R22

(T250841_0)--60 --50 --40 --30

--30

--20

--10

0

10

--20 --10 0 10 20

20

30

40

50

60

SAB202S SAB202L

R22

MALE DRIVE

FEMALE DRIVE

C�

C�

0178-250-EN 23



Operatinglimits

R134a

(T250821_1)

SAB 202S/L VMY 447H/M

--20

--10

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

0

10

20

0 10 20 30 �C

30

40

50

60

70

HLI + ECO

C�MALE DRIVE

SAB 202:

R134a

FEMALE DRIVE

SAB 202:no HLIoperation

VMY 447:Below curvefull flow oilpump required

HLI

Max. limit for model S/H Max. limit for model L/M

Operatinglimits

R404A - R507

(T250830_2) Evaporating temperature


--30

--20

--10

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

0

--30 --20 --10 0

10

20

30

40

50

SAB202S/L VMY447H/M

10

SAB 202:

SAB 202:no HLIoperation

VMY 447:Below curvefull flow oilpump reguired

HLI

MALE DRIVE

R404A-R507

FEMALE DRIVE

HLI + ECO

Max. limit for model S/H Max. limit for model L/M�C

�C

24 0178-250-EN

Operatinglimits

R407C


--30

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

--20

--10

0

10

--20 --10 0 10 20

20

30

40

50

---70

60

VMY 447:Below curve full flowoil pump required

MALE DRIVE

HLI

FEMALE DRIVE

SAB 110standard units notfor Booster opr.

Limit - model MB/B

HLI +econ

(T250133_1)

SAB 202 S/L, VMY 447 H/M

R407C

SAB 202:NO HLIoperation

Max. limit for model S/H, SAB 110LTC �C

TE �C


Max. limit for model M, SAB 202L

VMY 436 MB/B, VMY 536 H/M/B

0178-255-EN

01.05

0178-250-EN 25

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

During operation of the compressor, the be-low points should be observed. These aredescribed in detail in the following sections.

1. Preparations before starting up.

2. Initial start.

3. Current control requirements at normaloperation.

4. Normal stop.

5. Preparations before a lengthy standstillperiod.

6. Pressure testing.

7. Evacuation.

8. Operating log.

1. Preparations before starting up

After the compressor unit has been installedin its final place and all connections for refrig-erant, water and electricity, instruments andsafety switches have been established, carryout the following:

a) Check that the rotating direction is correctwith the coupling dismounted. The rotatingdirection is marked by an arrow on thesuction cover of the compressor.

b) Check the rotating direction of the oilpump.

c) Mount coupling and check that tolerancesand alignment are in accordance with thecoupling instruction.

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 thermo-static vacuum gauge for measuring ofpressure and fill up with dry air ornitrogen until the pressure reaches 1 bar.Then empty again to 4-5 mm Hg.

e) Charging of oilCharging of oil is carried out by means ofa portable oil charging pump, see Fig. 1.1.

The charging of oil is carried out in the fol-lowing way: The high-pressure hose pos.7, see Fig. 1.1, is connected to the chargevalve pos. 24 on the unit via the non-re-turn valve pos. 12 and the correct reduc-tion nipple. See also Fig. 1.2. The free endof the suction hose from the pump pos. 1is placed together with the by-pass hosepos. 2 in the oil barrel. The ball valve pos.9 and the charge valve pos. 24 will openwhereupon the pump pos. 5 will start. Theoil will now circulate until the system isfree from air bubbles whereupon the ballvalve pos. 9 will close. The oil will now becharged to the unit.

When the desired amount of oil has beencharged, the pump will stop and thecharge valve pos. 24 will close. Open theball valve pos. 9 carefully so that the pres-sure is equalized. The hoses can now bedismounted. Loosen the non-return valvecarefully so that the remaining pressure isequalized. Remember to mount the capnut on the charge valve and to seal the oilbarrel if there is any oil left.

26 0178-250-EN

Fig. 1.1

LENGTH: 460

1

5

7

DETAILA

9 2

20

1/4” RG

DETAILA

3/8” RG

1/2” RG

7/8” RG

HEIGHT: 350

WIDTH: 340

WEIGHT: 22

(RG = PIPETHREAD)

Fig. 1.2 Piping Diagram for Oil Charging

COMPRESSOR UNITA24

12

7

9

5

20

1

B

2

0178-250-EN 27

Oil charging, weight and shipping volumeSAB 128/163 Mk3 and SAB 202

Oil Charging (oil level at the middle of upper sight glass during operation)

Oil coolerLitres Oilseparator

LitresCompressor + Pipes

LitresTotal unit,LitresOil cooler

Type SAB128

SAB163

SAB202

SAB128

SAB163

SAB202

SAB128

SAB163

SAB202

SAB128

SAB163

SAB202

OOSI 1614OOSI 2114OOSI 2714OOSI 3214OOSI 4114

1120

11203148

1120314886

8089

103112123140

216225236253291

OWSG 1615OWSG 1619OWSG 2115OWSG 2119OWSG 2719OWSG 3219OWSG 4119

25

3925

3963

25

396378119

60 80 180 9 12 25

87

97117

131155

230

244278283324

HLI 0 0 0 69 92 205

f) Open all internal valves.

g) Slowly open the suction and dischargestop valves and fill up the plant with refrig-erant according to the instruction manualfor this plant.

2. Initial start-up

a) Check that the compressor is easy to turnby hand.

b) Check oil level in the oil separator.

c) Open suction and discharge stop valvescompletely. Open the remaining internalvalves.Check that all external valves on the re-frigeration plant are open or closed in ac-cordance with the piping diagram.

d) Check the free access of the cooling waterto the oil cooler, if any.

e) Check the supply of power to the com-pressor.

f) Check the position of the Vi-slide andmake sure that the capacity slide is in itsminimum position.

g) Start compressor as described in the UNI-SAB II manual.

h) Watch out for abnormal sounds and checkthat the compressor works up a differentialpressure.

If nothing abnormal has been observed,allow the compressor to work at normaloperating pressure, and adjust the capac-ity regulation to its immediate requirementor to automatic operation. Currently checkpressure, temperatures and power con-sumption.

ImportantPay attention to the procedures for run-ning down of the evaporating pressure asindicated in the instruction on refrigerationplants.

i) Do not leave the compressor for the first60 mins.

28 0178-250-EN

3. Current control at normaloperation

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

4. Normal stop

Regulate the compressor down to min. ca-pacity.Set the change-over switch on stop.

5. Preparations before a lenghtystandstill period

Once the compressor has been pressureequalized, close the stop valves of the com-pressor unit as well as all other valves con-necting the unit to the plant, e.g. those of oilcoolers or economizers.

Switch off and safeguard the compressormain switch.

6. Pressure testing

Before charging the plant with refrigerant, itmust be pressure tested and emptied.

Pressure test the plant using:

S Dry air - Pressurized cylinders containingdry atmospheric air may be used - neveruse oxygen cylinders.

S Air compressor for high pressure.

S Nitrogen.

ImportantDo not use the plant compressors forpressurizing the plant. Water or any otherliquid must not be used in connection withpressure testing.

In case nitrogen is used it is important toplace a reduction valve with pressuregauge between the nitrogen cylinder and theplant.

During pressure testing it is important thatpressure transducers and other controlequipment are not exposed to the test pres-sure. Similarly, the compressor stop valvesmust be closed during testing.

Normally, the plant safety valves should beblanked off during the pressure testing astheir opening pressure is lower than the testpressure.

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

S The entire plant is strength tested accord-ing to the local rules for pressure testing.

S Usually, the test pressure must not beallowed to exceed the design pressure.However, also in this case the local rulesand regulation apply.

S In case there is a request for the compres-sor to be pressure tested together with theunit, the test pressure on the compressormust not exceed 24 bar.

S Hereafter, lower the pressure to 10 bar for24 hours -- as a first leak testing -- as atight plant will maintain this pressure dur-ing the entire period.

During leak testing, it is permitted to enter therooms and approach the plant.

0178-250-EN 29

S As a second leak testing search all weld-ings, flange joints etc. for leaks by apply-ing soapy water, while at the same timemaintaining the 10 bar pressure.

During the pressure testing set up a pressuretest report containing the following:

� Date of pressure testing.

� Who carried out the testing.

� Test pressure

� Comments.

7. Evacuation

After pressure testing the refrigeration plantmust be evacuated in order to remove atmo-spheric air and moisture. Evacuation must becarried out on all types of refrigeration plantsregardless of the type of refrigerant to befilled into the plant.

Note that HCFC, HFC and CFC refrigerantshardly mix with water. Consequently, it is im-portant to make a particularly thorough evac-uation of these plants.

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

The following table indicates the boiling pointof water at very low pressures:

Boiling pointof water �C

At pressuremm HG

5

10

15

20

6,63

9,14

12,73

17,80

For evacuation, use a vacuum pump whichempties the plant of both air and water va-pour.

The vacuum pump must be able to lower thepressure to approx. 0.1 mm Hg (mercurycolumn), and it must be equipped with a gasballast valve. Use this valve to the greatestextent possible in order to prevent condensa-tion of water vapour in the vacuum pump.

ImportantNever use the refrigeration compressor foremptying of the plant.

In order for an evacuation to be satisfactorilycarried out the final pressure must be below5 mm Hg. Attention should be paid to the factthat there is a risk that the water still presentin the refrigeration plant may freeze in casethe ambient temperatures are below 10�C.In that case it is necessary to heat up thesurroundings of the components as ice onlyevaporates slowly.

Evacuation is recommended carried out asfollows:

S Carry out an evacuation to a pressure be-low 5 mm Hg.

S Next blow in dry air or nitrogen in the sy-stem to a pressure equal to atmospheric.

S Evacuate again to a pressure below 5 mmHg.

S Shut off the vacuum pump from the refrig-eration plant and check that the pressuredoes not rise within the next few hours. Ifthere is still water in the system, it willevaporate and cause a pressure increase.This means that the evacuation has notbeen satisfactorily carried out and has tobe repeated.

30 0178-250-EN

8. Operating logTo be in control of the operating conditions ofthe plant it is recommended to keep an oper-ating log in order to be able to keep an eyeon any changes that may occur in the operat-

ing conditions.

Below table is an example of such an operat-ing log. The information in this log is neededin order to make a satisfactory diagnosis.

Compressor Condenser Temperature

Inlet Outlet Inlet InletOutlet OutletPres. Temp.Temp. Pres.

Cooling waterAir

1 2

Power consump.

Fact.:No.:CV/kW:COS Ø:n: rpm

Temp. ofambient

Time

Machine

Suct.m

an.

Disch.m

an.

Number

of

Discharge

Suctionpipe

airSuction pipe Air Suction pipe

Electric motorpipetemp.

revolutions

temperature

room

C�C�C�C�C �C �C�C�C�C�lhC�C�C �C�rpmC�C�kWA V

0178-028-EN

99.05

0178-250-EN 31

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

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

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

Preparations before compressorinspection

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

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

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

S Close suction stop valve pos. 20.

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

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

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

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

SAB 110, SAB/163 and SAB 202

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

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

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

VMY with external oil filter

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

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

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

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

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

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

32 0178-250-EN

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

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

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

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

Cleansing of oil in the unit

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

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

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

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

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

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

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

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

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

0178-250-EN 33

Checking the oil

20000h 30000h 40000h

5020010002500

500010000150002000025000

300003500040000

�

�

�

�

�

�

�

�

�

�

�

�

�

�

�

�

�

�

�

�

�

�

�

�

�

�

�

�

�

�

�

�

�

�

�

�

�

�

�

�

�

�

�

�

�

�

�

�

�

�

�

�

�

�

�

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

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

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

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

� The oil charge must be replaced with fresh oil.

Service schedules after initial start-up of compressor.

Service schedules after each main inspection.

Operating hours between main inspectionsSee chart for main inspections

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

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

34 0178-250-EN

Activities during a service inspection

Daily

Periodic service Activity

1.1 External inspection and leak check.

1.2 Check the oil level in the oil separator.

1.3 Check pressures and temperatures.

1.4 Check for unusual vibrations or noise.

1.5 Record operating data in the log book.

1

5.1 Clean the compressor suction filter.

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

5.3 Fit a new oil filter cartridge.

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

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

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

After 2500 hours’operation

5

2.1 Clean the suction filter.After 50 hours’ operation2


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

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


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

que.


3


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


4

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

0178-250-EN 35

Periodic service Activity





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

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

After 5000 hours.operation

This service should berepeated after every5000 hours of operation

6

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

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


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


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

Major service

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

7

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

36 0178-250-EN

Assessing the oil

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

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

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

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

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

S be clear and shiny

S not contain any visible particles

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

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

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

Analytical evaluation

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

The analysis allows the following to be deter-mined:

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

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

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

0178-250-EN 37

Procedure

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

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

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

Analysing the oil

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

Limiting values

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

Parameter Unit Metode Spec.Værdi Max. Min.

Spec.Værdi Max. Min.

Spec.Værdi Max. Min.

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

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

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

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

Udseende -- -- rapport rapport rapport

Farve -- ASTM D1500

rapport rapport rapport

Uopløseligt Pentan W% MM 490(5μm)

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

Oxidering abs/cm IR,1700-1720/cm

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

Nitrering abs/cm IR,1627-1637/cm

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

Kvælstofforbindelser abs/cm IR,1547-1557/cm

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

Max. værdier for metalindhold i olien

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

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

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

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

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

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

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

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

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

38 0178-250-EN

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

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

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

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

� Whether the oil is no longer fit for use.

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

0178-250-EN 39

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

R717

R717

--50

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

T0177068_0

--10--505

10

20

25

30

35

15

--20--30

40

45

50

55

40000 hour interval

TE (�C)

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

Normal operat. cond.30000 hour interval

Condensing temp.

Evaporating temp.

“Booster” conditions

1.2 1.9 2.9 3.5 4.30.4 5.2 6.2 7.3 8.6 10.0

0.4

2.42.93.54.3

5.2

7.3

8.6

10

11.7

6.2

1.9

0.7

13.5

15.5

17.8

23.1

TC(Bar,a)

TE (Bar,a)

(�C)(Bar,a)

0.7 2.4

1.2

20.3

0178-030-EN

95.10

0178-256-EN

96.02

40 0178-250-EN

Oil charging, weight and shipping volumeSAB 128/163 Mk3 and SAB 202

Oil charging (oil level at the middle of upper sight glass during operation)

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

Shipping volume (excl. motor)Compressor type

m3

Basic UnitKg

Compressor blockKg

Oil coolerType

SAB128

SAB163

SAB202

SAB128

SAB163

SAB202

SAB128

SAB163

SAB202

OOSI 1614OOSI 2114OOSI 2714OOSI 3214OOSI 4114OWSG 1615OWSG 1619OWSG 2115OWSG 2119OWSG 2719OWSG 3219OWSG 4119HLI

KgSAB128

SAB163

SAB202

78130

120

185

20

78130180215

130

210310

20

7813098180215

380

21031044074020

700 950 2100 230 500 1040

10081060

1050

1115

950

1528158016301665

1580

16601760

1470

32183270332033553520

3270

33503450358038803160

Oil separatorLitres

Compressor + pipesLitres

Total, unitLitres

Oil coolerType

SAB128

SAB163

SAB202

SAB128

SAB163

SAB202

SAB128

SAB163

SAB202

OOSI 1614OOSI 2114OOSI 2714OOSI 3214OOSI 4114OWSG 1615OWSG 1619OWSG 2115OWSG 2119OWSG 2719OWSG 3219OWSG 4119HLI

LitresSAB128

SAB163

SAB202

1120

25

39

0

11203148

25

3963

0

1120314886

25

3963781190

60 80 180 9 12 25

8089

87

97

69

103112123140

117

131155

92

216225236253291

230

244278283324205

Total, unitKg

Oil coolerType

OOSI 2114OOSI 3214OOSI 4114OWSG 2115OWSG 2719OWSG 4119HLI

SAB128

SAB163

SAB202

5

6

4

8

9

7

11

1210

0178-275-EN

96.12

0178-250-EN 41

Temperature and pressure settings SAB 202

The setting of pressures and temperaturesmust be made in accordance with tables 1and 2, supplemented by the numberednotes.

Any deviation from the factory settings can,in view of the current operating conditions, bewritten down in the column Current plant.

Table 1 -- Screw compressors -- Measured and calculated pressures

Measuring Current plant Notes--5,01,5

333

--1,0

15,016,0

1

11

1,0

--

4,02,5

2+42+4

0,00,0

2+62+6

2,0 2+6+101,5 2+6+10

4,0 2+63,0 2+6

1,0 2+70,7 2+7

5,57,0

0,51,0

4,02,5

2+62+6

SettingsFactory

High alarmHigh warningLow warningLow alarm

Set point 1Set point 2


Low warningLow alarm




Set point 1Set point 2


High alarmHigh warning

Suction pressure

Discharge pressure

[bar]

[bar]

Oil press.Calculated value

SAB Mk 1 compressors

Diff. pressure acrossoil filter [bar]

[bar]

VMY Mk 3 compressorsStop/start of full flowpump

SAB 202 compressorStop/start of oil pump

Calculated value

Oil press. [bar]Calculated value






VMY Mk 2-2,5 compressor

42 0178-250-EN

Table 2Screw compressors -- Measured and calculated temperatures

Measuring Current plant Notes

100,090,0--65,0

11

--

60,055,025,020,0

2+42+42+4

2+4

60,0 150,0 14,0 1

12,0

110,0100,02,00,0

2+42+42+42+4

10,00,0

2+42+4

Factory

Settings

Discharge temp.

Oil temperature

Brine temperature

Suction gas superheat

Disch. gas superheat

[�C]

Calculated value

Calculated value

[�C]

[�C]

[�C]

[�C]






0178-250-EN 43

Notes:

Note 1 The alarm cannot be switched off until the cause has been removed.

Note 2 The alarm can be switched off immediately

Note 3 The alarm is switched off automatically.

Note 4 Alarm monitoring 300 sec delayed after compressor start.

Note 5 (not defined for screws)

Note 6 Alarm monitoring 45 sec delayed after compressor start.

Note 7 A delay of 30 sec, no matter when the limits are exceeded.



Note 10 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

0171-470-EN

97.07

44 0178-250-EN

Servicing the Refrigeration Plant

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

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

S the desired temperatures are observed,

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

S the condenser pressure is not excessivelyhigh and

S the plant works as it is supposed to.

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

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

Change the drying filter regularly.

Check Interval Activity

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

Pressureand temp. Daily

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

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

Accumulated dirt causes reducedrefrigerant supply to the evapor-ator.

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

FiltersClean whenrequired

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

Dehumidi-fier When re-

quired

0178-250-EN 45

Check Interval Activity

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

Periodically

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

Periodically

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

Safety pressure controlsAutomatic operating controlsAlarms

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

Automaticcontrols Periodically

Lubrication of electric mo-tors

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

Electricmotor

PeriodicallyAlignment of couplingV-belt drive

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

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

Condenser Periodically-- normallymin. 4times ayear

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

EvaporatorWhen re-quired

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

0178-260-EN

00.12

46 0178-250-EN

Maintenance of compressor SAB 202Dismantling and assembly

Service work on the SAB 202 compressormust be carried out of by professional andwell-trainied staff who are familiar with thecompressor.

This instruction is a description of the com-plete dismantling and assembly of the com-pressor, although this will not always be re-quired.

When dismantling, parts should be marked toensure that they can be remounted in thesame position as before.

Torque moments for screws and bolts asstated in the table on Torque momentsshould be strictly observed.

Preparations before dismantling

The following is a description of a completedismantling, inspection and assembly of thecompressor.

Partial dismantling and inspection can beundertaken while the compressor is securedto the base frame. To allow a completedismantling, however, the compressor mustbe lifted off the baseframe. For furtherdetails, see the section below entitledSequence for dismantling the compressor.

It is important that dismantling and handlingof the various parts be done as described inthis instruction in order to avoid damagewhen restarting the compressor.

Therefore, read the instructions carefullybefore commencing the work.

Before disassembly of the compressor ordismantling of its pipe connections, thepressure must be equalized to atmos--pheric.

As O-ring gaskets have a tendency toexpand beyond their size when exposed tooil and refrigerant, it is useful to have anextra set of gaskets ready before startingwork. See the list of spare part sets in thisinstruction manual.

ToolsApart from having the necessary tools athand (see the tool list in the instructionmanual), it is an advantage to place thecompressor on an iron plate whendismantling completely. This will allow foreasy removal of oil leaking from thecompressor during disassembly.

It is also recommended to position thecompressor in a room with plenty ofsurrounding space and to ensure that theroom is clean and dustfree.

Evacuation of refrigerant gas

Shut off suction and discharge stop valvesand evacuate the refrigerant gas asdescribed in the section Protecting theenvironment.

Removal of various accessories

When working on the compressor, the powerto the compressor motor must be cut off andit must be ensured that the compressorcannot be inadvertently started (if needed,remove the main fuses).

During an overhaul of the compressor or ifthe 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

0178-250-EN 47

plant and oil separator (in case of totaldismantling).

3. Oil pipes connected to the compressor.

Note:There may be oil in these pipes. Theyshould therefore be loosened carefully inorder to allow for collection of this oil.

When the oil pipes have been removed,they should be stored to prevent themfrom being bent or damaged.

4. Electrical connections to the compressorblock

In the following section the pos. numbersrefer to the spare parts dwg. 0661-850 forSAB 202.

Draining oil from the compressor:Following dismantling of the oil pipes, someoil may still be left in the compressor. Most ofit can be removed by unscrewing thethreaded plug pos. 24 on the bottom side ofthe compressor while still suspended, forexample, in the crane. (see weights underCompressor Data SAB 202)

Note:For cleaning or wiping of compressorparts, never use twist or any other fluffymaterial.

Dismantling the compressor

Sequence for dismantling of thecompressor:

Parts to be dismantled Sequence

Oil filter

Shaft seal, balance pistonand cap cover

Slide stop for Vi-regulationSuction cover and bearings

Rotors and bearings at compressor

Capacity indicator

23

4

56

78

9

Suction filter and compr.protect.system1

Thrust cover/regulating cylinder

in compressor shaft end

Regulating slide

discharge end10

Non-return valve

Each point is described in the followingsections, in connection with the statednumbers.

Reassembling the compressorClean all parts carefully before reassembly.Examine the parts for damage and wear.Replace damaged or worn parts with newones. Examine all gasket to see if they canbe reused. If in doubt, replace with newparts.

Before remounting, lubricate all parts,including screws, with clean fresh refrigerantoil.

48 0178-250-EN

1. Oil filterOil filter pos. 470 is a replaceable filtercartridge, mounted in the compressor blockas shown on the spare parts drawing. As thefilter capacity of the filter cartridge is beingused the pressure loss across the filter willincrease. This is registered by the twopressure transducers pos. 752 and pos. 753.

Make sure that a new filter cartridge is athand as the replaced oil filter cannot becleaned.

Before removing the filter cartridge from thecompressor block, stop the compressor andthe pressure will be equalized to atmosphericpressure. Further, empty the oil filterhousing of oil, which is done by usingdrainage valve pos. 48 -- see piping diagramas well as fig. 1.1. This drainage is most eas-ily carried out while there is still some excesspressure left in the compressor.

Fig. 1.1

48 Cutting ring connectionPipe dia.OD = 10 mm

ID = 8 mm

1.1 Replacement of oil filter

Once the pressures in the compressors hasbeen equalized to atmospheric and oil

drained off the oil filter housing, the oil filtercan be removed in the following way:

1.1.1. Remove the four screws, pos. 476,while keeping the flange for the oilpipe fixed to the cover, pos. 450.

1.1.2. Dismantle wiring connections onpressure transducer pos. 753.

1.1.3. Remove the four screws, pos. 456,and cover, pos. 450, and oil filtercartridge, pos. 470, can now beextracted manually as one entity. Payattention to O-rings, pos. 475 and pos.452.

1.1.4. By dismantling nut pos. 455 the filtercartridge pos. 470 can be pulled outacross stay bolt pos. 458. Payattention to O-ring pos. 453. As it isnot possible to clean the filtercartridge, replace it by a new one.

1.1.5. Solenoid filters pos. 459/460 are notdismantled but are wiped clean of anymagnetic particles with a clean andfluff-free piece of material.

1.2 Fitting of oil filter1.2.1. After cleaning cover pos. 450 on the

inside, mount filter cartridge pos. 470and O-ring pos. 453. Fasten theseparts with nut pos. 455.

1.2.2. Position the complete cover, pos. 450,together with O-ring, pos. 452, in thecompressor 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 topressure transducer, pos. 753.

0178-250-EN 49

2. Suction filter and compressorprotecting valve

2.1 Suction filterThe suction filter is built into thecompressor housing above the rotors.

The purpose of the filter is to collectthe impurities conveyed from theevaporator system with the suctiongas.

Experience shows that a good deal ofimpurities is collected in the filterduring the initial period followingstart-up of a new refrigeration plant.

It is important, therefore, to clean thesuction filter when the compressor hasoperated for 200 hours after the initialstart-up.

If the suction filter is not taken out andcleaned, there is a risk of it bursting asa result of too high a differentialpressure across the filter.

Removal and cleaning2.1.1. When the pressure in the compressor

has been equalized to atmospheric,

remove the cover, pos. 705, asfollows:

2.1.2. Remove the screws, pos. 721, thatkeep the pipe connection, pos. 720,fixed to the manifold, pos. 710.

2.1.3. Before removing screws, pos. 706, itis a good idea to support the cover,pos. 705, by suspending it in eye boltno 28 from the tools kit. Fit the eyebolt in the threaded hole in the outerdiameter of the cover. Total weight ofthe cover is approx. 45 kg.

2.1.4. After the screws, pos. 706, have beendismantled, lift the cover a fewmillimetres and carerully pull it out ofthe compressor block. Take care thatthe long valve, pos. 704, does not doany damage to the suction filter, andpay attention to the O-rings, pos. 707and 722.

2.1.5. The suction filter, pos. 170, isavailable in an old and a newconstruction of which the new suctionfilter is fitted with a collar as illustratedin the drawing:

D A D

C

B

50 0178-250-EN

The two different filters can bemounted on the compressor randomly.

Remove the suction filter manually orpull it out using the two extractionfittings in the old construction, or thetwo 7 mm diameter holes, pos D, asillustrated in the drawing.

Make sure that filth does not get intothe compressor when dismantling thesuction filter.

2.1.6. Cleanse the suction filter in oil solventand blow clean it with compressed air.

Mounting2.1.7. Before mounting check that the filter

mesh in the suction filter isundamaged. Further, the filter housingin the compressor and cover pos. 705together with valve pos. 704 must becompletely clean without any furtherdismantling taking place. Makesure that non-return valve pos. 259moves easily back and forth.

2.1.8. Mount the suction filter in the filterhousing manually so that the above-mentioned two extraction fittings orthe flange, pos. A, front the flange,

pos. 705. Additionally, the new suctionfilter must be turned for the notch,pos. C, to point slantwise to the rightas shown in the drawing in section2.1.5. The two holes, pos. D, must bepositioned horizontally.

2.1.9. Position the cover, pos. 705, andmake sure that the valve does notdamage the suction filter duringmounting. It is a good idea to use eyebolt 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 alight turn so that the cover fits in withthe two plant surfaces. Then fastenthe screws with the prescribed torque,in accordance with the table onTorque moments.

2.2 Compressor protecting systemTo protect the compressor against in-admissible high pressures thecompressor has a built-in protectingvalve type POV, pos. 704, controlledby pilot valve type BSV8, pos. 700.The protecting system is describedbelow:

0178-250-EN 51

Fig. 1 Pilot valve, BSV8, pos. 700 Main valve, POV, pos. 704

Oil separator, condenser Condensing pressure Evaporating pressure

Evaporator

Compressor

Functional description

The pilot valve, shown in fig. 1, is actuated bythe high pressure P1. The valve is suppliedwith a stainless metal bellow �. Thereference pressure in the bellow is theatmospheric pressure. The effective area ofthe bellow is exactly equivalent to the area ofthe valve seating, which means that the backpressure P2” does not affect the openingpressure of the valve.

The main valve is a normal closed valve. Thehigh pressure P1 is affecting the lower side ofthe valve cone � propagating up through thepiston rod � to the upper chamber � of thevalve, producing a pressure on the piston �.The area of the piston is larger than the areaof the valve seating. Together with the powerof the spring this will keep the valve closed.

When the pressure P1 reaches the set pres-sure of the pilot valve, it will start opening.The pressure P2” of the pilot line and of thelower chamber � of the main valve will

increase. The pressure of the lower chamberis limited by flow through the nozzle �. Whenthe flow through the pilot valve exceeds thecapacity of the nozzle, the pressure of thechamber � will increase, providing theopening of the main valve. When thepressure P1 is reduced, the pilot valve willclose, and the pressure P2” is equalizedthrough the nozzle �. The spring will thenclose the main valve. The closing time is < 30seconds, depending on the size of thenozzle. The spring is dimensioned to the ef-fect that the difference pressure (P1-P2) of 7bar 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.

52 0178-250-EN

Dismantling and assembly

Usually, it is not necessary to dismantle thecompressor protecting system from flangepos. 705, and it is not advisable to dismantlethe individual components.

Any checking of the correct openingpressure, which is stamped on the nameplateon the pilot valve, should be done on theentire system.

Test pressure is added through a flangemounted on the manifold pos. 710. That iswhere the pipe connection pos. 720 isusually fitted. Once the opening pressure hasbeen reached, the BSV8 pilot valve opensand the compressed air flows out throughthe lateral connecting piece on the POV mainvalve, which opens modulating, thusequalizing the pressure.

At the same time pipe connection pos. 1 infig. 2 should be leak tested. This is done asfollows:

a: Shut the flange just mentioned on the ma-nifold pos. 710 tightly and jam in flangepos. 2 with the lateral connecting piece onthe POV valve, as shown in fig. 2.

b: Put a pressure of approx. 7 bar on thesystem and apply soap water to the pipeconnection pos. 1 right to the pilot valve.

Fig. 2

BSV 8 pilot valve

7 bar

POV main valve

2

1

Pipe connection pos. 720

As it appears from fig. 3 the pipe connection,pos. 720, has a bigger cross-section for HFCand HCFC compressors than for R717compressors.

However, the two models have one thing incommon: they follow the same procedure forcleaning the suction filter as described insection 2.1.

Fig. 3 with main valve POV 50 with main valve POV 80

720

715

705

710A

721A

722A

705

720B

710B

721B722B

0178-250-EN 53

3. Non-return valveThe non-return valve is mounted on theintermediate flange pos. 253 and positionedin the suction chamber. While thecompressor is idle the non-return valve isclosed by means of spring pos. 261. Seesectional drawing.

After start-up of the compressor thenon-return valve opens and the compressoris able to suck in refrigerant gas.

When the compressor stops, the non-returnvalve shuts off immediately and herebyprevents the compressor from runningbackwards.

In valve cone pos. 259 a hole of dia. 6 mmhas been bored which slowly equalises thepressure in compressor and oil separator tosuction pressure at compressor standstill.

Dismantling

S Dismantle the compressor protectionvalve and the suction filter as describedin section 2.

S Seal the opening to the rotors with a clothfree of flocks in order to prevent foreignparticles from falling down to the rotors.Do never use twisted yarn, paper orseveral small cloths.

S Now the suction non--return valve can bedismantled by means of the screwpos. 258.

S Dismantle the valve cone pos. 259 by re-moving the countersunk screw pos. 265.

S Dismantle the valve spindle pos. 260 bypushing the spindle guide pos. 256 so thatthe locking ring pos. 268 is clear of thespindle guide. Dismandle the locking ringand extract the spindle from the spindleguide. Note that the spindle is spring-loaded.

S Tape bearings, pos. 262 and pos. 263,usually remain in the groove of theintermediate flange, pos. 253, and mustnormally not be replaced. However,replacement should take place in case thetape of the bearing bushing is removed.The tape must then be positioned with itsperforated side against the spindle fornon-return valve.

Mounting

Assemble the non-return valve in the reverseorder from described above. Note thefollowing, however:

S The bearing tapes, pos. 262 and pos. 263,must be undamaged and correctly fitted inthe grooves in the spindle guide, pos. 256.The perforated side of the tape must facethe spindle, pos. 260.

S The O-ring, pos. 707, must be in onepiece and mounted on the flange, pos.705, before it is fitted on the compressorhousing with the screws, pos. 706.

After the mounting has been completed,check that the non-return valve is easy topush into the suction filter and that the springforces the valve cone back correctly.

54 0178-250-EN

4. Shaft seal and lip seal arrangementFig. 4.1

110

156C

156F

156K

156A

325

156G

156D

156E

156H

139

163

156I 156B 113 112 111 21

166

160A

160E

A

C

D

B

Fig. 4.1a

Pos. No. Designation Quantity

156AA Shaft seal cover SM/LM 1

156AB Shaft seal cover SF/LF 1

156B Balance piston 1

156C Slide ring 1

156D Sealing ring 1

156EA Retaining ring for 156 D,SM/LM 1

156EB Retaining ring for 156 D,SM/LF 1

156F O-ring, dia. 88.49 x 1

156G O-ring, dia. 107.54 x 1

156H O-ring, dia. 142.47 x 1

156I Countersunk screw 4

156K Cylinder screw 2

The shaft seal pos. 160 as illustrated in fig.4.1 is mounted at the compressor shaft. Theshaft seal must ensure that refrigerant and oilfrom the inside of the compressor do not es-cape into the atmosphere both when theshaft is rotating and when it is standing still.The shaft seal has therefore two sealing sys-tems, the primary shaft seal and the lip sealarrangement as described in the following.

Primary shaft seal

The shaft seal is of the slide ring type. It con-sists of a slide ring made of special carbonand mounted in the rotating part of the shaftseal pos. 160A. It rotates together with theshaft and slides against a steel ring pos. B,which is inserted in the shaft seal cover pos.156A. The sliding surfaces of the two ringsare surface-ground and lapped together, thus

0178-250-EN 55

ensuring the desired tightness both when thecompressor is and is not in operation.

It is therefore important to be very carefulwith the lapped sliding surfaces as eventhe smallest scratch will reduce the tight-ness of the shaft seal.

The shaft seal is mounted and dismountedas described in the following. The rotatingpart pos. 160A is secured to the compressorshaft by means of three pointed screws pos.160E. The outer and inner O-ring pos. C andD ensure tightness between the shaft sealand the shaft seal cover pos. 156A and thecompressor shaft respectively.

Lip seal arrangement

When the compressor has not been in oper-ation for a long period of time, the oil in theshaft seal chamber, which helps to keep theshaft seal gas-tight, will drain away from thechamber, making it possible for smallamounts of refrigerant to leak from the shaftseal.

To avoid this situation, a sealing ring pos.156D must be used. This ring ensures thatthe oil stays in the shaft seal chamber. In thisway there will always be a thin oil film be-tween the two sliding surfaces of the shaftseal and thus complete gas-tightness be-tween the inside of the compressor and theatmosphere.

The sealing ring pos. 156D is mounted in theshaft seal cover pos. 156A and seals againstthe sliding ring pos. 156C, as illustrated infig. 4.1.

Dismounting of shaft seal and lip seal ar-rangement

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

S Remove the screws pos. 167 and pull outthe shaft seal cover. If the cover sticks, itcan be pushed out by mounting two of thescrews pos. 167 in the two threaded holesof the cover.

S The steel slide ring pos. A and the sealingring pos. 156D will come out with thecover and can then with great care bepressed out of the cover. The oil splashring pos. 162 will also come out with thecover and can then be removed manually.By dismounting the screws pos. 156K, theretaining ring pos. 156E can be removedfrom the shaft seal cover and the O-ringpos. 156H can be dismounted. Now pushthe sealing ring pos. 156D out of the re-taining ring.

S Dismount the four countersunk screwspos 156I, Allen key size 4 mm.

S Pull out the slide ring 156C by means oftwo long M6 screws, which are mounted inthe two threaded holes in the flange. TheO-ring pos. 156G can now be removedmanually.

S Now there is enough space to loosen thethree pointed screws pos. 160E a coupleof turns by means of the shortened Allenkey - size 3 mm - which is included in theshaft seal set.

S When the three pointed screws have beenloosened, the rotating part - with the car-bon ring - can be pulled out over the shaft.Tools will usually not be necessary.

S Dismount the screws pos. 113 by meansof Allen key - size 4 mm.

S By fitting the above-mentioned two longscrews (M6) in the threaded holes of thebalance piston pos. 156B, the piston cannow be pulled out manually. The O-ringpos. 156F will come out with the piston.

56 0178-250-EN

Mounting of shaft seal and internal oilseal

After cleaning the shaft seal parts and thecompressor shaft and checking them forscratches and marks, oil all surfaces with thesame type of oil which is used in the com-pressor. Now the shaft seal and the oil sealare ready to be mounted.

S First place the balance piston pos. 156B(see fig. 4.1) on the compressor shaft andturn it so that it is possible to mount thescrews pos. 113. Tighten the screws to thetorques indicated in the instruction man-ual. Make sure that the O-ring pos. 156Fhas been fitted in the balance piston be-fore the piston is mounted.

S Mount the rotating part of the shaft sealpos. 160A and tighten it by means of thepointed screws pos. 160E. Make sure thatthe O-ring has been mounted in the rotat-ing part.

S Mount the slide ring pos. 156C and tightenit by means of four countersunk screwspos. 156I. Make sure that the O-ring pos.156G has been mounted.

Before mounting the shaft seal cover pos.156A on the compressor block, carry out thefollowing:

S Press the sealing ring pos. 156D intothe retaining ring pos. 156E. It must beturned as shown in the drawing fig. 4.2and must only be pressed so far intothe retaining ring that the two surfacesare flush with each other as illustratedin fig. 4.2.

Fig. 4.2

156E

156D

Plant

S Fit the retaining ring pos. 156 E in theshaft seal cover pos. 156A. Turn it sothat the two screws pos. 156K can bemounted and tightened. Make sure thatthe O-ring pos. 156H has beenmounted in the retaining ring.

Note that there are two types of shaftseal covers and retaining rings, onetype for compressors driven by malerotor and one type for compressorsdriven by female rotor. The many boredholes in the retaining ring must beplaced above the centre line of thecompressor shaft when the shaft sealcover has been fitted on the com-pressor.

S Mount the steel ring pos. B and the O-ring pos. C in the shaft seal cover.Make sure that the pin pos. 161catches the key groove of the cast ironseat.

S Mount the O-ring pos. 166.

S Place the shaft seal cover on the shaftand move it carefully forward until ittouches the rotating part. Before thescrews pos. 167 are tightened, there mustbe a gap of 3-4 mm between the twoflanges as shown in fig. 4.3.

It is recommended to cross-tighten thescrews pos. 167 so that the shaft seal isnot damaged due to uneven tightening.Tighten the screws to the torques indi-cated in the instruction manual.

0178-250-EN 57

S Mount the oil splash ring pos. 162. Fit thecoupling for the motor as described in theinstruction manual. Turn the compressorshaft manually to check that it is able torotate freely.

Cap cover

After dismantling the screws pos. 167, dis-mount the cap cover pos. 163 by fitting two ofthe screws in the free threaded holes in theflange of the cap cover. Thus the cap covercan be pushed out. Remounting of the capcover is carried out in the same way as theshaft seal cover.

Fig. 4.3

3-4 mm

58 0178-250-EN

5. Thrust cover and regulatingcylinder

The purpose of the regulating cylinder inthrust cover, pos. 40, the built-in piston sys-tem and the capacity slide, pos. 200, is toadapt the capacity of the compressor to theimmediate cooling requirements of the plant.

The system works by letting the piston con-sisting of parts pos. 201, 202, 203 and 204move the capacity slide pos. 200 back andforth hydraulically. This opens modulatinglyfor an internal by-pass channel which - whenthe position of the piston is to the extremeright on the drawing - is most open. The com-pressor now runs at its lowest capacity.

Dismantling

S First, dismantle the pipe connections tothe cover, pos. 60.

S During manual Vi regulation it is anadvantage to unscrew the Vi slide as faras possible by turning the spindle, pos.180 , clockwise. This slackens the spring,pos.191, as much as possible.

S Next, dismantle the complete capacityindicator by unscrewing two diagonallypositioned screws, pos. 62. Mount twothreaded spindles no. 22 in their place aswell as nuts no. 9.2 from the tools kit asshown in fig. 5.1.

9.2 22 T0177135_14

60Fig. 5.1 62

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

large spring, pos. 191, will, via capacity slide,pos. 200, and the piston, loosen the cover,pos. 60. The cover is now pulled straight outin order to avoid damaging the spindle, pos.210.Watch out, there may be oil behind thecover, pos. 60.

S It is now possible to pull the completecapacity slide with piston, pos. 201 and202, out of the cylinder. Please note thatthe Vi slide, pos. 190, can also beextracted from here if necessary. First dis-mantle the blank-off screw and the gasket,pos. 24/25, however and push the Vi slideslightly 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 ina crane before the screws, pos. 41 areremoved.

S Now mount the two pointed screws no. 45from the tools kit in the holes A, see fig.5.2, and insert them by turning them only3 to 4 turns into the thread. Next, fit thetwo screws no. 16.1 in the thread of thethrust cover on top of the two pointedscrews in holes A.

S By tightening screws no 16.1 alternately,the thrust cover is pulled free of the twoguide bushings, pos. 22, that guide thethrust cover towards the compressorblock. The bushings are positioned inholes B.

Fig. 5.2

B

A

B

A

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

0178-250-EN 59

with cover, pos. 60, can be found in section6: Regulating slide.

6. Regulating slide

Dismantle the complete capacity slide withpiston, pos. 201 og 202, as described insection 5: Thrust cover and regulatingcylinder.

Any dismantling of the piston rod, pos. 207A,and the slide, pos. 200, can be done byremoving the set screw, pos. 311, as well asthe 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 valveensures the quick movement of the capacityregulating slide to its minimum position asthe oil is emptied through the non-returnvalve.

In case the sealing ring, pos. 204, has beendamaged it must be replaced. This is donebe removing the groove nut, pos. 206, andthe locking plate, pos. 208, whereby theouter and inner rings of the piston can bedismantled. Pay attention to the O-ring, pos.203.

Antifriction tapes, pos. 209, have been fittedon the end surface of the capacity slide.Their length is adapted so that they can beplaced loosely in the groove of the capacityslide.

Mounting

Mounting of the thrust cover, capacity slideand capacity indicator is done in the followingorder:

S Mount the two guide bushings, pos. 22, inholes B of the compressor block, see fig.5.2.

S Position the thrust cover with the O-rings,pos. 43 and 49, against the compressorblock and guide it into its place by meansof the guide bushings which are pulledtowards 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 itmust be refitted. Fit and tighten thescrews, pos. 192 and 24/25.

S Assemble the complete capacity slide onthe work bench while paying specialattention to the following:

-- that the screw, pos. 311, with lockingdevice, pos. 312, has been tightenedcorrectly.

-- that the two antifriction tapes, pos. 209,are fitted correctly in the capacity slide,pos. 200.

-- that the steel ball, pos. 207E, and thecirclip, 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 groovenut, pos. 206, and secured with thelocking plate, pos. 208. Remember thatthe 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 thecomplete capacity slide in the thrust coverwhile guiding it carefully into place untilthe spring starts resisting.

S Mount the two threaded spindles no. 22in the end surface of the cylinder andposition the cover, pos. 60 on thethreaded spindles, while first letting thespindle, pos. 210, catch the pin, pos.207C.

60 0178-250-EN

By an alternate tightening of nuts no. 9.2the cover is pressed against the capacityslide and the entire system is pressedagainst the spring.Take special care not to damage thesealing ring, pos. 204, while inserting itin the cylinder.

S Tighten two of the screws, pos. 62. Next,dismantle the two threaded spindles andnuts which are replaced by the two otherscrews, pos. 62.

S Mount pipe connections.

7. Slide stop for Vi regulation

The purpose of the Vi-regulating system is toregulate the built-in volume ratio of thecompressor so that the compression ratio ofthe compressor is equal to the pressure ratiobetween the condensing pressure and theevaporating pressure in the refrigerationplant.

The system works by displacing the slidestop, pos. 190, hereby - via the regulatingslide, pos. 200 - changing the size of the dis-charge port of the compressor. This changeof the size of the discharge port increases -or diminishes - the compression chamberand consequently the compression ratio.

As described in the following, theVi-regulation can be done in two ways:

A: Manual Vi-regulationB: Automatic Vi-regulation

The two systems cannot be mountedsimultaneously, however.

A: Manual Vi-regulation

Manual adjustment of the Vi slide stopposition is described in a separate section inthis instruction manual. Please refer to tableof contents and fig 7.1.

Dismantling

S After dismantling the screws, pos. 198, theentire 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 unscrewedcompletely from the thread in the threadedwasher, pos. 189, the unit can be removedmanually.

S By dismantling the screws pos. 196, thecover, pos. 181, is dismantled from thebearing retainer, pos. 185, and the sealingwasher, pos. 182, the sealing ring, pos.183, and the O-ring, pos. 184, can be re-moved manually.

S The spindle, pos. 180, and the ballbearings, pos. 186, can now be pushedout of the bearing retainer, pos. 185.

S The slide stop, pos. 190, and the slideguide, in which the spring has been fitted,are pressed together and should normallynot be disassembled.The whole unit cannot be extracted fromthe compressor until the suction cover,pos. 20, has been dismantled. Cf. section8 or the description found in section 5.

0178-250-EN 61

S The screw, pos. 192, acts as a slide stopand should normally not be dismantled.Cf. section 5.

Mounting

When mounting - which is done in reverseorder - attention must be paid to thefollowing:

S Insert the ball bearings, which must bewell lubricated with ball-bearing grease, inthe bearing retainer, pos. 185, with thecollar of the spindle, pos. 180, in between.Avoid knocking on the bearings.

S Before clamping together the slide stopcover, pos. 181, and the bearing retainer,pos. 185, position the sealing washer,pos. 182, the sealing ring, pos. 183, andthe O-ring, pos. 184, as shown in drawing.The open side of the sealing ring, pos.183, must face the ball bearing. The

clamping is done by means of screws,pos. 196.

Check that the spindle is easy to turn.

S Mount the whole unit in position byscrewing the spindle into the threadwasher, pos. 189, until the slide stop cov-er, pos. 181, bears against the suctioncover, 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 ismoved by oil pressure controlled by solenoidvalves and a position transmitter pos. 410.

Adjustment of the system is described in thefollowing chapter: System for regulating thecapacity and the Vi-ratio of SAB 202 of thisinstruction manual.

T0177135_1

Fig. 7.2

62 0178-250-EN

Dismantling of the Vi-regulating system

S First dismantle the electrical connection tothe position transmitter pos. 410.

S Dismantle the pipe connection to thecover, pos. 380.

S After dismantling the screws, pos. 382,it is possible to extract the cover, pos. 380including its parts as one unit, but caremust 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. Thismakes it possible to remove the positiontransmitter, pos. 410, with the flange, pos.402.

S Dismantle the driving disk, pos. 395, andthe screw, pos. 396, while holding it backby means of a screwdriver of a suitablesize inserted in the slot of the driving disk.

S By removing the screws, pos. 401, it ispossible 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 inthe following section.

S Dismantle the piston in the flange, pos.380, by removing screws, pos. 387,whereby the flange, pos. 384, the sealingring, pos. 371, and the ball bearing, pos.393, can be dismantled.

S Slide guide and slide stop, pos. 190, can-not be extracted before the suction cover,

pos. 20, has been removed. See section 8or the description found in section 5.

Mounting

When mounting - which is done in reverseorder from dismantling - attention must bepaid to the following:

S On mounting the sealing ring, pos. 371,the open side must be facing theflange, pos. 384.

S Mount the flange, pos. 380, and tightenwith screws, pos. 382. Remember the O-ring, pos. 381.

S Position the complete magnetic coupling,pos. 405, with spindle, pos. 390 and sealwith O-ring, pos. 406. See Assembly ofmagnetic coupling in the following section.

S On fastening the driving disk, pos. 395,with the screw, pos. 396, the slot in thedriving disk must be facing verticallydown as shown on drawing and be heldback by means of a screwdriver of a suit-able size inserted in the slot.

395

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

0178-250-EN 63

Position transmitter

S In case arm no. 4 has been dismantledfrom the transmitter, it must be fittedcorrectly as follows:

S Find the 4mA point of the transmitterby turning the shaft as described inthe Instruction manual for UNISABII.

S Mount arm no. 4 so that pin no. 3 ispositioned as shown on the sketch.

S Tighten the pointed screw no. 5.

S Mount the transmitter, pos. 410, as shownin fig. 7.2 with the connection facing down-wards.

5

4

3

Magnetic coupling for Vi-indicationThe rotating movement from the spindle, pos.390 - see fig. 7.2 - is transferred to the trans-mitter, pos. 410, through a magneticcoupling, pos. 405, which is completely tightso that neither oil nor refrigerant can passthrough the coupling.

Usually, it is not necessary to dismantle themagnetic coupling, but on dismountingspindle, pos. 390, proceed as follows:

Fig. 7.3

4062

3

10

4

6

N

S

SSNN

SS N

NS

S NN

N SNS

S

NN

S

A - A

NS

5

from T4161061_0

A

A

78

1

11

9

390

Dismantling:

S After the magnetic coupling has been dis-mounted from the compressor as alreadydescribed, dismantle circlip no. 1. The

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

64 0178-250-EN

S After removing screw no. 4 spindle pos.390 can be dismantled.

S Bearing no. 3 can be released once circlipno. 5 has been removed.

S Should it be necessary to dismantle themagnetic coupling, screw no. 6 can beloosened by inserting a 2.5 mm Allen keyin the hole in the magnet retainer no. 7.Pay attention to washer no. 11. Magnetretainer no. 7 and flange no. 8 an now bepulled apart.

S After removing circlip no. 9, ball bearingno. 10 can be pulled out.

Assembly of magnetic coupling

Assembly is done in the reverse order to thedismantling. Note the following, however:

S We recommend not to insert magnetretainer no. 2 in the coupling until thespindle, pos. 390, has been fitted as themagnetic force makes it very difficult todismantle the parts again.

8. Suction cover and bearingsat compressor shaft end

Before the bearing cover at the suction end,pos. 20, can be dismantled, the followingparts 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 and380 for auto. Vi.

Dismantling

S Dismantle the screws, pos. 113, at thebalance pistons, pos. 134 and 137.

S Pull out the balance pistons, pos. 134 and137 as well as the spacer rings, pos. 135and 138 manually.

S Suspend the bearing cover in a crane withshackle and wire. (Weight 101 kg)

S Dismantle the screws, pos. 26, 27 og 28.

S Mount the pointed screws no. 45 from thetools kit in the two threaded holes at thetop of the bearing cover as shown in fig.8.1 and fig. 8.2. Screw the pointed screwscompletely into the compressor housing.

S Mount the stay bolts no. 11 from the toolskit in the two top holes, in which the bolt,pos. 28, has been mounted. The staybolts must guide the suction cover while itis being pulled across the shaft pins. Seefig. 8.2.

S Mount the screws no. 17.1 in the sameholes as the pointed screws. By tighteningthe screws the bearing cover will comeloose. See fig. 8.1.

T0177135_2

17.1 20 45

Fig. 8.1

0178-250-EN 65

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

Fig. 8.2

Holes forstay bolts

Holes for pointed screws

T0177135_3

S With an arrangement as shown in fig. 8.3the slide bearings can be pulled out of thebearing cover. Screw the threaded pinsno. 3 into the threaded holes of the slidebearing. Puller no. 2 is pushed against thethreaded pins and kept in place by nutsno. 9.2.

S Position the thrust plate for puller no. 1 ata right angle to the first plate. Bytightening screw no. 4 the slide bearingwill be pulled out.

Fig. 8.3

T0177135_6

11220 1114 9.2 2 1 3

Mounting

To mount the slide bearings, pos. 111, carryout the following procedure:

S Before the slide bearing, pos. 111, ispushed into place on the cover, pos. 20,the guide pin, pos. 112, should bemounted as illustrated in fig. 8.4.a.The guide pin is knocked just 5 mm intothe hole in the slide bearing and isstraightened up to stand at a right angle tothe end plate.

112

Fig. 8.4.a 40

112111

66 0178-250-EN

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

Fig. 8.4.b

T0177135_7

11220111

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

T0177135_7

11220111

9.1 5 8 76

S The guide pin, pos. 112, will at the sametime be pushed into the slide bearing, pos.111, and this guarantees that the slidebearing is positioned correctly.

S The suction cover, pos. 20, is mounted onthe compressor housing, pos. 10, whenthe rotors have been mounted.Cf. chapter 9.

9. Rotors and bearings atcompressor discharge end

Before the rotors can be removed from thecompressor, the parts mentioned in section 7must be disassembled. Then proceed asfollows:

Dismantling

S The thrust cover, pos. 40, must bedismantled as described in section 5.

S Loosen the four locking screws pos. 45,next loosen adjusting screws pos. 443-4 turns. Dismantle cross bar pos. 46 byremoving screws pos. 47.

S Remove inner covers pos. 153 by mount-ing tools no. 26 and 27 in the threadedholes in the cover which is now carefullypulled out.

Take care not to lose the twocylindrical steel rolls pos. 155.

S Next dismantle screws, pos. 115, and thethrust washer pos. 114 can be removed.During their dismantling the rotors shouldbe locked in order to prevent them fromrotating.For this purpose use arrangement in fig.9.1 at the shaft end of the rotors.

0178-250-EN 67

Fig. 9.1

T0177135_0 V13

17.2

110

13

12

17.2

Remember to dismantle the tools againbefore pressing out the rotors.

S It is now possible to push out the rotors,pos. 110, - one at a time - by means of thetools shown in fig. 9.2.

Fig. 9.2

133

132

15 17.3 14 16.1 17.3 15

18

16.2

17.3 14 16.1 17.3

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

thread hole at the end of the rotor toprotect the centre hole.

S Then mount the plate no. 14 with thescrews 17.3 and the bushes no. 15. Screwno. 16.1 is mounted hereafter.

S By tightening the screw no. 16.1 the rotoris automatically pushed out of the ballbearing, pos. 132.

S When plate no. 14 is dismantled again,the outer ring and the shim, pos. 133, canbe dismantled manually.

The innermost inner ring of the ballbearings can later on be dismantled fromthe rotors with tool no. 49 when the rotorshave been removed from the compressorblock.

S Both rotors should be pushed as far out ofthe block to allow a soft lifting sling to beplaced around them.

Since the weight of a set of rotorsamounts to approx. 170 kg, a crane oranother approved lifting device should beused to lift the rotor set off the block.

S Pull out the main bearings, pos. 111, usingthe tools shown in fig. 9.3. The bearingsshould normally not be reused.

Fig. 9.3

T0177135_8

141 101113 1 2 44.2

68 0178-250-EN

S The discharge ports, pos. 140 and 141,are dismantled in the following way:

S Dismantle the screws, pos. 142 and thesealing plates, pos. 143, as shown infig. 9.4.

T0177135_15

14010 143Fig. 9.4 141

142

S Dismantle the screw, pos. 144, in eachdischarge port as shown in fig. 9.4.a.

Fig. 9.4.a

144

A-A

A

A

S An adjustment device fitted at each dis-charge port must be loosened before thedischarge ports can be dismantled. Theadjustment device exists in two differentdesigns dependent on whether the com-pressor was delivered before or afterJanuary 1999.

S Design 1 (before January 1999)As shown in fig. 9.4.b., the lockingscrew, pos. 146, is first dismantled bymeans of an NV5 Allen key, and then

the adjusting screw, pos. 145, is loose-ned 2 turns with the same Allen key.

T0177135_15

10Fig. 9.4.b

140141

145

146

S Design 2 (after January 1999)This design is easier to use as the ad-justment is made from the outside asillustrated in fig. 9.4. c.

148 147 10 149B 149A140141

Fig. 9.4.c

First, the blank off screw, pos.149A,and the gasket, pos. 149B, aredismantled. Then the locking screw,pos. 147, is dismantled with the Allenkey no. 27-1. Loosen the adjustingscrew, pos. 148, two turns with thesame Allen key.

S The discharge ports, pos. 140 and 141,can now be pulled out carefully using awooden stick or the wooden handle of ahammer.

Mounting

Before positioning discharge ports pos. 140and 141 in the rotor housing, check that theyare free of burrs and marks, especially on the

0178-250-EN 69

surfaces that are going to adjoin the rotorhousing.

Likewise, check the rotor housing for similardefects on the corresponding contact sur-faces.

Push the discharge ports into place in therotor housing and fasten with screws pos.142 and new steel gaskets, pos. 143.

S Tighten the screws, pos. 142, with half thetorque moment required (cf. the torquetable) to ensure that the discharge portsstay close to the end plate in the rotorhousing.

Now loosen the screws and tighten themslightly again to facilitate the following ad-justment -- which is the same for both de-signs. Cf. the section Dismantling.

Mount the capacity slide, pos. 200, andtighten the adjusting screw, pos. 148 (145)slightly.

S While the capacity slide is pushed backand forth, tighten the screws, pos. 148(145) alternately until the capacity slidescan 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 offscrews, pos. 149A, and the gaskets, pos.149B, should be mounted and tightened.

S The screws, pos. 142, must be tightenedwith the prescribed torque moment.

Please remember that the used steelgaskets, pos. 143, must not be reused.They must be replaced by new ones toensure tightness.

S Finally, the screws, pos. 144, should bemounted in the two discharge ports - cf.fig. 9.4.a - and tightened with the pre-scribed torque moment.

S Before the slide bearings, pos. 111, arefitted the guide pins, pos. 112, should bemounted as illustrated in fig. 9.5.a.

Fig. 9.5.a

112

40

112111

The guide pin is only knocked 5 mm into thehole in the slide bearing and it is straightenedup to stand at a right angle to the end plate.

When placing the slide bearing on the com-pressor block, turn the bearing for the guidepin to reach the 6 mm hole in the dischargeport - as illustrated in fig. 9.5.b.

Fig. 9.5.b141 111140 112 10112

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

70 0178-250-EN

Fig. 9.5.c141 107 8 5 140

The guide pin, pos. 112, will at the same timebe pressed into the slide bearing, pos. 111,and it is thereby ensured that the slide bear-ing is positioned correctly.

Mounting of the rotors

Before the rotors, pos. 110, are mounted inthe rotor housing it is recommended that theVi-slide, pos. 190, is fitted in the rotor hous-ing to support the rotors.

Fig. 9.6

MaleFemale

8

8

8

The rotors are marked with a number on theend surface that faces the suction end of thecompressor.

The marking must have the same number onboth rotors and the catching between the ro-tors 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 maleand female rotors are positioned in the rotor

housing as indicated on the spare partsdrawing and cast on the end cover pos. 20.

Mounting of covers and bearings

After fitting the rotors in the compressorblock, mount the following:

1. Tighten the suction cover, pos. 20, withthe screws, pos. 26. Mounting must bedone using the staybolts no. 11 mountedas as in fig. 8.2. The suction cover mustbe fastened with the screws, pos. 26, 27,and 28.Remember the O-ring, pos. 21.Check that the slide stop, pos. 190, moveseasily back and forth.

2. Lock the rotors as shown in fig. 9.1.

3. Lubricate the rotor shaft with Molykotegrease.

Press the inner ring of the ball bearing intoplace by using the tools arrangementshown in fig. 9.7.

T0177135_10

110

Fig. 9.7

10 25.2 14

Inner ring for pos. 132

4. As shown in fig. 9.8, the thinnest spacingwasher, pos. 133, from the set of adjust-ment washers is fitted, i.e. the washerwhich is 5.6 mm thick.

5. The ball bearing, pos. 132, is fitted. Theoutermost inner ring is not yet to bemounted.

0178-250-EN 71

6. Fit the inner covers, pos. 153, without theO-rings, pos. 154.

7. Mount the cross bar, pos. 46, with thescrews, pos. 47. The adjustment screw,pos. 44, should be mounted but not tight-ened.

8. Dismantle the locking tools mentioned initem 2.

9. Mount the balance pistons, pos. 134/137,in the suction side and tighten with thescrews, pos. 113. Push the spacer rings,

pos. 135/138, into place. They shouldreach the retaining pins, pos. 136/139.

T0177135_12

11010 141 133 132 44 45

Fig. 9.8

111 153 46

72 0178-250-EN

Adjusting the axial play of therotors

After mounting of the bearings, as describedin the previous section, the axial play of therotors can be adjusted with the tools arrange-

ment shown in fig. 9.8.The dial meter measures on balance pistonpos. 134 for the female rotor and on pos. 137for the male rotor.

Start by adjusting the female rotor.

T0177135_9

20 134/137 111

Female Male

110Fig. 9.9 22 25.1 20 21 50

19 23 24

Adjustment

9.1 Use the tools arrangement in fig. 9.8.By tightening nuts no. 25.1 until coverno. 20 touches pipe pieces no. 21 thespring will push the rotor up againstthe discharge port at the other end ofthe compressor frame.Leave adjusting screw pos. 44 loose.Position dial meter on 0.

9.2 Now screw in adjusting screw pos. 44at the female rotor and tighten with 32Nm.Read the dial meter and note thedifference that indicates how much therotor can be moved axially.

a: This movement may, f.inst., be 0.430mm.

b: As the correct movement must bebetween 0,13 and 0,22 mm the me-dium figure to be used is 0,175 mm,which is deducted from the measuredvalue that in example point a amountsto:

0,430 -- 0,175 = 0,255 mm

9.3 From the set of adjusting shims selectthe shim that is 0,255 mm thicker thanthe one that was first mounted andwhich in the example pt. 3 was 5,600mm. The thickness is stamped on theshims. In the example given thismeans: 5,600 + 0,255 = 5,855. Theshim that measures 5.85 is thenchosen in accordance with thisexample.

9.4 By inserting the new shim as shown infig. 9.7 (pos. 133) and repeat theadjustment mentioned in point 9.2 it ismade sure that that the movementkeeps within the tolerances mentionedin point 9.2 (0.13 and 0.22 mm), andthe exact measure is noted for laterapplication -- (see section 9.10).

The exact measure for the female rotormay, f.inst., be 0,171 mm after the ad-justment mentioned in sections 9.3and 9.4. In order to be able to insertthe shims, proceed as follows:

-- Loosen adjusting screw pos. 44.

0178-250-EN 73

-- Dismantle toggle pos. 46.

-- Remove inner cover pos. 153.

-- Remove by hand the outer ring of theball bearing with the balls.

Do not dismantle the remaining parts in thetools arrangement.

9.5 The adjustment completed, loosen ad-justing screw pos. 44 and toggle pos.46 and dismantle inner cover pos. 153.

9.6 With tools as shown in fig. 9.5 mountthe outermost inner ring, and fastenthe thrust washer, pos. 114, by meansof the screw, pos. 115.Tighten screw with 70 Nm.

9.7 Insert the cylindrical steel roll, pos.155, in the groove of the outer ring ofthe ball bearing turning it so that it thegroove faces upwards.

9.8 Position the O-ring, pos. 154, on theinner cover, pos. 153, and mount toolsno 26 and 27 on the cover.

Replace the inner cover and turn itwith tools until the groove in the covercatches steel roll pos. 155. This is feltas the cover during the turning iscarefully pressed inwards and thencan be pressed in a little further whenthe steel roll is caught by the groove inthe cover.

9.9 Mount toggle and tighten the adjustingscrew with 32 Nm. Check the move-ment of the dial meter once more. Itmust now be within 0.13-0.22 mm.

Should the measure, against allexpectations, not be within the statedlimits, the entire adjusting proceduremust be repeated right from pt. 9.1.

Adjust the male rotor in the same wayas described in points 9.1 to 9.9, but mountthe adjusting tools laterally reversed to thearrangement in fig. 9.8. Tool no. 12 must bemounted on the male rotor so that it gets thesame length as the female rotor.

Final adjustment

When both rotors have been adjusted andthe exact measures noted, we are ready forthe final adjustment of the rotors.First check that the two adjusting screws,pos. 44, are loose.

9.10 The final adjusting measure must be0,02 mm less than the exact measure.If, for inst., the exact measure is 0,171mm for the female rotor as indicated inexample pt. 9.4, the final adjustingmeasure must be:

0,171 -- 0,02 = 0,151 mm

With the adjusting tools mounted onthe female rotor as shown in fig. 9.8and the dial meter set on 0, tightenadjusting screw pos. 44, while readingthe dial meter. The indicator of the dialmeter must move the final adjustingmeasure.

9.11 After the final adjustment lock the ad-justing screw pos. 44 with pointedscrews pos. 45, and the adjustment ofthe female rotor has been completed.

9.12 Next mount adjusting tools at the malerotor as indicated in pt. 9.9.Theadjustment described in sections 9.10and 9.11 is now repeated for the malerotor.

9.13 Check that the rotors are easy to turnby hand.

74 0178-250-EN

10. Capacity indicatorThe SAB 202 compressor is equipped with astandard position transmitter which registersthe compressor capacity and transmits it tothe regulating system.

Function:On moving the capacity slide pos. 200 thespindle, pos. 210, is turned by means of thehelical key groove in the spindle. The spindleturns the transmitter, pos. 350, via themagnetic coupling, pos. 216, which is com-pletely tight so that neither oil nor refrigerantcan pass through it.

Fig. 10.1 Magnetic coupling pos. 216

210

�

�

�

��

�

��

��

�

�

218 217 61 60 219 224 72 73

1 70 71

350

75

74

2

221

223

3

�

�

50

216

�

Dismantling

After cover, pos. 60, has been dismantledfrom cylinder, pos. 50, remove the followingparts:

S By removing screws, pos. 73, thefollowing parts are dismantled:

-- Flange pos. 72

-- Sight glass, pos. 75

-- O-ring pos. 74

-- Supporting ring pos. 224

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

S Dismantle indicator dial, pos. 221, byloosening screw, pos. 223.

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

0178-250-EN 75

Fig. 10.2

from T4161067_22192

A

N

S

S SN

N

SSN

NS

SN

N

NSN

SS

NN

S

AA - A

NS

Magnetic coupling for capacity indication pos. 216

210

218

21760

1

S By dismantling circlip no. 1, as illustratedby fig. 10.2, the inner magnet retainer no.2 and spindle, pos. 210, can be pulled outagainst the magnetic force.

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

A further dismantling of the magnetic cou-pling is usually not necessary. Reference ismade to section 7, however.

Note:We recommend not to insert magnet re-tainer no. 2 in the coupling until spindle,pos. 390, has been fitted as the magneticforce makes it very difficult to dismantlethe parts again.

Assembly

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

Pay attention to the following, however:

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

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

40�

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

S Transmitter, pos. 350, must be fitted onthe sight glass, pos. 75, so that theelectric socket faces downwards when the”0” mark of the sight glass stands rightabove the slot in the indicator dial asdescribed above.

S The retaining pin no. 3 of the transmittermust engage in the slot in indicatorwasher, pos. 221, on mounting sightglass, pos. 75.

76 0178-250-EN

TransmitterUsage:

The position transmitter is used for remoteindication of compressor capacity. Byintegrating electronic limit switches into thecontrol, max. and min. compressor capacitycan be signalled, for instance.

AssemblyThe following drawing shows a positiontransmitter for capacity signalling andindication. The transmitter is fitted in the sightglass with the plug facing vertically down.The transmitter arm is turned by the indicatordial by means of pin no. 3 engaging in theslot of the dial, pos. 221.

T0177063_0

13

No. 3

2

0%2.

2.5

3.

4.5 4.3.5

SPAN + ZERO

100%

Slide position

Volume ratio

Connect the position transmitter to thecontrol system according to the followingtable:

Terminal Used for

12

Signal 0--20 mAPower supply24 V DC +/--20%Earth connection 0VNot used

3

Adjustment:

S Turn the transmitter shaft until the outputsignal is approx. 4mA. On UNISAB II thedisplay shows 0%. Secure the arm oppo-site the 0% mark on the sight glass. Fitsight glass with transmitter on the com-pressor. Make sure that the pin no. 3catches the slot in the indicator dial!

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

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

S With the capacity slide in maximumposition, adjust the output signal to 20mAon the SPAN screw. One turn changes thesignal to 1mA.

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

0178-258-EN

98.05

0178-250-EN 77

System for regulating the capacityand the Vi-ratio of SAB 202

This chapter comprises the following threesystems:

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 ofyour compressor.

1. Regulating of compressorcapacity

The regulating system is a completeassembly as shown in fig. 1. It regulates thecompressor capacity by supplying or drainingoil from the capacity cylinder pos. 50 (seespare parts drawing).

The system is connected to the oil pressureat connecting branch B and the oil returns

from the capacity cylinder through branch A.Branch C is connected to the capacity cylin-der.

The system has built in two throttle valvespos. 72, by which the oil flow and thus thevelocity of the capacity slide can be regu-lated. The throttle valves are meant to createa regular movement of the capacity slide,adapted according to the operating condi-tions.

Turning the spindle clockwise reduces theoil flow.

Solenoid valves:

Pos. 70 is a normal closed valve.

Pos. 71 is normal open meaning that with adead coil it is open for passage.

78 0178-250-EN

72 72

71

NCNO

7074 73

A

C

B

Fig. 1

Function

1. At a constant capacity both solenoidvalves are closed so that pos. 70 is deadwhereas pos. 71 is supplied with current.

2. On regulating to a higher capacity poweris supplied to coil pos. 70 so that bothcoils are now supplied with current. Here-by, pos. 70 opens and puts oil pressure onthe capacity cylinder, and pos. 71 remainsclosed.

3. On regulating to a lower capacity the cur-rent is cut to both coils. Hereby, pos. 70closes and cuts the oil pressure to the ca-pacity cylinder. Pos. 71 opens and lets oilflow away from the capacity cylinderthrough the force of spring pos. 191.

4. By standstill of the compressor the currentto both solenoid valve coils is interrupted.Hereby, the capacity piston is moved to its0% position -- as described in pt. 3, andthe compressor is unloaded at the nextstart-up.

0178-250-EN 79

2. Automatic regulation of theVi-slide

For regulation of the Vi-slide position use thesame type of regulating system that is usedfor regulating the compressor capacity.

This system has been described in the pre-vious section.

In the following functional description the so-lenoid valve in the Vi-regulating system des-ignated as indicated in the dash-and-dot lineframes 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 bya UNISAB II, and they work as follows:

2.1 At 100% compressor capacity:

S Pos. 73 is open and maintains the oilpressure on the Vi-slide piston so that theVi-slide pos. 190 is permanently pressedagainst capacity slide pos. 200. (Seespare parts dwg.). Pos. 74 remainsclosed.

S The Vi-regulating is controlled by the ca-pacity regulating system which, by minorcorrections of pos. 200, adapts the Vi-ratioto the suction- and discharge pressureson the compressor. By this regulation pos.

70 and pos. 71 will receive opening andclosing signals without it leading tochanges in the compressor capacity.

2.2 At reduced compressorcapacity

When compressor capacity is reduced from100%, the following happens:

S With the UNISAB II regulating system thecapacity slide is moved away from theVi-slide, creating a gap between the twoslides.The solenoid valves in question are here-after controlled by UNISAB II so that thecapacity requirement and the Vi-slide posi-tion are controlled by the pressure ratioabove the compressor.

When the compressor capacity increases to100% and pos. 200 reaches pos.190, theregulating systems will return to the functiondescribed in section 2.1.

2.3 When the compressor stopsWhen the compressor stops, the current iscut to all four solenoid valves.

Hereby, pos. 74 and pos. 71 open and allowthe two regulating slides to move to theirminimum position as the slides are pressedaway from each other by the force of springpos. 191.

80 0178-250-EN

3. Manual regulation of the Vi-slide

Instead pf the automatic regulation of theVi-side, as described in section 2, regulationmay be done manually.

However, bitg systems are not found in thecompressor at the same time.

Function

The Vi- slide pos. 190 works as a movablestop for the capacity slide, thus regulating thesize of the discharge port (pos. 140/141) andconsequently the built-in Vi volume ratio ofthe compressor.

The Vi-slide is moved by turning the spindlepos. 180 a preditermined number of revolu-tions.

S By turning the spindle clockwise a lowerVi is obtained.

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

Important

S Adjustment must only take place while thecompressor is at standstill.

S On regulating the Vi-slide to max. or min.position it must not be tightened againstthe end stops. This could impede the mo-

vement of the capacity slide.If, therefore, the Vi-slide is adjusted tomax. or min. position, the spindle must beloosened by turning it 1/2 to 1 turn in theopposite direction from its extreme posi-tion.

For correct adjustment of the Vi-slide positionuse the shown doagrams which are appliedas follows:

For the current refrigerant, type of compres-sor and the evaporating temperature TE fol-low the horizontal line to the intersection withthe curve for the current condensing tempe-rature TC. From this intersection two rea-dings can be made by following the line up ordown:

S Vertically up, reading of the Vi-ratio refer-ring to the scale on the compressor capa-city indicator. Note, whether or not yourcompressor is connected to an economi-zer

S Vertically down, reading of the number ofrevolutions the spindle pos. 180 must beturned anti-clockwise -- from tis extremeposition -- in order to obtain the optimumefficiency at the given temperature condi-tions TE and TC. Note, wether or not yourcompressor is connected to an economi-zer.

0178-250-EN 81

T250824

Adjustment of theVi-slide positionSAB 202SR22R134aR404A/R507R407C

AdjustingTurns on the adjusting screw

Volumeratio Vi

Evaporatingtemperature


of Vi

Single stage

Economizer

Single stage

Economizer

--60

--50

C� --20--25

0 40 60 62

0 20 40

--10

60

302010

0

62

--40

--30

--20

--10

0

10

20TE

40

5550

C�TC

2 3 3.5 4 4.5

2 2.5 3 3.5 4 4.5

Vi

Vi

SAB 202S

R22R134aR404A/R507R407C

T250825

Adjustment of theVi-slide positionSAB 202LR22R134aR404A/R507R407C

Economizer

Economizer

--60

--50

C� --20--25

0

0

40 60 67

20 40

--10

60

302010

0

67

--40

--30

--20

--10

0

10

20TE

40

5550

C�TC

2 3 3.5 4 4.5

2 2.5 3 3.5 4 4.5

Vi

Vi

SAB 202L

R22R134aR404A/R507R407C

AdjustingTurns on the adjusting screw

Volumeratio Vi



of Vi

Single stage

Single stage

82 0178-250-EN

T250826

Adjustment of theVi-slide positionSAB 202SR717

--60

--50

C�

--40

--30

--20

--10

0

10

20TE

--20--25

020 40 60

0 20 40

62

60

100

--10

62

403020

5055

CTC�

R717

2 2.5 3 3.5 4

2 2.5 3 3.5

4.5

4 4.5

Vi

Vi

SAB 202S

--60

--50

C�

--40

--30

--20

--10

0

10

20TE

--20--25

020 40 60

0 20 40

62

60

100

--10

62

403020

5055

CTC�

R717

2 2.5 3 3.5 4

2 2.5 3 3.5

4.5

4 4.5

Vi

Vi

SAB 202S

Adjusting

Turns on the adjusting screw

Volumeratio Vi



of Vi

Single stage

Single stage

Economizer

Economizer

T250827

Adjusting of theVi-slide positionSAB 202LR717

--60

--50

C�

0

0

20 40 60

20 40 60

--20--25

67

100

--10

67

--40

--30

--20

--10

0

10

20TE

403020

5055

CTC�

R717

2 2.5 3 3.5 4

2 2.5 3 3.5

4.5

4 4.5

Vi

Vi

SAB 202L

Adjusting

Turns on the adjusting screw

Volumeratio Vi



of Vi

Single stage

Single stage

Economizer

Economizer

0171-465-EN

00.10

T0177082_0

0178-250-EN 83

Torque moments for screws and bolts

Metric thread (ISO 8.8)

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

0.28

2.1

2.7

0.53

3.9

5.2

0.94

6.8

9.2

2.2

16

22

4.1

30

40

7.0

50

69

11

80

108

15

110

147

23

170

225

30

220

295

38

270

375

52

370

510

68

490

670

Kpm

ft.lbf.

Nm

Metric thread (ISO 12.9)

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

Kpm

ft.lbf.

Nm

0.42

3.0

4.1

0.78

5.7

7.6

1.4

10

14

3.2

23

31

6.1

44

60

10

75

98

16

120

157

23

160

225

34

240

335

44

320

430

55

400

540

76

550

745

100

720

980

Connecting rods with UNF thread

HPO/CMO HPC/SMC 100 SMC 180

UNF

Kpm

ft.lbf.

Nm

5/16”

2.1

15

20

3/8”

4.4

32

43

5/8”

17

130

167

Bolts for top-, side- and end covers

T/CMO T/SMC 100 T/SMC 180

Kpm

ft.lbf.

Nm

M12

85

HPOTop/side End

coverscovers

130

Top/sidecoverscoversEnd Top/side and end

covers

135

M14 M12

200

M14

135

M14

HPC

200

M14

420

M20

Top/side and endcovers

Top/side and endcovers

63 100 95 147 100 147 310

8.6 13.7 13.2 20.3 13.7 20.3 42.7

M

Location

Compressor

B

B

AMR

Serie 52

D

84 0178-250-EN

Bolt on discharge valve

HPO/CMO HPC/SMC 100 SMC 180

Kpm

ft.lbf.

Nm

3.2

23

32

10.2

75

101

35

255

344

Compressor Type Coupling ThreadTorque

Kpm. ft.lbf. Nm

34

55

128

275

34

34

41

55

128

177

245

275

25

40

95

200

25

25

30

40

95

130

175

200

3.5

5.6

13

28

3.5

3.5

4.2

5.6

13

18

25

28

5/16”

7/16”

1/2”

11/16”

AMR225

AMR312S

AMR350S

AMR450S

200

225

262

312

350

375

425

450

HPO/CMO/TCMO

104-108

112-116

186-188

HPC/

SAB

VMY

5/16”

5/16”

3/8”

7/16”

1/2”

9/16”

5/8”

11/16”

SMC/TSMC

Serie52

34

41

25

30

3.5

4.2

5/16”

3/8”

225

262

128

163

Serie52

202 55405.6312 7/16”

ThreadTorque (B)

Kpm. ft.lbf. Nm

B D

13

20

20

13

96

96

147

147

B D B D

130

130

200

200

Type

CouplingTypeCompressor Type

Dependson the sizeof the motor

0178-259-EN

98.05

0178-250-EN 85

Oil separator

31

30

34

30

27A 27B

Fig. 1

Design and operating modeAs illustrated in fig. 1 the oil separator systemconsists of two vessels, of which the upperone is the oil separator. Here the oil is sepa-rated from the discharge gas and led downinto the bottom vessel which serves as the oilreservoir.

Both vessels are firmly connected to pipesthat cannot be cut off one from the other.

Oil separatorAs illustrated in fig. 2, the discharge gas andthe oil from the compressor first pass thedemisters in which the main part of the oil isseparated from the discharge gas anddrained into the oil vessel.

Fig. 2

27A 27B

��

Demister

From the compressor

�

� �

To oil vessel

� �

Fine oil separator elements, pos. 55

However, the discharge gas still contains acertain amount of fine oil drops that are sep-arated as the discharge gas passes the fineoil separator elements (the fine filters)This oil is returned to the compressor in sep-arate pipe systems as described further on inthis section.

As the velocity and specific weight of the gasinfluences the efficiency of the fine oil sepa-rator elements, the units are available in twoexecutions according to the following guide-lines:

86 0178-250-EN

1: Refrigerants HFC and HCFCAll units types SM-LM-SFand LF are deliv-ered with two built-in fine filters and bothconnecting branches, 27A and 27B, areconnected to the refrigeration plant.

2: Refrigerant R717

S All units types LM-SF og LF are delive-red with two built-in fine filters and bothconnecting branches, 27A and 27B, areconnected to the refrigeration plant.

S Unit type SM is delivered with one finefilter and only the open connectingbranch, 27A/27B, is connected to therefrigeration plant.

Normally, the fine oil separator elementsneed not be inspected, but if it is considerednecessary -- e.g. in case an increasing oilconsumption has been observed in the unit --they can be removed through the ends of theoil separator.

In the case of units with two fine filters it isessential that the pressure loss through theoil separator and the piping system is thesame in both passes. This requires that thepipe connections from the oil separator to therefrigeration plant are of equal length and assymmetrical as possible as shown in fig. 1and 2, whereas the asymmetrical principlesketch shown in fig. 3 should be avoided.

Fig. 1 Fig. 2

x x

to condenser to condenser

Fig. 3

Oil return system for fine filterelementWhether the unit is delivered with one or twodischarge stop valves, thus with one or twofine oil separator elements, two oil returnpipes will be fitted on the unit. This may beseen from the piping diagram at the end ofthis book.

Throttle valves pos. 52 are used for adjust-ment of the oil flow through the oil return sys-tems. Their adjustment is just enough tomake the pipelines feel warm during opera-tion. In general, it is recommended not toopen the throttle valves more than 4 turns.At the same time gas bubbles should bevisible in sight glass pos. 53.

0178-250-EN 87

Oil vesselAs already mentioned, the lubricating oil iscollected in the oil vessel. The oil level inthe vessel must always be visible in sightglasses pos. 31. The correct amount of oil inthe unit is stated in a table in a previouschapter 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 compres-sor is started. Remember to switch off theheating elements when oil is drained off theoil vessel before an oil renewal.

Also remember that if the unit has been idlefor a lenghty period without the heating ele-ments being switched on, these must be con-nected at least 8 hours before the unit is setinto operation.

0171-561-EN

95.10

88 0178-250-EN

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

2

3

4 5

1

T0177037_0

No Used for12345

Hot oil inletCooled oil outletWater inletWater outletType plate

6

6 Air purging from water side

For cooling of the oil with water a weldedshell and tube heat exchanger can be deliv-ered of the OWSG/OWRG type.

Design

The oil cooler consists, in principle, of a cy-lindrical jacket with a steel tube insert.

The cooler has oil inlet and outlet sockets inthe jacket, whereas the inlet and outlet forwater are placed in one of the end covers.

The covers are made of cast iron. The tubeinsert consists of two tube plates, each with anumber of tubes welded in.

Baffle plates are placed between the tubes toextend the oil’s passage through the cooler,thus causing the oil to flow across the tubes,

which significantly improves the heat trans-mission from the oil to the cooling water.

The end covers on the cooler are formed toguide the water back and forth a number oftimes in order to ensure an adequate watervelocity.

Oil cooler type OWRG is made of stainlesssteel in two versions for fresh water and seawater, respectively. The type is indicated onthe type plate of the cooler.

Futher, the oil cooler can be manufacturedwith corrosion plugs on the end covers. Tomaintain the corrosion resistance of the twotypes of oil cooler, it is a condition that thepipes never become overheated. Conse-quently, they must not be uncovered.

To avoid this, it is important that:

0178-250-EN 89

S there are no air pockets on the water sideof the oil cooler. Therefore, the oil coolermust be supplied with a purge valve ontop of the cover without connections. Thisvalve may be left out if the water dischar-ge pipe points upwards, so that air canescape together with the water.

S the water velocity through the oil coolershould never be below 1.5 m/sec. Further-more, this high water velocity preventsfouling in the oil cooler.

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

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

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

Application

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

When operating with a cooling tower, rust in-hibitors, algicides and anti-fouling must beadded to the water according to normal prac-tice in connection with cooling tower sys-tems.

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

CleaningFouling or soiling of the water side of thecooler will reduce the heat transfer, and hen-ce the capacity of the cooler.

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

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

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

90 0178-250-EN

Regulating the oil temperature

Open system:

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

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

Instead, the following is prescribed:

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

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

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

Closed system:

OWSG

If this oil cooler is connected in a closedsystem, such as a heat recovery system, thewater flow can still be regulated.

OWRG

Only use the mentioned oil coolers for theprescribed water flow in order to minimize therisk of corrosion as a result of the combina-tion of high temperature and Cl÷ content inthe cooling water.

Therefore, we recommend the use of thesame regulating system as prescribed underOpen system.

0178-261-EN

97.03

0178-250-EN 91

Refrigerant-cooled Oil Cooler type OOSISAB 202

Oil inlet23

Oil outletRefrigerant inlet

4 Refrigerant outletOil draining (oil side)5

6 Oil draining (refrigerant side R717)

1 pass

2 pass

36

63

2

1

1

4

5

T0177101_0/1

5 2

4

1

For cooling of the oil with refrigerant a clos-ed, welded tubular heat exchanger of theOOSI type can be used.

DescriptionThe OOSI oil cooler is an all-welded tubularheat exchanger manufactured in steel. Onthe inside the pipes are equipped with a spe-cial insert in order to improve the heat trans-fer.

The oil flows through the pipes, while the re-frigerant evaporates outside the pipes. It is aflooded system, which is to say that the re-frigerant leaves the oil cooler as partly evap-orated (mixture of liquid and vapour). Thisensures that, under normal conditions, no oilis accumulated on the refrigerant side.

MountingIn order for the condenser to function correct-ly it has to be mounted higher than the oilcooler to ensure a natural circulation of the

refrigerant. The draft on the following page isan example of a common pipe layout.

Ex. 1: The receiver is placed above the oilcooler.

Ex. 2: In case the inlet height (H1) is insuffi-cient a small priority vessel can beplaced between condenser and re-ceiver as shown in the example.

If it proves quite impossible to obtaina satisfying inlet height, a pumpcould possibly be mounted for therefrigerant supply.

Normally, the inlet height (H1) will besufficient when constituting min. 75%of the return height (H2), providedthat the horizontal length of the re-turn pipe is less than 50% of the ver-tical pipe length or if executed min. 1pipe dimension larger.For detailed calculations and choiceof velocity, please see Capacities.

92 0178-250-EN

C

to the receiver

A

D

E

A

Receiver

B

R

B

R

C

Condenser

B

From the compressor

D

Alternativearrangement

Increase 1:300

to the evaporator

H1

H2

or main receiver

Ex. 1 Ex. 2

From the condenser

Decrease 1:300

Oil cooler Oil cooler

The oil temperature, typically within the rangeof 35-60�C, depends on the actual operatingconditions and size of oil cooler.

The choice of size of oil cooler also dependson the chosen oil type. The design oil tem-peratures for the various oil types may beseen from YORK Refrigeration’s Oil Recom-mendation. The set points of the safetyequipment are adjusted accordingly. Normal-ly, the alarmlimit is 10K above the design oil temperaturefor the oil type in question. As to its control,see instruction manual.

Oil temperature regulation

Most units are fitted with an oil temperatureregulating system as described in the fol-lowing section. This system is of special im-portance if, f.inst. during cold periods, thecondensing temperature at times drops be-low 20�C during operation or below 10�Cduring standstill.

Should this oil temperature regulating systemnot be fitted and the condensing temperaturedrops below 10�C at standstill, the liquidsupply line to the oil cooler must be closed.For this purpose, a solenoid valve with a lowpressure drop, closing whenever the com-pressor stops, can be mounted. The valve

reopens once the compressor is workingagain and the oil temperature has reachedmin. 20�C.

Before the compressor is started, the oil inthe pipe system must have a temperature ofat least 10�C. In machine rooms without anyheating it may be necessary to mount a heat-ing rod. Normally, oil separators are standardmounted with heating rods in order to ensurea sufficiently high oil temperature in the oilseparator.

In case several oil coolers are mounted inparallel with a considerably different flow re-sistance due to the pipe lengths etc, a throttlevalve (R) (see Ex. 1) can be fitted in theliquid supply line (A), so that the flow can beequalized between the oil coolers and thusensure the full function of all oil coolers. Donot throttle so much that the oil cooler doesnot remain flooded.

Do not throttle the oil temperature by throt-tling on the liquid supply line (A) or the returnline (B). In that case the oil cooler does notremain flooded, and the return line will onlycontain refrigerant gas.

Hereby, oil will accumulate on the refrigerantside in the oil cooler, causing malfunction anda heavy thermal loading of the oil cooler. Thisincreases the risk of its break-down.

0171-562--EN

95.10

0178-250-EN 93

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

5 1 4

2 3

T0177038_1

No. Used for

1234

Hot oil inletCooled oil outletWater inletWater outlet

Construction

The B-type oil cooler is a stainless steel plateheat exchanger. A V-pattern is moulded intoeach plate together with the inlet and outletholes. The plate heat exchanger is as-sembled by turning the V-pattern upwardsand downwards, alternately. All points of con-tact between the V-patterns are copper-welded. A supporting plate is soldered ontoeither side. Between the support plate fittedwith connecting branches and the first heat-exchanger plate, a row of channels is visible.By means of a welding rod, for instance,check that the V-pattern faces up-wards, pre-venting water from accumulating here. Owingto the principle of its design, the heat ex-changer cannot be stripped down and mustnot be used in R717 plants.

Application

The B-type oil cooler can only be used withfreshwater as cooling agent.

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

Cleaning

Since the oil cooler cannot be dismantled,mechanical cleaning is not possible. It istherefore recommended that the water filterbe fitted before the oil cooler. Cleaning canonly be done with a cleaning fluid. The clean-ing intervals for the cooling water side of theheat exchanger should be determined on thebasis of the water’s hardness and tendencyto deposit scale.For cleaning purposes a weak acid can beused as e.g. a 5% phosphoric acid or, if theheat exchanger is cleaned often, a 5% oxalicacid solution. Rinsing with plenty of purewater is then required to remove any remain-ing acid and dirt.

94 0178-250-EN

Oil temperature regulation

Open system

If the oil cooler is connected in an open sys-tem, ie that it is cooled by means of waterfrom a cooling tower, other fresh water or seawater, the oil temperature must not be regu-lated by altering the water flow through thecooler.

A decreasing water flow could lead to foulingand perhaps clogged-up cooling pipes whichwould lead to corrosion on the pipes.

Instead, the following is prescribed:

S Adjust the oil flow through the cooler bymeans of the temperature regulated three-way valve.

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

Closed system

Only use the B-type oil coolers for the pre-scribed water flow in order to minimize therisk of corrosion as a result of the combina-tion of high temperature and Cl÷ content inthe cooling water.

Therefore, we recommend the use of thesame regulation system as prescribed underOpen system.

0178-277-EN

98.05

0178-250-EN 95

Oil temperature regulating systemSAB 110, 128, 163, 202 and VMY 536

In above screw compressor units, in whichthe oil system is cooled by means of either arefrigerant-cooled oil cooler type OOSI or awater-cooled oil cooler type OWSG, the oiltemperature is usually regulated by a ther-mostatic three-way valve as illustrated infig. 1.

Fig.1

A

This thermostatic three-way valve is used inthe following dimensions for above-mentio-ned compressor units:

Compres-sor unit

Valvedimension

Weldedconnection

SAB 110 RT3 DN 25

SAB 128 RT3 DN 25

SAB 163 RT5 DN 40

SAB 202 RT6 DN 50

SAB 330 RT6 DN 50

VMY 536 RT6 DN 50

The valve dimension can be read from thenameplate on the valve cover.

Function

Valve pos. 46 is fitted in a bypass piping sys-tem as shown in fig. 2:

Fig. 2To the compressor

Oil cooler

From oil receiver

Three-wayvalve

As shown in fig. 3 and 4, it works by letting abuilt-in thermo element, pos. 1, regulate acone, pos. 2, so that cold and warm oil ismixed to the set temperature.

In fig. 3 the thermo element is shown in itscold position, i.e. the flow of cold oil has beenshut off whereas the flow of warm oil is com-pletely unobstructed. Fig. 4 illustrates the op-posite situation in which the thermo elementis in its warm position, hereby shutting off theflow of warm oil.

96 0178-250-EN

During operation the thermo element will ad-just the regulating cone modulatingly so thatthe two oil flows are mixed to the set oil tem-

perature, leaving the valve through connect-ing branch A.

Fig. 3 Fig. 4

BVarm oilfrom oilseparator

C

A

B

A

Cooledoil fromoil cooler

Oil withcorrectmixed temp.

Thermo element in cold position Thermo element in warm position

C

2

1

�

�

Varm oilfrom oilreceiver Cooled

oil fromoil cooler

The thermo element is factory set to maintaina mixed oil temperature of 48�C, allowing fora few degrees’ deviation and it cannot bereadjusted.

Service:

As a rule, it is not necessary to dismantle awell-functioning three-way valve as it doesnot contain any gaskets or wearing parts thatmust be replaced at fixed intervals.

Dismantling:

During dismantling, if any, apply the followingprocedure:

S After the pressure in the piping systemhas been equalized to atmospheric, un-screw the four Allen screws that keep thecover fixed to the valve housing.

S The cover which reaches down into thevalve housing in order to keep the thermoelement in a fixed position, is most easilydismantlled by turning it slightly and then

lift it up by means of a big screwdriver.Watch out ! There may still be oil in thesystem.

S The thermo element can now be extractedfrom the valve housing by hand.

Assembling:

Assembling the valve is done in the reverseorder and attention should be paid to the fol-lowing:

S The O-ring, fitted in the cover, should bereplaced by a new one. See section SpareParts Survey in this manual.

S No sealing ring should be fitted betweenthe inner guideway of the cover and thevalve cone.

S In case the three-way valve does not reg-ulate the oil temperature correctly, thethermo element and cone can be replacedas one entire unit. See section SpareParts Survey in this manual.

0170-017-EN

98.05

0178-250-EN 97

Heating rods, pos. 30

In order to keep the lubricating oil in the com-pressor warm during a period of standstill,the oil reservoir has one or two heating rodsbuilt in. Before start-up, the heating rod (s)must have been activated for 6-8 hours inorder to ensure that there is only a minimumof refrigerant in the oil. When containingmuch refrigerant, the oil will lose its lubricat-ing property and the following operational in-terruptions may occur:

In reciprocating compressors there is aserious danger of vigorous oil foaming whenthe compressor starts as a result of a fallingsuction pressure.

For screw compressors starting with muchrefrigerant dissolved in the oil, there is a riskof the compressor being stopped by the FlowSwitch as the oil will be foaming owing to thefall in pressure through oil pipe and oil filter.

As illustrated on the drawing the heating rodconsists of an electric heating element, incor-porated in a dia. 30 mm pipe. The entire hea-ting cartridge is screwed on tight at theG 1 1/4” thread.

Note:The heating rod must not be energized ifthe oil level in the reservoir is below theminimum mark in the sight glass, and itshould generally be switched off duringcompressor operation. Remember to turnoff the heating rod whenever the crank-case of the reciprocating compressor isopened for inspection.

The following table indicates which heatingrods are used for the various compressortypes. In the spare parts lists for compressoror unit you will find the current part numbers.

Marking: Prod. nr.WattVoltManu. date

L1

L2

NV 50G 1 1/4”

80

50

30 Ø30

Heating rods

PowerWatt

VoltageV

L1mm

L2mm

Used for:

270270270

250230115*

158 175

CMO - TCMO - SMC 100 - TSMC 100

460460460

250230115*

158 175HPO - HPC, SMC 180 - TSMC 180VMY 347 /447 -- 536SAB 110 -- 128 -- 163 -- 202 -- 330

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

0178-266-EN

97.12

98 0178-250-EN

External oil filter

The compressor unit may be executed withan external oil filter, pos. 106, mounted inthe oil pipe between the oil separator/the oilcooler and the compressor. In case of an ex-ternal oil filter, no oil filter will be mounted inthe compressor block.Concerning the construction of the compres-sor unit, please see page 1.

The external oil filter may be designed witheither one or two parallel filters.

The filter housing may be either cast orwelded, but the filter insert is the same forboth.

3 2 1 5 4 6 3

T0177149_9 v5

The filter is a vertical filter in which the oilmust pass the filter cartridge from the insideand out. In this way dirt will accumulate onthe inside of the filter cartridge and thus notfall into the filter housing during a replace-ment of the filter cartridge. The filter is pro-tected against bursting because UNISAB llstops the compressor if the pressure dropacross the filter exceeds 1 bar.

Stopping the compressor at too high a differ-ential pressure happens with a 30 seconddelay as the pressure difference may mo-mentarily exceed 1.0 bar if the compressor isstarted up with cold oil.

Opening the oil filterBefore the filter is opened, new O-rings pos.2 and 5 should be available in case the exist-ing ones cannot be reused. The filter car-tridge pos. 6 cannot be cleaned and reusedbut has to be replaced.

1. Stop the compressor after regulating itdown to minimum capacity.

2. Close the valves on both sides of the oilfilter.

3. Open the ventilating valve/plug at the topof the oil filter carefully in order to equalizethe pressure in the oil filter to atmosphericpressure.

4. Take off the cover at the top of the oil filter.The filter insert can now be removed with-out the use of tools. The oil charge in thefilter housing may be drained through thedrain valve/plug at the bottom of the filterhousing and the filter housing can bewiped clean.

Replacement of the filter cartridgeWhen the filter insert has been removed, it isdismounted by dismantling the hexagon nutat the end of the filter.

Throw away the filter cartridge (it cannot bereused).

Clean the magnetic rod with compressed air.

Position the new filter cartridge by fastening itin the fixture.

0178-250-EN 99

Top up the filter housing with clean refriger-ant oil after positioning the whole filter car-tridge.

The interval for changing the filter cartridgevery much depends on how carefully the re-frigerating plant has been cleaned at the as-sembly.

The first replacement of the filter cartridgecan be expected after a few hours’ operation.

Note:Remember to open the stop valves beforeand after the oil filter before restarting thecompressor.

Unit with double oil filterIf the unit has two parallel filters only, one fil-ter should be used at a time. The filter whichis not being used can be cleaned while thecompressor is working.

By cleaning the oil filter while the compressoris working it is important to be aware of thehigher pressure when the ventilating valve/plug is opened. There may be a lot of oilfoam, especially in the case of (H)CFCplants.

Note:While the compressor is working, bothdischarge valves should be open to avoidthat a hydraulic pressure arises in the filterhousing.

0178-265-EN

97.12

100 0178-250-EN

Oil pump pos. 63

1 2 3

The pump principle

DescriptionThe oil pump, pos. 63, is an internallytoothed gear pump with built-in pressurerelief valve and slide ring shaft sealing. Thepump is fitted with suction inlet facing down-wards and discharge connection and outletfrom pressure relief valve facing upwards.The pump is fitted on an intermediate piecewhich again is mounted on the electric motor.The electric motor is fastened to the oil sepa-rator by means of a small frame.

Start-upIn consideration of bearings and shaft seal-ing, the pump may only run without an oilflow for brief periods. On charging of oil to acompletely empty oil separator it must bemade sure that the pump is filled with oil inaccordance with the instruction: Preparationsbefore Start-up.

ServiceThe oil pump is designed as one unit andshould not be separated. However, the shaftseal is regarded as a wearing part which canbe replaced in case of leakage.

If the shaft seal is going to be replaced, youcan do one of two things:

1. Drain the oil from the oil separator anddismantle all pipe connections to thepump. Dismantle the 2 screws that keepthe intermediate piece and the oil pumptogether. The oil pump can now be pulledout of the intermediate piece and the shaftseal replacement can be carried out on aworkshop table.

2. Dismantle the screws between the inter-mediate piece and the oil pump.Dismantle the screws that keep the motorfixed to the oil separator, at the same timesupporting the motor. The motor with theintermediate piece can now be pulledaway from the oil pump. It may be neces-sary to dismantle the wires leading to theelectric motor in order to remove it suffi-ciently. Now carry out the replacement ofthe shaft seal with the pump still mountedin the pipe system.

Replacement of shaft sealThe easiest way to replace the shaft seal isto follow below procedure:

S Remove the half section of coupling andthe key fitted in the oil pump shaft.

S Dismantle the 3 screws keeping the shaftseal housing fixed to the oil pump.

0178-250-EN 101

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

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

T0177149_0 V3 413 2

S Pull off the shaft seal housing by turningthrust screw no. 2. Replace the O-ringpos. 6, which seals the shaft seal housing,if damaged.

S Loosen the 3 pointed screws in the rotat-ing part of the shaft seal pos. 9, and pull ifoff the pump shaft. In order to remove thefixed part of the shaft seal, bearing pos.10 must first be pressed out with punchno. 5.Remember to dismantle locking ring pos.11. The fixed part of the shaft seal cannow be pushed into the shaft seal hous-ing.

S Tape over the key way in order to protectthe O-ring of the shaft seal and lubricatethe shaft in refrigerating machine oil. Takecare not to damage the lapped surfaceson the shaft seal parts.

S Press the rotating part of the shaft sealover the shaft. On mounting of the shaftseal, press it against the oil pump housingwith a 0.05 mm feeler gauge in between.Tighten the 3 pointed screws in turns.

S Mount the fixed part of the shaft seal in-side the shaft seal housing. Make sure

that the retaining pin in the shaft sealhousing engages in the shaft seal.

S Carefully pull the shaft seal housing overthe shaft and tighten it by means of the 3screws.Remember to mount O-ring pos. 6.

S Carefully mount bearing pos. 10, using thehollow punch no. 6, then mount circlippos. 11.

S Remount key and half-section of coupling.Leave an opening of 3 mm between cou-pling and shaft seal housing.

S Mount oil pump on the intermediate pieceof the motor, while making sure that thehalf-sections of coupling engage correctly.Remount pipe connections and motor.

Checking the rotating direction ofthe motorBefore the initial start-up of the oil pump re-member to check that the oil pump has thecorrect rotating direction. This is done bylooking through the fan shield mounted atthe end of the motor away from the oil pump.Seen through this shield the motor mustrotate clockwise.

102 0178-250-EN

Spare Parts drawings

Pos. Designation1 Pump cover2 Pump shaft3 O-ring4 Pump wheel5. Housing6 O-ring8 Shaft seal housing9 Shaft seal10 Bearing11 Circlip12 Rotor shaft13 Shim14 Shim

Tools

1

3

T0177149_0 V4

2 5 6

4

No. Designation1 Puller2 Screw M10 x 753 Threaded rod M8 x 1504 Nut M85 Punch, solid6 Punch, hollow

0178-264-EN

94.05

0178-250-EN 103

The oil pump filter

T0177149_0/1

1 4 5

3

7

6

2

The filter consists of a filter housing, pos. 1,a flange for the end cover, pos. 2, an insertfor 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, andscrews for the cover, pos. 7.

The purpose of the filter is to protect the oilpump against dirt in the oil.

In order to clean the filter element, close thevalves pos. 60 and 65. Hereafter, open thefilter and take out the filter element.

Note:Some oil will be present in both the filterand the oil pump. This oil may be drainedoff through valve pos. 62.

The filter element can be cleaned in a clean-ing fluid by means of a stiff brush and pres-surized air. Hereafter, refit the filter elementand close valves pos. 62 and 64. At thesame time open valves pos. 60 and 65.

0171-566-EN

95.10

104 0178-250-EN

Safety and monitoring devicesSAB 110, SAB 128/163 Mk3, SAB 202, SAB 283L/283E

Compressor units with relay control or termi-nal strip for remote control are normallyequipped with the following instruments forsafety and operating control, depending onthe specific order.

Safety devices

Pos. 28 Safety valve on oil separatorwith exhaust to the atmosphere.The exhaust line must be routedfrom the engine room out intothe open air.

The SAB 110 compressor has abuilt-in by-pass safety valvewhich, in case of too high differ-ential pressure across compres-sor, will lead gas from the oilseparator to the compressorsuction chamber. The openingpressure the of safety valve isindicated on its name plate.

Pos. 43 Flow control in the oil distributorpipe. A spherical float with apermanent built-in magnet isable to actuate a reed switch inthe float guide. The switch is wi-red up to a timing relay whichwill stop the compressor if theflow control chamber is not filledwith oil within max. 50+10 sec.after start-up, or after 10 sec.without oil during normal opera-tion.

Pos. PAZ1 Pressure cut-out KP1, whichstops the compressor in theevent of the suction pressurefalling below the set value. The

pressure cut-out is not equippedwith a reset, so the compressorstarts again when the pressurehas risen above the differencebetween the setpoints of thepressure cut-out.

Pos. PAZ2 High pressure cut-out KP5. Thepressure cut-out is intended tosafeguard the compressoragainst excessive dischargepressure.

Note: On units to be approved by TÜV(Germany), the KP5 is replacedby a pressure cut-out KP 7ABSwhich has been approved byTÜV. This high pressure cut-outwill stop the compressor in theevent of damage to the cut-outbellow or excessively high dis-charge pressure.

Pos. PDAZ 11 Differential oil pressure cut-out MP55. This pressure cut-outis designed to ensure sufficientlubricating pressure and oilpressure for capacity regulation.The pressure cut-out is equip-ped with a time lag of 45 secs.If the preset differential pressurehas not been obtained by thattime, the compressor will stop.The MP55 is equipped withmanual reset.

Pos. 0376-A12Differential pressure cut-out forcontrol of pressure drop acrossoil filter. If pressure drop acrossoil filter becomes excenssive

0178-250-EN 105

due to impurities, the pressurecut-out will stop the compressorand a pilot lamp will light. Futh-er, the differential pressure cut-out contains a visual indicationof presure drop represented bya green field for permissiblepressure drop and a red field in-dicating excenssive a pressuredrop across oil filter in whichcase the pressure cut-out willstop the compressor.

Pos. TAZ12 Thermostat KP79 with sensor inoil flow control. Designed to sa-feguard against excessive oiltemperature.

Pos. TAZ13 Thermostat KP79 or KP81 withsensor in oil separator.Designed to safeguard againstexcessive discharge gas tempe-rature.

Pos. TC14 Thermostat KP77 with sensor inoil separator. Designed to safe-guard against too low discharge

pipe temperature and hence toolow oil temperature in connec-tion with HLI oil cooling.

Please see section on setting of safety devi-ces for various values.

Monitoring devicesPos. PI15 Suction pressure gauge

(evaporator pressure)

Pos. PI16 Discharge pressure gauge (con-denser/intermediate pressure)

Pos. TI5 Thermometer in oil separator(discharge gas temperature)

Pos. TI6 Thermometer in oil flow control(oil temperature)

Pos. TI7 Thermometer with sensor insuction pipe. Supplied as extra.Used to calculate superheat ofthe suction gas. Superheat isthe temperature differencefound by deducting the tempera-ture read off the suction pressu-re gauge from the temperatureread off the thermometer.

0171-464-EN

94.05

106 0178-250-EN

Refrigeration Plant Maintenance

Operational reliability

The prime causes of operating malfunctionsto the plant are:

1. Incorrect control of liquid supply to theevaporator.

2. Moisture in the plant.

3. Air in the plant.

4. Anti-freezing liquid is missing.

5. Congestion due to metal shavings anddirt.

6. Congestion due to iron oxides.

7. Congestion due to copper oxides.

8. Inadequate refrigerant charge.

Below, some information is given about waysof keeping contaminants out of the refrigera-ting system and at the same time facilitatingday-to-day supervision of the refrigerationplant.

Pumping down the refrigerationplant

Before dismantling any parts of the refrigera-tion plant for inspection or repair, pump-downmust be carried out.

1. Open suction and discharge stop valveson compressor.

2. Close liquid stop valve after condenser orreceiver so that liquid refrigerant can becollected in the tank. Any solenoid valvesin the liquid line should be opened byforce, adjusting the thermostat to its low-est position so that the liquid line can be

bled of refrigerant. Adjust any constant-pressure valves to bring evaporator pres-sure down to atmospheric.

3. Start up the compressor. Adjust regulat-ing system to lower suction pressure.

4. Keep a close eye on the suction pres-sure gauge!When the suction pressure isequal to atmospheric, stop the compres-sor and quickly shut off the discharge stopvalve. Shut off any stop valve in the oil re-turn line.

If the receiver has an extra stop valve inthe feed line, this can be closed; practical-ly the entire refrigerant charge will thenremain shut off in the receiver.

Note:The receiver must not be overfilled! Thereshould be a minimum gas volume of 5%.

5. A slight overpressure should normally re-main in the piping system - this safe-guards the system against the penetrationof air and moisture.

6. Before dismantling parts, the operatorshould put a gas mask on.

Dismantling plant

In order to prevent moisture penetrating intothe refrigeration plant during any repair work,it is advisable to follow the rules below:

1. No component should be opened un-necessarily.

2. When dismantling the system, the pres-sure in the system should be a little higherthan atmospheric.

0178-250-EN 107

3. Note:If the piping system is colder than the sur-roundings, there is a considerable risk ofdamp precipitation (condensation) on coldplant parts. Plant components to be dis-mantled must be warmer than the ambi-ent temperature.

4. No two points in the system should beopened at the same time.

5. Plug, close or at least cover opening withoiled paper or suchlike.

6. Be aware of the possibility of filtersbeing very moist.

Tightness testing and pump-downof refrigeration plantBefore charging refrigerant into that part ofthe refrigeration plant which has beenopened, this should be pressure-tested asdescribed in the section entitled Pressuretesting.

Afterwards, pump down in order to eliminateair and moisture. In this regard, consult thesection on Evacuation.Otherwise, follow the instructions given in theseparate instruction manual on plant compo-nents.

Note:If the oil in the crankcase of the pistoncompressor or the oil separator of thescrew compressor has been in contactwith the atmospheric air for any length oftime, it must be replaced with fresh oil ofthe same grade and make.

0171-627--EN

95.01

108 0178-250-EN

Troubleshooting on the Screw Compressor Plant

Operating condition

Experience shows that pressure and temper-ature variations in a refrigerant system canprovide information about the operating con-dition of the refrigeration plant.

In particular, suction and condenser pres-sures as well as the temperatures of suctionand discharge gases may provide importantinformation as to the operating conditions ofthe plant.

Considerable changes in operating condi-tions can often be produced by only veryslight modifications to variable pressures andtemperatures.

Using the following troubleshooting chart, it ispossible to ascertain the cause of and reme-dy for any operating disturbance.

Using the troubleshooting chartIn the following chart each individual errorpossibility is indicated by a code number inthe left hand column, with the error brieflydescribed in the second column. The thirdcolumn states code numbers for the possiblecauses of the error.

The code numbers refer to the subsequentchart. The section entitled Remedying mal-functions states how to remedy the observederror. See the following example for the cor-rect procedure.

ExampleObserved error: “excessive suctionpressure” - error code 5.Cause codes: 2. (compressor lacks capac-ity) and 48. (safety valve leaky or opens pre-maturely).The entry keys to the subsequentsection are therefore (5,2) and (5,48).

FaultCode

Observed Fault Probable causes

1 Excessive suction pressure 2, 28, 48, 49.2 Suction temperature is too low 31, 32.3 Suction pressure is too low 1, 14, 27, 28, 29, 30, 33, 40, 42.

4 Compressor starts and stops too frequently, atlow-pressure cut-out 1, 14, 27, 28, 29, 30, 33, 39, 42, 49.

5 Excessive suction pressure 2, 48.6 Compressor starts and stops too frequently, at

high-pressure cut-out 38, 41, 43, 44.

7 Excessive condensing pressure 22, 23, 24, 26, 38, 41, 43, 44.8 Condensing pressure too low 2, 22, 23, 24, 26.9 Oil pressure too low 5, 11, 25, 31, 32.

10 Oil temperature too high 13, 18, 19, 20, 37, 48.11 Oil temperature too low 21, 50.12 Excessive pressure drop across oil filter 19.

13 Excessive capacity -- aut. controls out of order 3, 4, 12.14 Insufficient capacity -- aut. controls out of order 3, 4.15 Oil level in the reservoir falls 15, 16, 17.

16 Oil foams vigorously during standstill 31, 32.17 Oil reservoir sweating during standstill 47, 50.18 Abnormal noise from compressor 5, 7, 8, 9, 10, 31, 32, 48, 52.

19 Compressor motor will not start 6, 12, 13, 19, 34, 35, 36, 40, 41, 45, 46, 4720 Compressor runs continuously 2, 3, 4, 42, 48, 49.21 Liquid in the suction line 1, 31, 32.

0178-250-EN 109

1 Compressor has excessive capacity2 Compressor lacks capacity3 Solenoid valve in regulating system

fails to open4 Timer or other automatic control out

of order5 Excessive capacity during

decrease in temperature

6 Capacity regulation not set to 0%7 Loose foundation bolts8 Misalignment of motor and

compressor9 Friction between rotors and housing

or defective bearings10 Loose bolts in coupling

11 Oil pressure regulating valve set toolow

12 Oil pump out of order13 Oil too hot - oil thermostat cut out14 Too much oil circulating in system

(evaporators)15 Filter in solenoid valve in oil-return

line clogged

16 Solenoid valve in oil return out oforder

17 During initial start-up, some of theoil will be led out into the plant

18 A valve in the oil line is beingthrottled

19 Oil filter clogged20 Insufficient water through oil cooler

21 Excessive oil cooling - oil too cold22 Insufficient water or air through

condenser23 Condenser tubing clogged by

sludge or scale24 Cooling water too hot25 Too much water through condenser

26 Water filter clogged27 Filter before valve in liquid or

suction line clogged28 Excessive suction gas superheating29 Freezing-up of thermostatic

expansion valve30 Thermostatic expansion valve has

lost its charge

31 Excess flow through expansionvalve (liquid in suction line)

32 Loose or misplaced sensor33 Solenoid valve in liquid or suction

line not opening34 Oil filter needs cleaning - pressure

cut-out has cut35 Oil pressure too low - pressure

cut-out has cut

36 Oil too hot - oil thermostat has cut37 Oil thermostat set too high38 High-pressure cut-out set too low39 Low-pressure cut-out set too high40 Low-pressure cut-out shut off

41 High-pressure cut-out shut off42 Insufficient charge in plant43 Too much charge in plant44 Air or non-condensable gases in

system45 Fuses blown

46 Thermal relay reset47 Main switch interrupted48 Safety valve leaky or opening

prematurely49 Evaporator soiled or iced up50 Heating element blown52 Liquid in suction line

Code CodeCause Cause

110 0178-250-EN

Remedying Malfunctions

1. Excessive suction temperature

1.2 Inadequate capacity Increase capacity

Safety valve leaky or opening pre-maturely

Check condenser pressure and adjust or repairsafety valve

1.28 Excessive superheating of suctiongas

Check and regulate thermostatic valves on eva-porators

1.48

2. Suction temperature too low

2.31 Liquid in suction line Regulate expansion valves or float valves

2.32 Loose or misplaced sensor Check whether sensors are making good contactwith suction pipe and whether correctly posi-tioned

3. Suction pressure is too low

3.1 Excessive capacity Reduce compressor capacity

3.14 Too much oil in evaporators Draw oil off evaporators

3.27 Filter in liquid line clogged Examine and clean filters in the liquid lines

3.28 Excessive superheating of suctiongas

Regulate expansion valves

3.29 Freezing in thermostatic expan-sion valve

De-ice thermostatic expansion valve with hot wetcloths and run the liquid from the receiverthrough the drying filter

Note:Never add methanol to the system to avoidfreezing, as this will give rise to corrosion andchemical attacks in compressor, etc.

3.42 Insufficient charge Charge more refrigerant into the plant

3.30 Thermostatic expansion valve haslost its charge

Valve fails to open - change the valve

3.33 Solenoid valve in liquid or suctionline not opening

Coil may have blown - change the coil

0178-250-EN 111

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

See point 3.14.1

4.14 See point 3.14

4.27 See point 3.27

4.28 See point 3.28

4.29 See point 3.29

4.30 See point 3.30

4.33 See point 3.33

4.39 Low-pressure cut-out set too high Adjust pressure cut-out

4.42 See point 3.42

4.49 Evaporator soiled or iced up Clean or defrost evaporator

5. Excessive suction pressure

5.2 Compressor lacks capacity Regulate compressor capacity

5.48 Safety valve leaky or opening pre-maturely

Adjust or repair valve

6. Compressor starts and stops too frequently at high-pressure cut-out

See point 7

7. Excessive condensing pressure

7.22 Insufficient water or air throughcondenser

Regulate water supply or clean condenser

7.23 Condenser tubing clogged bysludge or scale

Clean condenser tubing

7.24 Cooling water too hot Procure colder cooling water or reduce compres-sor capacity

112 0178-250-EN

7.26 Water filter clogged Clean water filter

7.38 High-pressure cut-out set too low Adjust pressure cut-out

7.43 Too much charge in plant Draw fluid off into empty vessel

7.44 Air or non-condensable gases insystem

Blow air out at condenser

8. Condensing pressure too low

8.2 Compressor lacks capacity Check whether compressor capacity corres-ponds to load on plant. Regulate water supply tocondenser.

8.25 Too much water through conden-ser

Adjust water supply

9. Oil pressure too low

9.5 Excessive capacity duringdecrease in temperature

Excessive capacity during temperature decrase(run-down) may result in liquid being suckedalong in suction line. This liquid may cause theoil in the oil reservoir to foam vigorously so thatthe oil pressure drops, thus stopping the ma-chine. Before restarting, check whether there isliquid in the oil reservoir.

This liquid must be boiled off using a heatingelement or by heating the oil reservoir with hotwater or steam. The plant must therefore be run-down at reduced capacity.

9.11 Oil pressure regulator set too low The regulator is set to the 2.5 kp/cm prescribedby the manufacturer, but must be checked duringoperations.

9.31 Excess flow through expansionvalve (liquid in suction line)

See comments under point 9.5

9.32 Loose or misplaced sensor Loose sensor on expansion valve may causeliquid throughflow to suction line - see also com-ments under point 9.5.

0178-250-EN 113

10. Oil temperature too high

10.13 Thermostat cut out See section Pressure and temperature settingsfor setpoint.. The reason for the oil overheatingmust be found in the following points

10.18 A valve in the oil line is beingthrottled

Check whether all valves are open

10.20 Insufficient water or refrigerantthrough oil cooler

Check whether valves are open or whetherwater filter or oil cooler need cleaning


Adjust or repair valve

11. Oil temperature too low

11.21 Excessive cooling of oil Regulate oil cooling

11.50 Heating element in oil reservoirout of order

Change heating element

12. Excessive pressure drop across oil filter

12.19 Oil filter clogged Change filter element

13. Excessive capacity - automatic controls out of order

13.3 Solenoid valve in regulating sys-tem fails to open

Change valve or coil

13.4 Timer or other automatic controlout of order

Change or fix

13.12 Auxiliary pump out of order When the compressor stops, the auxiliary pumpmust ensure capacity regulation is set to 0% ca-pacity so that the compressor is ready for re-starting.

Check whether the pump is being energized orwhether pump or motor is out of order.

14. Insufficient capacity - automatic controls out of order

14.3 See point 13.3

14.4 See point 13.4

114 0178-250-EN

15. Oil level in the reservoir falls

15.15 Filter for solenoid valve in oil-re-turn line clogged

Clean filter

15.16 Solenoid valve in oil return out oforder

The oil return line must be hot during operation.

15.17 During initial start-up, some of theoil will be let out into the plant

On HCFC plants, particularly, some of the oil willcirculate in the plant.

When the system is balanced, top up with oil, ifnecessary.

16. Oil foaming vigorously during standstill

16.31 Excess flow through expansionvalve (liquid in suction line)

Check expansion valve

16.32 Loose or misplaced sensor Check sensor positioning

17. Oil reservoir sweating during standstill

17.47 Main switch interrupted If the compressor is stopped and the current in-terrupted at the main switch, any refrigerant inthe oil reservoir will evaporate. As the heatingelement in the oil reservoir has also been cut off,the heat needed for evaporation must be takenfrom the surroundings. The oil will therefore govery cold and will require heating up before re-starting.

17.50 Heating element blown See point 17.47

0178-250-EN 115

18. Abnormal noise from compressor

If any abnormal noise is coming from the compressor, the machine must be stopped immediately,and the cause pinpointed and remedied before restarting.

18.5 Excessive capacity duringrun-down

Excessive capacity during run-down may resultin liquid being sucked along into the compressorsuction line. Therefore, operate at reduced capa-city during run-down.

18.48 Safety valve opens Check opening pressure of safety valve

18.7 Loose foundation bolts Tighten bolts

18.8 Misalignment of motor and com-pressor

Adjust alignment

18.9 Friction between rotors.Friction between rotors anddefective bearings

Do not start the compressor. Open and repair.

18.10 Loose bolts in coupling Stop compressor and tighten bolts

18.31 Liquid in suction line Check and adjust the valves with excessthroughflow

18.32 Loose or misplaced sensor Check sensor positioning

19. Compressor motor will not start

19.6 Capacity regulation not set to 0% See under points 13.3-13.4 and 13.12

19.46 Thermal relay has interrupted Check cause of overloading

19.12 Auxiliary pump out of order See under point 13.12

19.13 Excessive oil temperature See under point 10

19.19 Oil filter clogged Clean oil filter. Reset pressure cut-out

19.34 Differential oil pressure cut-outhas cut

Clean oil filter. Reset pressure cut-out

19.35 Oil pressure too low See under point 9

19.36 Oil too hot See under point 10

19.40 Low-pressure cut-out interrupted The compressor will restart after a rise in suctionpressure sufficient to re-activate the pressurecut-out - see point 3 also.

19.41 High-pressure cut-out interrupted See under point 7

19.45 Fuses blown Check cause and change fuses

19.47 Main switch interrupted Switch power on

116 0178-250-EN

20. Compressor runs continuously

20.49 Evaporator soiled or iced up Clean or defrost evaporators

20.2 Compressor lacks capacity See under point 14

20.3 Solenoid valve in capacity regula-ting system fails to open

See under point 13.3

20.4 Timer or other automatic controlout of order

See under point 13.4

20.42 Insufficient charge on plant Top plant up with refrigerant


See point 10.48

21. Liquid in suction line

21.1 Compressor has excessive capa-city

Reduce capacity

21.31 Excess flow through expansionvalve

Adjust expansion valve

21.32 Loose or misplaced sensor for ex-pansion valve

Check sensor positioning and rectify

0170-151--EN

00.06

0178-250-EN 117

Selecting Lubricating Oil for SABROE Compressors

During the past few years YORKRefrigeration has experienced a number ofproblems with mineral oils, particularly inR717 plants. The problems can be dividedinto two groups:

a: The oil changes viscosityb: The oil decomposes (becomes very black)

The problems have been seen with severalmineral oil brands, often occuring within afew operating hours and resulting in severeconsequences for both compressor andplants.

Following the careful investigation undertak-en by YORK Refrigeration during the pastfew years, it has been decided to introduce arange of synthetic oils which can fulfil the de-mands of modern refrigeration plants.

Mineral oils may continue to be used in re-frigeration plants, providing the lubricatingquality is carefully monitored. For modern,high capacity refrigeration plants, where longlifetime for both lubricants and moving partsis expected, YORK Refrigeration recom-mends the choice of synthetic lubricating oils.

The application areas and specifications forthese synthetic oils can be found in the fol-lowing pages. Installers and/or users are atliberty to choose either YORK Refrigeration’sown or alternative oil brands which fulfil thenecessary specifications.

General

This recommendation only deals with the lu-brication of the compressor. The perfor-mance of the lubricant in the plant (receiver,evaporator, etc.) must, however, also be tak-en into consideration.

Lubricating oils with relatively high viscositiesmust be used to ensure satisfactory lubrica-tion of refrigeration compressors.

To obtain the best lubrication, the oil must:

S Provide the required fluidity at the lowestevaporating temperature encountered inthe plant and at the highest permissibletemperatures in the compressors.

S Provide acceptable fluidity at start-up.

S Provide sufficient oxidation stability (the oilmust be moisture-free when added to thesystem).

S Provide sufficient chemical stability whenused together with the particular refriger-ant.

In addition, the extent to which different re-frigerants dissolve in the oil must be deter-mined, so that the oil return systems, etc. canbe designed to function properly.

Stratification

It should be noted that in certain plants, par-ticularly with HFC and HCFC refrigerants, theoil may stratify into layers in the refrigerantreceivers and evaporators at certain operat-ing conditions and at particular oil concentra-tions.

The Oil recommendation diagrams forSABROE compressors for HFC and HCFCwill indicate the limits for Sabroe oils at whichthis stratification occurs. The oil concentra-tions stated in these diagrams must not beexceeded. This will enable suitable oil rectifi-cation/return systems to be designed to bal-ance with the compressor oil ”carry-over” sothat the maximum concentration is not ex-ceeded.For area A in the diagrams, the max oil con-centration in liquid phase must not exceed

118 0178-250-EN

2%. For the other area, the max. oil con-centration must not exceed 5%. For area B:please contact YORK Refrigeration.

Plants with several different compressortypes/makes

In plants comprising several different inter-connected compressor types and makes, it isstrongly recommended that all compressorsshould use the same type of oil. This is es-sential where automatic oil return systemsare employed.

If it is intended to change the oil from onetype to another, please refer to the Oil chang-ing on SABROE compressors later in thispublication.

Selecting the lubricating oil

There are a number of operating diagramsfor the selection of lubricating oils for Sabroecompressors operating with various refriger-ants. Once the general conditions concern-ing the lubrication of the compressor and oiltype in the plant have been considered, thespecific plant conditions must be takeninto consideration.

Use the Oil recommendation diagrams to se-lect the appropriate oil code number.

The oil code number consists of letters des-ignating the oil type together with the Sabroeviscosity grade number.

Codedesign Oil types

M Mineral oil

A Synthetic oil based onAlkylbenzene

PAO Synthetic oils based onPolyalphaolefin

AP Mixture of A and PAO-oils

E Synthetic ester-based lubricants

In the oil recommendation diagrams for eachrefrigerant and compressor type, it is pos-sible to determine the code number for the

oil best suited to the operating conditions.With this code number, it is possible to se-lect the correct Sabroe oil for the application.The marked area on each side of the sepa-rating line in the diagram shows the zonewhere both oils are useable.

Oil types and oil companiesAs a result of the large number of oil compa-nies world-wide that deals in oil for refrigera-tion plants, it is impossible for YORKRefrigeration to test the many differentbrands of oil on the market. It is our experi-ence, however, that some oil brands duringuse can change character and thus no longerfit the specifications given by the companiesat delivery. We have thus experiencedchanges in the specifications as well as inthe formula and performance without havinghad any information about this from the oilcompany. This makes it very difficult forYORK Refrigeration to give a general ap-proval of the various oil brands.

For this reason YORK Refrigeration has, incooperation with a large recognised oil com-pany, developed a series of three oils whichcover most purposes. YORK Refrigerationhas however, also listed a limited number ofoils which can be supplied through YORKRefrigeration. The typical data of these oilscan be found in the Data Sheet for SabroeOils. We suggest you to use these Sabroeoils, which are delivered in 20 litre pails and208 litre drums and can be ordered using theparts no. listed in the List of Oils.

It is of course possible to use similar oils fromother oil companies, and in this connection,the Data Sheet for Sabroe Oils may be help-ful.

Please note, however, that YORKRefrigeration has not tested any other oilsthan our own brand, and hence we cannot

0178-250-EN 119

answer for the quality, the stability or the suit-ability of other oils for any purposes. The oilcompany in question is thus solely responsi-ble for the quality and suitability of the oil de-livered, and if any problems are experiencedwith these oils in the compressors or in therefrigeration plant, the oil supplier should becontacted directly.

When choosing oils from other oil compa-nies, please pay particular attention to theoil’s effectiveness in the compressor and therefrigeration plant as a whole.

Pay particular attention to the following as-pects:

S Oil type

S Refrigerant type

S Compressor type

S Miscibility between refrigerant and oil

S Operating data for the compressor

� Discharge gas temperature

� Oil temperatures:

Reciprocating compressors:

Normal oil temp. in the crankcase50-60 �C

Max. permitted oil temperature = Set-ting point for alarm

Min. permitted oil temperatures = set-ting point for alarm - if fitted

Screw compressors:

The oil temperature before injection inthe compressor, but after the oil cooler

Max. permitted oil temperature = set-ting point for alarm

Min. permitted oil temperature = set-ting point for alarm

� Condensing pressure

� Evaporating pressure

S Oil viscosity in the compressor duringoperation and under the influence of:

� Refrigerant type and solubility of refrig-erant in the oil

� Operating temperatures

� Vapour pressure in the oil reservoir

Reciprocating compressor: Suctionpressure and oil temperature in thecrankcase.

Screw compressor: Discharge pressureand gas temperature.

S Compatibility with the neoprene O-rings:the aniline point gives an indication of howthe O-ring material reacts to the oil.At an aniline point less than approximately100�C the material tends to swell, and atan aniline point higher than approximately120�C it tends to shrink.

For this reason it is not recommended tochange oil type from M oil to PAO oil as aleakage may occur if the O-rings are notchanged. YORK Refrigeration thereforerecommends using the Sabroe AP68 oilas it reduces the risk of leaks considerablyin this case.

120 0178-250-EN

YORK Refrigeration can supply a calculationshowing the operating data on request.

Attention is drawn to the following viscositylimits during operation:

S Optimum viscosity range(to be designed for) = 20 to 50 cSt

S Max. permissible viscosity =100 cSt

S Min. permissible viscosity =10 cSt(only applicable to HCFC and HFC undercartain operating conditions: 7cSt)

S Max. permissible viscosity during thestarting of the compressor = 500 cSt

Maximum refrigerant concentration in the oilat running condition: 25% - also if viscosityrequirements are met.

Use of mineral oil

Lately we have experienced a number ofproblems with mineral oil, particularly in R717plants. The problems can be divided into twogroups:

a: The oil changes viscosity within a fewoperating hours.

b: The oil decomposes (becomes veryblack) within a few operating hours.

The problems have been seen with severaloil brands and have resulted in severe con-sequences for both compressors and plants.

When using mineral oil, it is thus importantthat the plant is monitored very closely, thatoil samples are taken regularly (every1-2,000 hours) and that the condition/colourof the oil is checked on a weekly basis.

YORK Refrigeration therefore recom-mends only to use M oil at moderate oper-ating conditions - cf. the attached oil rec-ommendation diagrams.

YORK Refrigeration is aware, however, thatseveral customers have been using mineraloils for many years without problems. Thosecustomers who wish to continue using miner-al oils in existing, as well as new, compres-sors can do so, providing the compressortype and operating conditions are similar tothe existing ones (excepting the HPC andHPO series compressors).

YORK Refrigeration has therefore decided tomarket a brand of mineral oil which has beentested and found to be suitable for most gen-eral refrigerating purposes.

If another brand of mineral oil is chosen, thespecifications in the data sheet in this recom-mendation should be followed as a guideline.

Mineral oil can be used in refrigeratingplants, providing the lubricating quality iscarefully monitored. For modern, high capac-ity refrigeration plants, in which a long life-time for both lubricant and moving parts isexpected, YORK Refrigeration recommendsusing synthetic lubricating oils.

A benefit of using the synthetic lubricant oil isa much lower oil carry-over to the plant andlonger intervals between oil changes.A better fluidity at lower temperatures alsogives an easier drainage at the cold parts ofthe plant.

How to use the oil recommendation dia-grams:

To determine the code number, first refer tothe Oil recommendation diagram for the re-frigerant and compressor type and then plotthe proposed operating conditions.

0178-250-EN 121

Example (recip. compressors):Refrigerant: R134aCondensing temp. TC +35�CEvaporating temp. TE --3�C

Please observe !Plants may operate at different conditionsfrom time to time, for example at differentevaporating temperatures due to plantvariations or at different condensing tem-peratures due to seasonal changes.By plotting TC and TE in the oil recom-mendation diagram, this example wouldrequire a No 1 oil. If, however, TEchanges at certain times, e.g. from --3 to+7�C, a No 2 oil should be utilised. But, as+7�C is inside the marked area, the No 1oil can be utilised also at this TE.



-30

-20

-10

-60 -50 -40 -30 -20 -10 0 10 20 30

0

10

20

30

40

50

60

70

1

2

F

140

122

104

86

68

50

32

�

158

TC

14

-4

-22

C�

F�8668503214-4-22-40-58-76TE

C�

� �

R134a

By referring to the Oil recommendation tableplaced at the bottom of each oil recommen-dation diagram, it is possible to select thecode number for the appropriate oil type. In

the example above, a oil code number E5can be selected.

E5 Y

E9 Y

1 2

Code no Area no

In plants which incorporate both screw andreciprocating compressors and where therecommendations indicate the use of differ-ent oil types, please contact YORKRefrigeration for advice.

Changing oil on Sabroe compressors

The oil should never be changed to anothertype without consulting the oil supplier. Nor isit advisable to ”top up” compressors with another oil than the one already used for theparticular plant and compressor.

Mixing different oils may result in operatingproblems in the refrigerant plant and damageto the compressors. Incompatibility betweenthe different oil types may degrade the lubri-cating properties or may cause oil residues toform in the compressor or oil separator or inthe plant. These oil residues can block filtersand damage the moving parts in the com-pressor.

Furthermore, changing the oil from one typeor make to another should only be undertak-en in connection with a careful procedure in-volving the drainage and thorough evacua-tion of the refrigeration plant. Information ona suitable procedure can be obtained fromYORK Refrigeration as well as from a num-ber of oil companies.

122 0178-250-EN

It is imperative that oil is only used from theoriginal container and that both the make andtype complies with the specification for theplant.

Ensure that the original container is sealedduring storage to prevent moisture from theair being absorbed into the oil - many oils,particulary the polyolester oils, are extremelyhygroscopic. Consequently, it is recom-mended that the oil is only purchased in con-tainers corresponding to the amount to beused on each occasion.

If the oil is only partially used, make sure thatit is effectively re-sealed in the original con-tainer and that it is stored in a warm, dryplace. Ideally with nitrogen blanking of the oilto keep the water content below 50 ppm.

Oil drums should, ideally, be ”racked” andmounted with a proper barrel tap to ensurean effective airtight seal.

Oil changing intervals

A list of the recommended intervals forchanging the oil can be found in the com-pressor instruction manual. These are pro-vided for guidance only. The actual intervalbetween oil changes will often be determinedby a variety of operating parameters withinthe plant.

It is strongly recommended to monitor thequality of the oil by carrying out oil analyseswith regular intervals. This will also give agood indication of the condition of the plant.The service can be supplied by YORKRefrigeration or the oil suppliers.

Oil recommendation diagram symbols:

Y : In case of a new plant. Very suitable.

l : In case you wish to change from mineral oil: Max oil concentration in liquid phase at: TE: 2% W

: Max oil concentration in liquid phase: contact YORK Refrigeration: Min suction temperature --50�C: at TE< --50�C superheating must be introduced.

* : Dry expansion systems only. Flooded systems to be considered individually: contact YORK Refrigeration

SH : Suction gas superheat, K (Kelvin)

: Zone in which both oils are useable: Calculation must be performed using COMP1

A

B

C

0178-250-EN 123

Data Sheet for Listed Sabroe OilsTypical data for lubricating oils for Sabroe compressors

Sabroe Viscosity Viscosity Spec. Flash p. Pour p. Anilin Acid no.

code cSt40�C

cSt100�C

Index grav. at15�C

COC�C

�C �Cpoint

mgKOH/g

M1 63 6.4 14 0.91 202 --36 81 0.02

A3 97 8.1 13 0.86 206 --32 78 0.05

AP1 64 9.3 121 0.858 195 --51 121 0.04

PAO3 66 10.1 136 0.835 266 <--45 138 0.03

PAO5 94 13.7 147 0.838 255 <--45 144 0.03

PAO9 208 25 149 0.846 260 <--39 154 0.03

E3Due to the big difference between polyolester-based lubricants from various suppliers it is

E5Due to the big difference between polyolester-based lubricants from various suppliers, it isnot possible to present typical data for these oils. When using another oil brand than the one

E9p p yp g

recommended by YORK Refrigeration, please contact the oil supplier to select the correctoil type

E11oil type.

The listed data are typical values and are intended as a guideline only when selecting a similaroil from a different oil company. Data equivalence alone does not necessarily qualify the oil foruse in YORK Refrigeration’s Sabroe compressors.

124 0178-250-EN

List of part numbers for available Sabroe oils

Oil brand Oil code noPart no.

Oil brand Oil code no.20 litre pail 208 litre pail

Mobil Gargoyle Arctic 300 M 1 (M68) 1231-264 1231-296Sabroe Oil A100 A 3 (A100) 1231-263 1231-262Sabroe Oil AP68 AP 1 (AP68) 1231-257 1231-260Sabroe Oil PAO68 PAO 3 (P68) 1231-256 1231-259Mobil Gargoyle Arctic SHC 228 PAO 5 (P100) 1231-282 1231-283Mobil Gargoyle Arctic SHC 230 PAO 9 (P220) 1231-284 1231-285Mobil EAL Arctic 68 E 3 (E68) 1231-272 1231-273Mobil EAL Arctic 100 E 5 (E100) 1231-274 1231-275Mobil EAL Arctic 220 E 9 (E220) 1231-279

Sabroe H oil E11 (E370) 3914 1512 954 1) 9415 0008 000

1) 18.9 litre pail (5 US gallons)

The oils recommended by the former Stal Refrigeration correspond to the following oils:

Stal Refrigeration oil type Sabroe oil

A Mobil Gargoyle Arctic 300 -- M1 (M68)

B Sabroe Oil PAO 68 -- PAO 3 (PAO 68)

C Mobil Gargoyle Arctic SHC 230 -- PAO 9 (PAO 220)

H Sabroe H oil -- E 11 (E 370)

0178-250-EN 125

R717one-stagereciprocatingcompressors



-30

-20

-10

0

-60 -50 -40 -30 -20 -10 0 10 20

10

20

30

40

50

C�

C

PAO 3 Y

AP 1 l/Y

1Code no Area no

1

F

122

104

86

68

50

32

14

-4

-22

� �

F�68503214-4-22-40-58-76TE

TC

M1 See note

Note: YORK Refrigeration recommends that the use of M oils is restricted to moderately loaded compressors andthat the oil quality is monitored carefully via regular oil analyses.


l : In case you wish to change from mineral oil

126 0178-250-EN

-30

-20

-10

0

-60 -50 -40 -30 -20 -10 0 10 20

10

20

30

40

50

C�

C�



R717two-stagereciprocatingcompressors

1

F

122

104

86

68

50

32

14

-4

-22

F�68503214-4-22-40-58-76TE

TC

�

PAO 3 Y

AP 1 l/Y

1

Code no Area no

M1 See note




0178-250-EN 127

0

10

20

30

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

40

50

60

70

80

C

C�



R717HPO and HPCreciprocatingcompressors

1

F

140

122

104

86

68

50

32

�

158

F�8668503214-4-22TE

104 122

�

176

TC

PAO 5 Y

1

Code no Area no

Please observe: PAO 5 oil is the only oil which can be used in the HPO and HPC compressors.


128 0178-250-EN




-30

-20

-10

0

-60 -50 -40 -30 -20 -10 0 10 20

10

20

30

40

50

C�

1

C�F

122

104

86

68

50

32

14

-4

-22

TC

�

F�68503214-4-22-40-58-76TE

A

A 3 Y

1

Code no Area no

C

Contact YORK Refrigeration

2

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

: Min suction temperature --50�C: at TE< --50�C superheating must be introduced.

AC

0178-250-EN 129

A 3 Y

1

Code no Area no

-30

-20

-10

0

-60 -50 -40 -30 -20 -10 0 10 20

10

20

30

40

50

C�

C�




1

F

122

104

86

68

50

32

14

-4

-22

TC

�

F�68503214-4-22-40-58-76TE

A

A 3 Y

1

Area no

C



A

C

130 0178-250-EN

R134aone-stagereciprocatingcompressors



E 5 YE 9 Y

1 2

Code no Area no

-30

-20

-10

-60 -50 -40 -30 -20 -10 0 10 20 30

0

10

20

30

40

50

60

70

1

2

F

140

122

104

86

68

50

32

�

158

TC

14

-4

-22

C�

F�8668503214-4-22-40-58-76TE

C�

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

0178-250-EN 131

R134atwo-stagereciprocatingcompressors



�

-30

-20

-10

-60 -50 -40 -30 -20 -10 0 10 20 30

0

10

20

30

40

50

60

70

1

C-40

F

86

68

50

32

�

14

-4

-22

-40

140

122

104

158

-70

F�8668503214-4-22-40-58-76TE

-94

�C

TC

E 5 Y

1

Code no Area no


132 0178-250-EN

E 3 Y

1

Code no Area no

-30

-20

-10

0

-60 -50 -40 -30 -20 -10 0 10 20

10

20

30

40

50

C�

C�



R407Cone-stagereciprocatingcompressors

F

122

104

86

68

50

32

14

-4

-22

TC

�

F�68503214-4-22-40-58-76TE

1

B

C

Y : In case of a new plant. Very suitable.: Max oil concentration in liquid phase: contact YORK Refrigeration


B

C

0178-250-EN 133

E 3 Y

1

Code no Area no

-30

-20

-10

0

-60 -50 -40 -30 -20 -10 0 10 20

10

20

30

40

50

C�

C�



R407Ctwo-stagereciprocatingcompressors

F

122

104

86

68

50

32

14

-4

-22

TC

�

F�68503214-4-22-40-58-76TE

1B

C



BC

134 0178-250-EN

-30

-20

-10

0

-60 -50 -40 -30 -20 -10 0 10 20

10

20

30

40

50

C�

C�



R404Aone-stagereciprocatingcompressors

F

122

104

86

68

50

32

14

-4

-22

TC

�

F�68503214-4-22-40-58-76TE

E 3 Y

E 5 Y

1 2

Code no Area no

1

2

C

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

: Zone in which both oils are useble

C

0178-250-EN 135

E 3 Y

1

Area no

-30

-20

-10

0

-60 -50 -40 -30 -20 -10 0 10 20

10

20

30

40

50

C�

C�



R404Atwo-stagereciprocatingcompressors

F

122

104

86

68

50

32

14

-4

-22

TC

�

F�68503214-4-22-40-58-76TE

1

E 3 Y

1

Area no

C

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

Code no

136 0178-250-EN

R410AHPO og HPCreciprocatingcompressors

F

122

104

86

68

50

32

14

-4

-22

TC

�

F�68503214-4-22-40-58-76TE

E 5 Y

1-40

-30

-20

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

0

10

20

30

40

50

60

C�

0 10 20 30 40 50

1

A

A-10

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

Code no Area no



0178-250-EN 137

-30

-20

-10

0

-60 -50 -40 -30 -20 -10 0 10 20

10

20

30

40

50

C�

C�




F

122

104

86

68

50

32

14

-4

-22

TC

�

F�68503214-4-22-40-58-76TE

1

E 5 Y

1

Code no Area no

C

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


138 0178-250-EN

E 5 Y

1

Code no Area no

-30

-20

-10

0

-60 -50 -40 -30 -20 -10 0 10 20

10

20

30

40

50

C�

C�




F

122

104

86

68

50

32

14

-4

-22

TC

�

F�68503214-4-22-40-58-76TE

1

1

Area no

C


0178-250-EN 139

R717screw compressors

Area noCode no

PAO 3 Y

AP 1 l/Y

1



-60 -50 -40 -30-30

-20

-10

0

10

-20 -10 0 10 20

20

30

40

50

C�

C�

1

F

122

104

86

68

50

32

14

-4

-22

�

TC

F�68503214-4-22-40-58-76TE

C

M1 See note



: Min suction temperature --50�C: at TE< --50�C superheating must be introduced.: Calculation must be performed using COMP1.


HLI: Calculation must be performed using COMP1

C

140 0178-250-EN

-30

-20

-10

0

-60 -50 -40 -30 -20 -10 0 10 20

10

20

30

40

50

C



1

R22screw compressorswith journal bearingsor roller bearings

�CF

122

104

86

68

50

32

14

-4

-22

�

F�68503214-4-22-40-58-76TE

�

TC

A 3 Y

PAO 5 Y

1 2*

Code no Area no

A

C

Using the calculating programme COMP1 it is possible to optimize the requirement for suction superheat values(SH) as stated in the diagram. See Oil types and oil companies in this section. Due to the ongoing development oflubrication oils, please contact YORK Refrigeration for an update on the requirement for superheat.





: Calculation must be performed using COMP1

A

C

HLI: Calculation must be performed using COMP1.

SH20

SH5

SH10 SH20 SH10SH5SH25

2

0178-250-EN 141

-30

-20

-10

0

-60 -50 -40 -30 -20 -10 0 10 20

10

20

30

40

50

C



1

R22screw compressorswith roller bearingsonly

�CF

122

104

86

68

50

32

14

-4

-22

�

F�68503214-4-22-40-58-76TE

�

TC

A 3 Y

1Code no Area no

A

C

Using the calculating programme COMP1 it is possible to optimize the requirement for suction superheat values(SH) as stated in the diagram. See Oil types and oil companies in this section. Due to the ongoing development oflubrication oils, please contact YORK Refrigeration for an update on the requirement for superheat.






A

C


SH20

142 0178-250-EN

C�



R134ascrew compressors

Area noCode no

E 5 YE 9 Y

1 2

-20

-10

-50 -40 -30 -20 -10

0

10

20

0 10 20 30

30

40

50

60

70C�

2

F

86

68

50

32

�

14

-4

140

122

104

158

F�8668503214-4-22-40-58TE

TC

1


Using the calculating programme COMP1 it is possible to optimize the requirement for suction superheat values(SH) as stated in the diagram. See Oil types and oil companies in this section. Due to the ongoing developmentof lubrication oils, please contact YORK Refrigeration for an update on the requirement for superheat.

Y : In case of a new plant. Very suitable.SH : Suction gas superheat, K (Kelvin)

: Zone in which both oils are useable: Calculation must be performed using COMP1

SH20

SH5

SH10

SH20

SH30

(See note)

Note: For the compressors type ”S”, ”Rotatune”, ”SAB 81”, ”SAB 83”, and ”SAB 85” only Sabroe oil H is approved.

0178-250-EN 143

E 3 YE 5 YE 9 Y



R404Ascrew compressors

-20

-10

-30-70 -60 -50 -40

0

-30 -20 -10 0 10 C�

10

20

30

40

C�

3

Area noCode no

1 2

F

104

86

68

50

32

14

-4

-22

�

F�503214-4-22-40-58-76TE

-94

TC

B

C




: Min suction temperature --50�C: at TE< --50�C superheating must be introduced.SH : Suction gas superheat, K (Kelvin)

: Zone in which both oils are useable


B

C

1

2 (3)

3 SH15

SH10

SH15

(See note)


(2)

144 0178-250-EN

R407Cscrew compressors



-20

-10

-30-70 -60 -50 -40

0

-30 -20 -10 0 10 C�

10

20

30

40

C�F

104

86

68

50

32

14

-4

-22

�

F�503214-4-22-40-58-76TE

-94

TC

E 3 YE 9 Y

1

Code no Area no

50122

20

68

1B

C


2

1

2



: Min suction temperature --50�C: at TE< --50�C superheating must be introduced.SH : Suction gas superheat, K (Kelvin)

: Zone in which both oils are useable


B

C

SH5

SH5

SH10

(See note)


0178-250-EN 145




R507screw compressors

-20

-10

-30-70 -60 -50 -40

0

-30 -20 -10 0 10 C�

10

20

30

40

C�

1

F

104

86

68

50

32

14

-4

-22

�

F�503214-4-22-40-58-76TE

-94

TC

E 5 YE 9 Y

1

Code no Area no

C


2

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

SH : Suction gas superheat, K (Kelvin): Zone in which both oils are useable


C

2

SH30

SH15

SH5

SH5


(See note)

146 0178-250-EN

List of Major Oil Companies

The oil from the companies listed below are NOT tested by YORK Refrigeration and are there-fore NOT approved by YORK Refrigeration either. The following list reflects the information pro-vided by the companies themselves. The assessment of durability and suitability of specific oilsfor specific purposes are entirely at the companies’ own discretion. Oils tested and approved byYORK Refrigeration can be found in the ”List of part numbers for available Sabroe oils”.

Oil Oil TypesCompany M A PAO AP E

Aral� �

Avia�

BP� � � �

Castrol� � � �

Chevron (UK: Gulf Oil)� � �

CPI Engineering Services� � �

DEA� � � �

Elf / Lub Marine 1� � �

Esso/Exxon� � �

Fina� � �

Fuchs� � � �

Hydro-Texaco� � � �

ICI�

Kuwait Petroleum (Q8)� �

Mobil� � � � �

Petro-Canada�

Shell� � � �

Statoil� �

Sun Oil� �

0171-669-EN

00.01

0178-250-EN 147

Alignment of VMY/SAB 202 unit and coupling

In order to ensure a long life for compressorand motor, the compressor unit and couplingneed to be set up with care.

Misalignment of compressor unit or couplingmay produce stresses and vibrations whichcan be transmitted to the compressorbearings and thus cause major damages.

Note:Before work on the coupling can proceed,it must be ensured that the compressorcannot be started inadvertently. If needbe, remove the motor protection devices.

Vibrations may be caused by the following:

a) Distortion between compressor unit andfoundation.

b) Distortion between compressor and baseframe.

c) Distortion between motor and base frame.

d) Strains from pipe connections betweencompressor and plant.

e) Incorrect alignment of coupling betweencompressor 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 responsiblefor points a-b-c-d-e. The other points must bechecked by the compressor or motor manu-facturer prior to delivery.

The following sections will deal with the indi-vidual points concerning the fitter.

Point a-1 Mounting unit straightonto foundation

When installing the unit straight onto a foun-dation, the foundation should be cast in ac-cordance with the foundation drawingforwarded.

When the foundation has been cast, with theholes marked out as shown, and has set, theunit should be positioned, allowing it to reston sleepers, laid with a spirit level, at asuitable height so that the foundation plate isslightly recessed into the foundation.

Check that the foundation plates are hard onthe base frame - this is best done by tyingthem up to the base frame with steel wire.

The concrete which is cast down around thefoundation bolts should have only minimalwater content to allow it to be rammed welldown around the bolts and up under thefoundation plates. Low water content doesnot cause the hardening concrete to shrink.

10-14 days should pass before tightening thefoundation bolts. Remove the steel wire be-forehand and check that there is no air spacebetween the footplate of the base frame andthe foundation plate. Otherwise, shims mustbe inserted between the plates beforelashing them down.

Point a-2 Mounting vibrationdampers

The units are invariably delivered without vi-bration dampers mounted.

The vibration dampers supplied are markedwith a code.

148 0178-250-EN

Matching codes are indicated in the drawingforwarded to the customer or dealer; theseare valid for the unit in question only.

It is important that the vibration dampers be

fitted correctly, as shown in the drawing for-warded, since the load on the foot-platesvaries.

A

T0177040_0

A

Standard type

Marine type

A -- 1 to 2 mm.

A -- 3 to 5 mm.

Standard type

The machine room or ship floor on which theunit is to be placed must possess thenecessary bearing strength and be levelenough for the difference in height betweenthe foundation plates not to exceed thescope for adjustment on the vibrationdampers, as stated in the positioningdrawing.

The vibration dampers are installed on theunit in their unstressed state while it is sus-pended from the crane; the unit is thenplaced in its final position.

The unit is aligned with the aid of wedgesplaced in the vicinity of the vibrationdampers.

When the unit is horizontal, both longitudinal-ly and laterally, the vibration dampers aretightened exactly enough to release thewedge.

The vibration dampers are intended to com-press between 1.0 and 2.0 mm under the ex-pected load at the corresponding point ofsupport.

To check that the vibration dampers areadjusted for the correct load, make a note ofmeasurement “A” in the unloaded state foreach individual damper. After mounting andadjustment, “A” should be reduced by 1 to 2mm.

When the adjustment is correct, tighten downthe lock nut.

Alignment of the unit against the foundationis now complete.

Marine type

Always fit the vibration dampers directlyunder the feet of the base frame.

Measure the A-measure of the vibrationdampers while unit is still suspended in thecrane. Measure it again once the unit is back

0178-250-EN 149

in its position. The difference (compression)must be between 3 and 5 mm for all vibra-tion dampers.

In case this is not observed liner plates mustbe inserted under the vibration dampers untilabove compression is reached.

Point b) Alignment of compressoron base frame

Check that the compressor feet surfacesmake full contact with the milled-off contactfaces of the base frame.

shiCheck with the fixing bolts loosened. If slipoccurs at one or more resting surfaces, shimup before tightening the bolts. If not shimmedup, there is a risk that the compressor maybe subjected to stresses which will damagethe bearings.

Point c) Alignment of motor onbase frame

Check the resting surfaces of the motoragainst the base frame in the same way asmentioned for the compressor.

Point d) Stress from pipeconnections

To prevent transmission of stresses from pipeconnections between unit and plant, caremust be taken that the pipes are laid so asnot to cause tensile or compression strainsduring expansion or contraction due to tem-perature changes. Steel pipes will expandapprox. 1 mm per metre per 100�C.

We recommend laying the piping as shown inthe sketch with a free length of min. 1.5 m intwo directions which are at right angles toeach other.

min. 1.5 m.

min. 1.5 m.

Connection tocompressor unit

Here a non--re-turn valve maybe fitted in thedischarge pipe

Do not mount pipe hangers close to the com-pressor unit.

On some elevated point on the compressorunit discharge pipe mount a non-return valveto prevent condensed refrigerant fromreturning to the oil separator.

Note:Pipe systems that connect the compressorunit with the remaining refrigeration plantmust be executed in a flexible way in or-der to prevent tensions in pipes and theirconnections.

Point e) Mounting and alignmentof coupling

hen all piping has been connected up to theunit, final alignment between compressor andmotor can be undertaken. See the followingsection.

150 0178-250-EN

Auxiliary tools for couplingalignmentFour sets of liner plates are supplied, eachconsisting of one 3 mm, two 1 mm, three0.25 mm, two 0.15 mm and two 0.1 mmplates to be placed under the motor feet.Four clamps are supplied with each unit, asshown in the sketch. These clamps can beused either to shift the motor sideways or tolift the motor with a view to inserting liners.

In addition, an alignment gauge is suppliedfor the coupling, as shown in the drawing,together with a set of feeler gauges.

Before mounting of coupling carefully cleanmotor and compressor shafts, half-sectionsof coupling, and bushing, if any.Then lubricate all parts in refrigerant machineoil. Do not use products containing anygrease or molybdenumdisulfide.

2

1

T0177059_0

0178-250-EN 151

Mounting and alignment

Be careful when aligning the coupling. Thebetter the initial alignment, the better the cou-pling will be able to absorb the small dis-placements which may arise during opera-tions.

If the coupling discs are changed, the entireset must be replaced at a time.

Note:When being dismantled, the couplingdiscs must be kept together in exactly thesame position in which they are received.

C

T0177120_0/V1

A

X2

Z

a

1

Coupling alignment

The principle of the alignment procedure is tomove the motor so that its shaft forms a con-tinuation of the compressor shaft, but withthe motor shaft 0.05 mm higher than thecompressor shaft. In operation, the compres-sor shaft is lifted, owing to the fact that itrests in slide bearings.

Mounting

1) Dismantle the coupling. Note the placingof bolts, washers and nuts, as these mustbe mounted in the same order again. Tie astring or a piece of thread through one ofthe bolt holes in the coupling discs in or-der to avoid the plates being turned rela-

tive to each other and relative to theflange.

2) Examine both compressor and motor shaftjournals as well as the bores of the hubsto ensure that they are free of burrs.Check that the key fits the shaft and hubexactly.

3) Mount the hubs on the shafts. It is recom-mended to heat the hub in water, oil orover a gentle flame. Do not heat the hubin spots, as this may cause adversestresses. When heated, the hub must im-mediately be placed on the shaft.

On SAB 202 compressors a bushing mustbe applied between compressor shaft andcoupling hub. On mounting adopt the fol-lowing procedure:

152 0178-250-EN

Position the coupling hub with the bushingon top of the shaft as shown in thefollowing drawing.

Compressor

Bushingand shaftmust beflush�

�

with eachother

Tighten the screws on the bushing cross-wise, first to 18 Nm and then to the finaltorque of 35 Nm. The screws must betightened cross-wise and a torque wrenchmust be used.

4) Position motor and compressor, andcheck the distance between the couplingflanges C. This distance is shown in thetables below. Motors with slide bearings orother equipment with end play in the shaftmust be in neutral centre position.

5) Insert the intermediate piece of thecoupling and the coupling discs andtighten the bolts. At the same time, fit thealignment gauge to the coupling flange ofthe compressor. The torque moment isgiven in the following tables.

Avoid mounting the bolts between thecoupling flange on the motor and thecoupling discs until alignment has beencompleted.

The following tables indicate the dimensionaltolerances and torques to be observed.

Table 1. Motor with ball bearings

Max. Variation at 180 � Rotation

Pos. 1 Pos. 2CouplingNo.

Diam. Distance TorqueAmm

Cmm

Horizontalmm

Verticalmm mm

312 198 140 55 0 -- 0.10 0.10 -- 0.20 0 -- 0.10

Nm

Table 2. Motor with slide bearings

Max. Variation at 180 � Rotation

Pos. 1 Pos. 2CouplingNo.

Diam. Distance TorqueAmm

Cmm

Horizontalmm

Verticalmm mm

312 198 140 55 0 -- 0.10

Nm

0 -- 0.100 -- 0.10

0178-250-EN 153

Obtaining parallel shafts on thehorizontal plane

1. Turn the coupling so that the alignmentgauge is in the upper position.

2. Guide the measuring pin (pos. 2) towardsthe coupling part using a 1 mm feelergauge and fix the pin.

3. Turn the coupling 180�. Measure by feelergauges how much the distance from themeasuring pin to the coupling part haschanged. This change is called X.

4. Insert shims of thickness “y” either underboth front feet or both rear feet, tilting themotor at the end desired.

The shim thickness is calculated using thefollowing formula:

y = X �2a

bsee the drawings

b

y

2a = the diameter described by the meas-uring pin when rotated 180�.

b = length between the fastening bolts onthe motor.

The motor can be lifted using the above-mentioned tools.

5. After fixing the motor bolts, repeat themeasurement and compare the result withthe values in the table.

Obtaining parallel displacement forcorrect centre height

Remember that the centreline of the motorshaft must be 0.05 mm higher than thecentreline of the compressor, as the rotorswill lift during operations.

1. Turn the coupling so that the alignmentgauge faces down.

2. Guide measuring pin (pos. 1) towards thecoupling part using a 1 mm feeler gaugeand fix the pin.

3. Turn the coupling 180� and measure theincrease in distance by feeler gauges.This increase is called “Z”.

Z = double the distance between thecentreline of the two shafts in the horizon-tal plane.

4. Lift the motor by placing shims with thick-ness Z / 2 + 0.05 mm underneath all fourfeet.

5. After securing the motor, repeat the meas-urement and compare the results with thevalues in the table.

Obtaining parallel shafts on thevertical planeIt only remains to push and turn the motor atthe level on which it is now shimmed up.

1. Turn the coupling so that the alignmentgauge faces horizontally out to one side.

2. guide both measuring pins towards thecoupling using a 1 mm feeler gauge.

3. Turn the coupling 180� and measure thedeviations using the feeler gauge.

4. Moving and turning the motor sidewayswith the adjusting screws, set the motor sothat the deviations are in accordance with

154 0178-250-EN

the values in the table. Remember that themotor must be secured during each meas-urement.

Final check and assembly1. Tighten the foundation bolts on the motor.

2. Check flange distance “C”.

3. Check the alignment of the coupling onthe horizontal and vertical planes for pos.1 and 2.

4. Fit the bolts between the coupling flangeand coupling discs on the motor andcheck the tightening torque for all thebolts.

5. Fit the outer shell of the coupling guard onthe adaptor plate which is secured on thecompressor shaft seal cover.

Push the inner shell, placed in-side theouter shell, so far towards the driving mo-tor that access to the rotating parts ismade impossible. See below drawing.

T0177045_0

6. Check the coupling alignment once morewhile still warm from operating and withpressure on the plant.

It is strongly recommended that the align-ment method described be used, as it meas-ures the relative position of the shafts directlyand eliminates all possible faults in the coupl-ing flanges.

0171-575-EN

01.03

0178-250-EN 155

Key to Piping Diagrams/Component List

CS Screw compressor

OS Oil separator

M Electric motor

EC Electronic control system

240 Coupling

_______________ S _________________

PT1 Pressure transducer(suction pressure)

PT2 Pressure transducer(discharge pressure)

PT3 Pressure transducer(oil pressure after oil filter)

PT4 Pressure transducer(oil pressure before oil filter)

PT5 Pressure transducer(oil pressure after oil pump)

TT5 Temperature transducer(discharge gas temperature)

TT6 Temperature transducer(oil temperature in flow control)

TT7 Temperature transducer(suction gas temperature)

GT8 Position transmitter (capacityslide)

GT9 Position transmitter (Vi slide)

PAZ10 Safety pressure cut-out(for TÜV, SDM and SA only)

PAZ1 Low-pressure cut-out(only for classified systems)

PAZ2 High-pressure cut-out

PDAZ3 Differential pressure cut-out(pressure drop across oil filter)

TI5 Thermometer(discharge gas temperature)

TI6 Thermometer (oil temperature)

TI7 Thermometer (suction gas tem-perature) - only if specially or-dered

PDAZ10 Oil pressure difference cut-out(oil pressure - discharge pressure)

PDAZ11 Oil pressure difference cut-out(oil pressure - suction pressure) -for classified systems only

TAZ12 Thermostat(oil temperature in manifold)

TAZ13 Thermostat(discharge gas temperature)

TC14 Thermostat(pilots solenoid valve pos. 82)

PI15 Suction pressure manometer

PI16 High-pressure manometer

PDI17 Oil difference manometer

FT18 Level switch

YY1 Double acting, four-way solenoidvalve -- unload capacity

YY2 Double acting, four-way solenoidvalve -- load capacity

YY3 Double acting, four-way solenoidvalve -- volume ratio/increase

YY4 Double acting, four-way solenoidvalve -- volume ratio/decrease

SC1 Throttle valve

SC2 Throttle valve

SC3 Throttle valve

SC4 Throttle valve

156 0178-250-EN

BP Throttle valve -- by-pass

LIT1 Oil level transmitter

19 Compressor safety valve

20 Suction stop valve

21 Non-return valve

22 Flanged joint discharge pipe -compressor

23 Suction filter built into compressor

23a External suction filter

24 Service valve - air purge valve

25 Oil separator

26 Non-return valve in outlet pipefrom oil separator

27 Stop and non-return valve in out-let pipe from oil separator

28 Safety valve - the unit

29 Change-over valve for doublesafety valve

30 Immersion heater in oil separator

31 Oil level indicators (2 pieces)

32 Oil cooler OOSI (refrigerant-cooled)

33 Oil cooler (water-cooled)

34 Stop valve for oil purging (oil side)

35 Stop valve for oil purging(refrigerant side)

36 Oil outlet branch to oil cooler/filter

37 Oil branch to pump suction end

38 Stop valve before oil filter

39 Oil filter

40 Oil inlet from pump

41 Non-return valve built into oil filter

42 Stop valve after oil filter

43 Combined flow control andoil distributing manifold

44 Check valve, rotor lubrication

45 Nozzle in injection pipe for rotors

46 Thermostatically-controlled 3-wayvalve for oil temperatureregulation

47 Service valve for oil drainage

48 Oil purge valve on oil filter

49 Thermostatic water valve forwater-cooled oil cooler

50 Stop valve

51 Oil filter

52 Nozzle/throttle valve

53 Oil level indicator

54 Stop valve

55 Oil separation element(fine separation)

56 Non-return valve

57 Hand-regulated valve

58 Temperature regulated main valve

59 Oil receiver

60 Stop valve

61 Oil filter

62 Oil charging valve

63 Oil pump

64 Stop valve for air purging of pump

65 Stop valve

66 Non-return valve for oil charging

67 Solenoid valve (NC) - open duringprelubrication

68 Stop valve

69 Non-return valve

70 Solenoid valve (NC) - capacityregulation min. --> 100%

0178-250-EN 157

71 Solenoid valve (NO) - capacityregulation 100 -> min.%

72 Throttle valve for regulation ofslide velocity

73 Solenoid valve (NC) - capacityregulation min. --> 100%

74 Solenoid valve (NO)

75 Non-return valve

76 Three-way non-return valve

80 Stop valve

81 Liquid refrigerant filter

82 Solenoid valve (NC)

TC83 Liquid injection valve TEAT

84 Stop valve

90 Oil supply to bearings atdischarge end

91 Oil supply to shaft seal and bear-ings at suction end

92 Oil injection in compressor

93 Oil return from capacity regulation

94 Oil to and from regulating cylinder

95 Liquid supply for HLI coolingVi 4.0

96 Liquid supply for HLI coolingVi 2.6

97 Economizer connection

98 Oil connection from flow switch

99 Oil to and from Vi regulation(only by auto-Vi)

100 Oil return from fine oil separator

101 Bypass throttle valve at suctionstop valve

102 Non-return valve

103 Stop valve

104 Nozzle

105 Flow switch

106 External oil filter

107 Oil filter for units with full flowoil pump

108 Oil regulating valve

110 Stop valve

TC111 Thermostatic valve


113 Liquid filter

114 Stop valve

115 Stop valve for oil purge

116 Economizer vessel

120 Stop valve

122 Main valve


124 Stop valve for oil drainage

125 Safety valve

126 Float valve

127 Stop valve

128 Stop valve


130 Stop valve

131 Stop valve

132 Liquid filter

PI139 Oil pressure manometer

140 Stop- and non-return valve

141 Main valve

142 Pilot valve

143 Solenoid valve

144 Stop valve

145 Float valve

158 0178-250-EN

147 Liquid filter

148 Stop valve for oil purge


150 Stop valve

151 Safety valve

152 Solenoid valve

153 Stop valve

154 Stop valve

160 Stop valve

200 Gas-powered stop valve


202 Stop/non-return valve

203 Non-return valve in discharge pipe

204 Stop valve after oil separator

205 Filter

206 Nozzle

207 Solenoid valve (NO)


FT209 Oil level switch in oil separator


211 Stop valve

212 Service valve - air purge valve


214 Filter

215 Non-return valve (5 bar)

220 Compressor protecting valve(main valve)

221 Compressor protecting valve(pilot valve for pos. 220)

222 Filter in economizer pipeconnection

223 Brake motor for capacity slide

224 Three-way solenoid valve

225 Oil return pump

226 Solenoid valve for baby slide (NC)

227 Quick closing oil drain valve

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

0171-466-EN

94.05

0178-250-EN 159

Ordering Spare Parts

When placing an order for spare parts,please state the following:

1. Shop No.

All compressors are fitted with an identifica-tion plate, which states the type and shop no.of the compressor and indicates what refrig-erant is to be used.

2. Part No.

Spare parts drawings and parts lists insertedin an instruction manual identify spare partswith the following:

a) Spare part no. -- which is a referencenumber to facilitate finding a part in thedrawing and cross-referencing in the partslist or vice versa.

b) Designation of the part.

c) Part no. -- a 7-digit number which refers toSABROE’s stores.

When you order spare parts, please alwaysadvise at least the designation and part num-

ber. If you are in any doubt, add the sparepart no. too.

3. Forwarding instructions

When ordering spares, please advise the for-warding address, and the address to whichthe invoice should be sent. If appropriate,please state the name of your local bank, theway in which you want the goods transportedand required delivery date.

4. Classification certificate

If you require a certificate from a Classifica-tion authority, please mark the orderappropriately, as the inspection and issuingprocedures take extra time and incur extraexpenses.

5. Quotation No.

If a quotation no. has been given during earli-er correspondence, please refer to this whenplacing your order -- it will help us to identifyand execute your order quickly.

160 0178-250-EN

Spare Part Sets for Screw Compressor and UnitTypes: SAB 110 - 128 (HR) - 163 (HR) - 202 - VMY347/447 and VMY 336-436-536

It is always an advantage to have a stock of spare parts for both compressor and unit. In thisway the customer or a YORK Refrigeration service engineer is able to carry out the necessaryreplacements without wasting time waiting for new spare parts to arrive.

On contacting YORK Refrigeration’s local representative, you may receive specifications forthe following spare part sets for compressor and unit.

Compressor Block:

S Standard set of sparesThis set contains a representative select-ion of O-rings and gaskets.

S Certificate set of sparesBesides the parts from the standard setof spares this set also includes all bear-ings as well as shaft seal.

Basic Unit:

S Standard set of spares:This set includes the following spare partsfor the below-mentioned components:

-- Oil separator:O-rings, gasket

-- Service valves:Gaskets, O-rings

-- Capacity regulating system:Gaskets, O-rings

-- Pressure outlet stop valve:Gaskets

-- Suction Inlet stop valve:O-rings, sealings rings, gaskets,teflon ring

-- Safety valve:Gaskets, cone, O-rings

-- Oil by-pass system:Gaskets, teflon ring

-- Oil pump:O-rings

S Certificate set of spares:Further to the parts contained in the stan-dard set of spares, this set also includesspare parts for the below-mentioned com-ponents:

-- Coupling:Screws and discs

-- Oil separator:Sight glass, oil separator element,heating element

-- Capacity regulating system:Solenoid valve

-- Safety valve:Spring

-- Solenoid valves:Coils

-- Oil pump:Shaft seal, filter

0171-945-EN

01.05

Documents

Instruction Manual SAB 202