SAB 128R and SAB 163R Mk4 Screw compressor units · Service Manual SAB 128R and SAB 163R Mk4 EN M...

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Screw compressor unitsSAB 128R and SAB 163R Mk4

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Service Manual SAB 128R and SAB 163R Mk4

EN

M anual forSAB 128R and SAB 163R Mk4

The screw compressor and unit can be fittedwith different equipment, depending on theirfunctions and requirements.

Some of these equipment is described in thisinstruction manual even though they are notfitted on your particular unit.

A cross (x) in the following table indicateswhich variants that are fitted on your unit --with the compressor no stated below.

Both compressor and unit are safeguarded.

Instrumentation

Oil cooling

Type of drive

Refrigerant

Compressor no

Designation

Ex-execution

Compressor SAB 128 SAB 163

(Male drive)

R717 Other __________

UNISAB II and manual regulation of the Vi slide

Water-cooled oil cooler OWRF/OWTF

Refrigerant--cooled oil cooler OOSI

UNISAB II and automatic regulation of the Vi slide

Refrigerant injection into discharge pipe BLI

Vessel type HESS

Closed system and vessel type EOSE

Open system and vessel type SVER

Economizersystem(ECO--system)

Service Manual SAB 128R and SAB 163R Mk4

EN

ContentsService Manual SAB 128R and SAB 163R Mk4

04. 02

Contents

This Service Manual contains the following Standard Documents:

1. Introduction

2. Signs and Warnings

3. Safety Precautions

4. Technical Description

6. Technical Data

9. Settings

10. Operating Instructions

11. Maintenance Instructions

12. Fault-finding Instructions

13. Service Instructions

20. Final Disposal

21. Appendices

ContentsService Manual SAB 128R and SAB 163R Mk4

1. IntroductionService Manual SAB 128R and SAB 163R Mk4

1--00173--529--EN

1. Introduction

The purpose of this manual is to provide theservice personnel with a thorough knowledgeof the Rotatune compressor as well informa-tion about:

S Dangers resulting from failure to complywith safety precautions when performingmaintenance tasks.

S What standard service tasks there arefor this equipment and how to safelycarry them out.

This manual describes how to repair rotatunecompressors. It also includes drawings indi-cating the location of the individual compres-sor parts.

To prevent any accidents, assembly and dis-assembly of components should only be car-ried out by authorized personnel.

It is essential that the service personnel fa-miliarize themselves with the contents of thismanual in order to ensure a proper and effi-

cient operation. Sabroe Refrigeration is notliable for damage occurring during the war-ranty period where this is attributable to in-correct operation.

Sabroe Refrigeration’s manual concept in-cludes six standard manuals: Engineering,Operating, Spare Parts, Service, Installationand Commissioning and Transport.

This manual was produced by:

Sabroe RefrigerationChr. X’s Vej 201DK-8270 HoejbjergDenmark

Copyright 2002 Sabroe Refrigeration

This manual must not be copied without thewritten permission of Sabroe Refrigerationand the contents must not be imparted to athird party nor be used for any unauthorisedpurpose. Contravention will be prosecuted.

In the space below you may enter the name and address of your local SabroeRepresentative

1. IntroductionService Manual SAB 128R and SAB 163R Mk4

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2. Signs and WarningsService Manual SAB 128R and SAB 163R Mk4

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2. Signs and Warnings

Table of Contents

Signs and Warnings 2--1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Identification of Sabroe Refrigeration Equipment 2--2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Unit Name Plate 2--4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Compressor Name Plate 2--4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Vessel Name Plate 2--5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Signs in Instructions 2--6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .The Sign: CAUTION 2--6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .The Sign: High Voltage 2--6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .The Sign: The Explosion-Proof Electrical Execution 2--6. . . . . . . . . . . . . . . . . . . . . . . . . . . . .The Label: The Temperature of Tangible Surfaces 2--6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .The Label: Internal Protection 2--7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Other Warning Labels 2--7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Emergency Stop 2--8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Safety at Servicing 2--8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Warnings in Instructions 2--8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .


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Signs and Warnings

The purpose of this document is to describe:

S How Sabroe Refrigeration equipmentcan be identified.

S All warning signs used on equipment de-livered by Sabroe Refrigeration.

S How information important to the safetyof personnel and equipment is presentedin instructions belonging to equipmentdelivered by Sabroe Refrigeration.

This document is intended for all user cat-egories.

This document describes the importance ofthe individual signs which are attached to theSabroe Refrigeration products.

Before a compressor/unit is put into oper-ation, it must be fitted with the warning signsbelonging to the type of compressor/unit inaccordance with the rules and regulations inforce.

This document was produced by:



This document must not be copied withoutthe written permission of Sabroe Refriger-ation and the contents must not be impartedto a third party nor be used for any unautho-rised purpose. Contravention will be pros-ecuted.

Danger !

Risk of injury to personnel and damage toequipment! Always read the safety precau-tions belonging to this equipment beforestarting the installation process. Failure tocomply with safety precautions may causedeath or injury to personnel. It may alsocause damage to or destruction of the equip-ment


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Identification of Sabroe Refrigeration Equipment

All Sabroe Refrigeration equipment can be identified by one or several name plates placed asillustrated in the following drawings:

Fig. 2.1 Rotatune Screw compressor unit, location of name plates

4840--433--2--1

Compressorname plate

Vessel name plate on oil separator


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Fig. 2.2 Location of name plates, unit with OWSG oil cooler

4840--437--2--2

Vessel name plate on oil cooler

Unit pipe system name plate

Fig. 2.3 Location of name plates, unit with OOSI oil cooler

Vessel name plate on oil cooler4840--435--2--3

Unit pipe system name plate


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Unit Pipe System Name Plate

Fig. 2.4 Unit Pipe System Name Plate

The unit pipe system name plate is posi-tioned on the frame - see Fig. 2.2 . The nameplate contains the following information:

S TypeManufacturer’s type designation.

S YearYear of manufacture.

S Identification noIndividual no for identification of suppliedpipe system.

S Design codeIf the unit has been approved by an auth-ority, the design code will be shown here.

S Approval noIf the unit has been approved by an auth-ority, the approval no will be shown here.

S Pressure systemLow pressure side of compressor pipingis referred to as LP.High pressure side of compressor pipingis referred to as HP.

S Fluid/GroupRefrigerant designation according toISO817 or fluid group according to direc-tive 67/548/EEC.

S Max allowable pressureShows max allowable pressure relativeto atmospheric pressure for which thepipe system has been designed.

S Leak test pressure, PTShows the pressure with which the pipesystem has been leak tested.

S Design temperature, TSShows min and max temperatures forwhich the pipe system including compo-nents have been designed.

S CE xxxxThe four digits compose the registrationno of the notified body in charge of theassessment modules for the unit.

Compressor Name PlateFig. 2.5 Compressor Name Plate

The compressor name plate is positioned onthe compressor - see Fig. 2.1. The plate con-tains the following information:

S Compressor noCompressor manufacturing number.



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S Nominal speedShows rotational speed of drive shaft attypical running condition.

S Swept volumeShows swept volume of compressor inm3/h at nominal speed.

S Allowable pressureShows max working pressure of com-pressor.

S Test pressureShows pressure at which compressorenclosure has been strength tested.

Vessel Name Plate

Fig. 2.6 Vessel Name Plate

The vessel name plate is positioned on theshell of the vessel as indicated in Fig. 2.1,Fig. 2.2 and Fig. 2.3. The name plate con-tains the following information:

S Vessel noVessel number stated by SabroeRefrigeration.



S Design codeShows the design code according towhich the vessel was manufactured.

S Approval no/CATShows the approval no of the vessel is-sued by the relevant authority as well asthe category according to PED97/23/EEC, Article 9.

S SideRefers to the columns “Shell” and“Tube”.

S MediaShows the refrigerant designation ac-cording to ISO817.

S Allowable pressure, PSShows min and max pressure relative toatmospheric pressure for which thevessel or vessel part has been designed.

S Allowable temperature, TSShows min and max temperatures forwhich the vessel has been designed.

S VolumeShows volume of the vessel in litres.

S CE xxxxThe four digits compose the registrationno of the notified body in charge of theassessment modules for the vessel.


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In the following section all signs whichmay be found on the equipment are de-scribed. However, the number of signsmay vary from product to product.

Signs in Instructions

The Sign: CAUTIONA CAUTION tag like the one illustrated belowis fixed to the compressor. The sign imposesthe users to read the Safety Precautions sec-tion in the manual before handling, operatingor servicing the compressor and unit.

Before handling, installing, operating orservicing the compressor and unit, readthe Safety Precautions section in theOperating Manual.It is the responsibility of the operator orhis employer that the Operating Manualis always available.This sign must not be removed nor bedamaged in any way.

Antes de manejer, instalar, poner en mar-cha o dar servicio al compresor y la uni-dad, leer la sección Precauciones deseguridad en el Libro de Instrucciones.Es respondabilidad del operarío o de supatrón, que el libro de instruccionespermanezca siempre al alcance de lamano.Esta señal no debe de ninguna manerasuprimirse o dañarse. 2516-297

CAUTION

The Sign: High Voltage

DANGER:HIGH VOLTAGE

Before working on any electrical circuits, turnthe machine Main Disconnect Device “OFF”and lock it. Dismantle the main fuses to thecompressor unit.

Unless expressly stated in applicable SabroeRefrigeration documentation or by a SabroeRefrigeration Field Service Representative,do NOT work with the electrical power “ON”.Any work with the electrical power “ON”should be performed by a Sabroe Refriger-ation Field Service Representative. The cus-tomer and subsequent transferees mustmake sure that any other person performingwork with the electrical power “ON” is trainedand technically qualified.

The Sign: Explosion-ProofElectrical Execution

If the compressor is delivered in an ex-plosion-proof electrical execution, it will to-gether with the Sabroe Refrigeration nameplate be fitted with an Ex-name plate like theone illustrated below.

T2516273_0


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The Label: Temperature ofTangible SurfacesWhen a compressor is working, the surfaceswhich are in contact with the warm dischargegas will also become warm. However, thetemperature depends on the refrigerantsused as well as the compressor operatingconditions. Often the temperature exceeds70°C [158 °F], which for metal surfaces maycause skin burns even at a light touch.

Consequently, the compressors are fittedwith yellow warning labels signalling thatpipes, vessels and machine parts will be-come so hot during operation that your skinwill get burnt if you touch them for one sec-ond or more.

The Label: Internal ProtectionCompressor blocks and units are usually de-livered without any refrigerant or oil.

To protect the compressors against internalcorrosion, they are delivered evacuated of allatmospheric air and charged with Nitrogen(N2) to an overpressure of 0.2 bar [3 psi].

In such cases a yellow label like the oneshown below is affixed to a visible spot onthe compressor.

Påfyldt beskyttelsesgasCharged with inert gasEnthält SchutzgasChargé du gaz protecteurContiene gas protector

N20,2 bar3 PSI

1534-169

Other Warning Labels

Hazardous substance!

Dangerous noise level,use hearing protectors!

Internal overpressure!

Cold surfaces!


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Emergency Stop

Fig. 2.7 Emergency stop on screwcompressor unit

4840--433--2--1

Emergency stop

Safety at Servicing

Before dismantling or servicing a compressoror unit, attention should be paid to the follow-ing points:

S Read the section Safety Precautions inthis manual before opening the com-pressor and other parts of the refriger-ation plant.

S Make sure that the motor cannot start upinadvertently. It is recommended to re-move all main fuses.

S Switch off all electric components on thecompressor/unit before starting the dis-mantling/servicing process.

S Make sure that there is neither overpres-sure nor any refrigerant in the part to bedismantled. Close all necessary stopvalves.

S Use gloves and protective goggles andmake sure to have a gas mask ready.

S Use the prescribed tools and check thatthey are properly maintained and in goodworking condition. In explosion-proofareas, use tools specially suited for thisspecific purpose.

Warnings in InstructionsThis section describes warnings used in in-structions pertaining to Sabroe Refrigerationequipment.

Information of importance to the safety ofpersonnel or equipment is given at three le-vels.

S Danger

S Warning

S Caution

There is an important distinction betweenthese three levels. However, the principle isthe same at all three levels.

Note:Sometimes information is presented in aNote. A Note is used to emphasize infor-mation. It is never used for informationwhich is of vital importance to the safety ofpersonnel and equipment.


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Texts Marked with “Danger!”

The example below shows how informationwhich is of vital importance to the safety ofthe personnel involved is presented.

Danger !

Risk of electric shock! Always turn off themain switch before servicing the unit! Con-tact with high voltage may cause death orserious injury.

Failure to observe information marked withDanger! may cause death or serious injuryto personnel or even to a third party.

Texts Marked with “Warning!”

The example below shows how informationwhich is of importance to the safety of thepersonnel involved or of major importance tothe safety of the equipment is presented.

Warning!

Risk of damage to compressor! Always con-sult your supplier before using a compressorunder operating conditions outside the speci-fied working range.

Texts Marked with “Caution!”The example below shows how informationwhich is of vital importance to the safety ofthe personnel involved is presented.

Caution!

Risk of incorrect viscosity! Always make surethat all oils used are mixable without causingchemical reactions. Chemical reactions mighthave serious effects on the viscosity.

Failure to observe information marked withCaution! may cause damage to the equip-ment.

3. Safety PrecautionsService Manual SAB 128R and SAB 163R Mk4

3--00173--529--EN

3. Safety Precautions

Table of Contents

Safety Precautions 3--1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .General Safety Instructions and Considerations 3--1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Personal Safety 3--1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Work Area Safety 3--2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Tool Safety 3--2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Lifting and Carrying Safety 3--2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Installation and Relocation Safety 3--3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Set-Up and Operation Safety 3--3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Maintenance Safety 3--3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Materials Used with this Product 3--4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .First Aid for Accidents with Ammonia 3--5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .First Aid for Accidents with HFC/HCFC. 3--6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Protecting the Operator as well as the Environment 3--7. . . . . . . . . . . . . . . . . . . . . . . . . . . . .


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Safety Precautions

The purpose of this document is to providegeneral safety precautions for this equip-ment. Additional safety precautions relatingto specific tasks are given in the correspon-ding documents.

The safety precautions are intended for alluser categories.




This document must not be copied withoutthe written permission of Sabroe Refriger-ation and the contents hereof must not beimparted to a third party nor be used for anyunauthorised purpose. Contravention will beprosecuted.

Danger !

Risk of injury to personnel and damage toequipment! Always read the safety precau-tions belonging to this equipment beforestart. Failure to comply with safety precau-tions may cause death or injury to personnel.It may also cause damage to or destructionof equipment.

Warning!

Read related safety precautions before oper-ating the compressor/unit. Failure to followsafety instructions may result in serious per-sonal injury or death.

Important

The safety precautions for this SabroeRefrigeration compressor have been pre-pared to assist the operator, programmer andmaintenance personnel in practicing goodshop safety procedures.

Operator and maintenance personnel mustread and understand these precautions com-pletely before operating, setting up, runningor performing maintenance on the com-pressor/unit.

These precautions are to be used as a sup-plement to the safety precautions and warn-ings included in:

a. All other manuals pertaining to the com-pressor/unit.

b. Local, plant and shop safety rules andcodes.

c. National safety rules and regulations.

General Safety Instructionsand Considerations

Personal SafetyOwners, operators, set-up, maintenance andservice personnel must be aware that con-stant day-to-day safety procedures are a vitalpart of their job. Accident prevention must beone of the principal objectives of the job, re-gardless of the activity involved.

Know and respect the compressor/unit. Readand carry out the prescribed safety pro-cedures.

Make sure that everyone who works for, withor near you fully understands and - more im-portantly - complies with the following safetyprecautions and procedures when operatingthis compressor/unit.


3--20173--529--EN

Observe the safety warnings on the com-pressor/unit.

Use safety equipment. Wear approved eyeor face protection as well as gloves whenworking with parts containing refrigerant.Safety shoes with slip-proof soles can helpavoid injuries. Keep your safety equipment ingood condition.

Never operate or service this equipment ifaffected by alcohol, drugs or other sub-stances or if in a condition which decreasesalertness or judgment.

Work Area Safety

Always keep your work area clean. Dirtywork areas with such hazards as oil, debrisor water on the floor may cause someone tofall onto the floor, into the machine or ontoother objects resulting in serious personalinjury.

Make sure your work area is free of hazard-ous obstructions and be aware of protrudingmachine parts.

Always keep your work area tidy so you areable to escape should a dangerous situationarise.

Report unsafe working conditions to yoursupervisor or safety department.

Tool Safety

Always make sure that the hand tools are inproper working condition.

Remove hand tools such as wrenches,measuring equipment, hammers, etc fromthe compressor/unit immediately after use.

Lifting and Carrying SafetyContact Sabroe Refrigeration in case ofquestions or if in doubt about the proper pro-cedures for lifting and carrying.

Before lifting or carrying a compressor/unit orother parts, determine the weight and size bymeans of eg tags, shipping data, labels,marked information or manuals.

Use power hoists or other mechanical liftingand carrying equipment for heavy, bulky orunwieldy objects. Use hook-up methods rec-ommended by your safety department andfamiliarise yourself with the signals for safelydirecting a crane operator.

Never place any part of your body under asuspended load or move a suspended loadover any other persons. Before lifting, be cer-tain that you have a safe spot for depositingthe load. Never work on a component while itis hanging from a crane or any other liftingmechanism.

If in doubt as to the size or type of liftingequipment, the method and procedures to beused in connection with lifting, contactSabroe Refrigeration before proceeding to liftthe compressor, motor, unit or its compo-nents.

Always inspect slings, chains, hoists andother lifting devices prior to use. Do not uselifting devices which are defective or in aquestionable condition.

Never exceed the lifting capacity of cranes,slings, eyebolts and other lifting equipment.Follow standards and instructions applicableto any lifting equipment used.

Before inserting an eyebolt, be certain thatboth the eyebolt and the hole have the samesize and type of threads. To attain safe work-ing loads, at least 90% of the threaded por-tion of a standard forged eyebolt must be en-gaged.


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Warning!

Failure to follow safety instructions on thispage may result in serious personal injury ordeath.

Installation and Relocation SafetyBefore lifting the compressor, unit or otherparts of the plant, consult the instructionmanual or Sabroe Refrigeration for propermethods and procedures.

An electrician must read and understand theelectrical diagrams prior to connecting themachine to the power source. After connect-ing the machine, test all aspects of the elec-trical system for proper functioning. Alwaysmake sure that the machine is groundedproperly. Place all selector switches in their

OFF or neutral (disengaged) position. The

doors of the main electrical cabinet must beclosed and the main disconnect switch mustbe in the OFF position after the power

source connection is complete.

Before starting the compressor for the firsttime, make sure that all the motors rotate inthe indicated direction.

Set-Up and Operation SafetyRead and understand all the safety instruc-tions before setting up, operating or servicingthis compressor. Assign only qualified per-sonnel instructed in safety and all machinefunctions to operate or service this com-pressor.

Operators and maintenance personnel mustcarefully read, understand and fully complywith all warnings and instruction platesmounted on the machine. Do not paint over,alter or deface these plates or remove themfrom the compressor/unit. Replace all plates

which become illegible. Replacement platescan be purchased from Sabroe Refrigeration.

Safety guards, shields, barriers, covers andprotective devices must not be removedwhile the compressor/unit is operating.

All safety features, disengagements and in-terlocks must be in place and function cor-rectly before this equipment is put in oper-ation. Never bypass or wire around anysafety device.

Keep all parts of your body off the com-pressor/motor/unit during operation. Neverlean on or reach over the compressor.

During operation, pay attention to the com-pressor unit process. Excessive vibration,unusual sounds, etc may indicate problemsrequiring immediate attention.

Maintenance SafetyDo not attempt to perform maintenance onthe compressor unit until you have read andunderstood all the safety instructions.

Assign only qualified service or maintenancepersonnel trained by Sabroe Refrigerationto perform maintenance and repair work onthe unit. They should consult the servicemanual before attempting any service or re-pair work and contact Sabroe Refrigeration incase of questions. Use only SabroeRefrigeration replacement parts; other partsmay impair the safety of the compressor/unit.

Before removing or opening any electricalenclosure, cover, plate or door, be sure thatthe Main Disconnect Switch is in the OFF

position and the main fuses are dismantled.If any tool is required to remove a guard,cover, bracket or any basic part of this com-pressor, place the Main Disconnect Switch inthe OFF position and lock it in the OFF

position. If possible, post a sign at the dis-


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connect switch indicating that maintenance isbeing performed. Dismantle main fuses tothe unit.

Before working on any electrical cir-cuits, place the Main Disconnect De-vice of the compressor/unit in the”OFF” position and lock it. Dismantlethe main fuses to the compressor unit.Unless expressly stated in applicableSabroe Refrigeration documentation orby appropriate Sabroe RefrigerationField Service Representative, do NOTwork with the electrical power ”ON”. Ifsuch express statement or advice ex-ists, work with the electrical power”ON” should be performed by a SabroeRefrigeration Field Service Represen-tative. The customer and subsequenttransferees must make sure that anyother person performing work with theelectrical power ”ON” is trained andtechnically qualified.FAILURE TO FOLLOW THIS IN-STRUCTION MAY RESULT INDEATH OR SERIOUS PERSONALSHOCK INJURY.

DANGER:HIGH VOLTAGE

When maintenance is to be performed in anarea away from the disconnect switch, andthe switch is not locked, tag all start buttonstations with a “DO NOT START” tag.

Adequate precautions such as warning no-tices or other equally effective means must

be taken to prevent electrical equipment frombeing activated when maintenance work isbeing performed.

When removing electrical equipment,number or place labelled tags on the wireswhich are not marked. If wiring is replaced,be sure it is of the same type, length, sizeand has the same current carrying capacity.

Close and fasten all guards, shields, covers,plates or doors securely before power is re-connected.

An electrician must analyse the electricalsystem to determine the possible use ofpower retaining devices such as capacitors.Such power retaining devices must be dis-connected, discharged or made safe beforemaintenance is performed.

Working space around electrical equipmentmust be clear of obstructions.

Provide adequate illumination to allow forproper operation and maintenance.

Materials Used with this Product

Always use Sabroe Refrigeration originalspare parts.

Please note the type of refrigerant on whichthe compressor operates as well as the pre-cautions that must be taken as described inthe following sections:

S First aid for accidents with ammonia

S First aid for accidents with HFC/HCFC.

S Protecting the operator as well as theenvironment.


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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. This means that noperson will remain voluntarily in concentra-tions which are hazardous. Since ammonia islighter than air, adequate ventilation is thebest means of preventing 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 bottleavailable containing a sterile isotonic(0.9%) NaCl-solution (salt water).

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

4. When applying first aid, the personsassisting should be duly protected toavoid further injuries.

Inhalation

1. Move affected personnel into fresh airimmediately and loosen clothingrestricting breathing.

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 orconcentrated 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 orconcentrated vapour

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

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

(wetted with a sterile isotonic (0.9%)NaCl-solution (salt water) to affectedareas until medical advice is available.

0170-008-EN

96.01


3--60173--529--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 contaminatedoil/refrigerant mixtures from electricallyburnt-out hermetic compressors.

0170-009-EN

01.10


3--7 0173--529--EN

Protecting the Operator as well as the Environment

Warning!


Increasing industrialisation threatens ourenvironment. It is therefore absolutely im-perative to protect nature against pollution.

To this end, many countries have passedlegislation 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


3--80173--529--EN

Furthermore, it can be said aboutrefrigerants:

HFC/HCFC

S If released to the atmosphere, haloge-nated refrigerants of the type HFC/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/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.

Ammonia

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

S Even small amounts of ammonia in water(2-5 mg per litre) are enough to 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.

CO2

S CO2 is a gas which can be dischargedinto the open without causing any harm tothe environment. It must be ensured, how-ever, that the eyes and skin of peopleworking in the proximity of the plant arenot exposed to the discharged CO2 as itcan be extremely cold.

S CO2 is a harmless gas, but in closedrooms it can displace the oxygen and thuscause suffocation.

S CO2 is odourless.

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 Plant

If 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.


3--9 0173--529--EN

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.

Lubricating Oils

Warning!

When charging oil, avoid that your skincomes into direct contact with the oil. Direct

contact 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 operatingconditions.

-- 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 refriger-ation 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.

4. Technical DescriptionService Manual SAB 128R and SAB 163R Mk4

4--00173--529--EN

4. Technical Description

Table of Contents

Technical Description 4--1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Areas of Application of Screw Compressor Unit 4--1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Application 4--1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .The compressor must NOT be used: 4--2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Description of the Screw Compressor 4--3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Compressor Description 4--4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Compressor 4--5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Suction Filter 4--7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Non-return Valve 4--7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Oil Filter 4--8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Flow Security 4--9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Systems for Regulating of Compressor Capacity and Vi-ratios 4--10. . . . . . . . . . . . . . . . . . . .1. Regulation of Compressor capacity 4--10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2. Manual Regulation of the Vi-slide 4--10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Compressor Protecting System pos. 220 and 221 4--14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Functional Description 4--14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Oil System 4--15. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Oil Separator for SAB 128R and SAB 163R 4--16. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Fine Separator Element 4--17. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Nominal Oil Carry-over to Plant 4--17. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Oil Level Glass 4--18. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Discharge Stop Valve and Non-return Valve 4--18. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Discharge Stop Valve 4--18. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Non-return Valve 4--18. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Oil Return Valve 4--19. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Function 4--19. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Heating Rods, Element for Oil Heating 4--21. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Oil Cooling System 4--22. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Water-cooled Oil Cooler, Type OWSG/OWRG pos. 33 4--23. . . . . . . . . . . . . . . . . . . . . . . . . .Oil Temperature Regulation 4--25. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Refrigerant-cooled Oil Cooler, Type OOSI 4--26. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Oil Temperature Regulating System 4--28. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Oil pump pos. 63 4--30. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Start-up 4--30. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Checking Rotating Direction of Motor 4--30. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Economizer 4--31. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Refrigerant Injection into Discharge Pipe, type BLI(Booster Liquid Injection), Screw Compressors 4--32. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Safety and monitoring devices 4--33. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Key to Piping Diagrams/Component List 4--35. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Instrumentation 4--41. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .


4--1 0173--529--EN

Technical Description

The purpose of this document is to describethe intended purpose, the physical charac-teristics and the functions of the screw com-pressor units.

This document is primarily intended for de-signers, service engineers, prospective cus-tomers, sales personnel and personnel un-dergoing training.





Areas of Application ofScrew Compressor Unit

Application

To prevent unintentional application of thecompressor, which could injure the personnelor damage the equipment, the following mustbe observed:

S The compressor must only be used as arefrigeration compressor with the number

of revolutions per minute specified bySabroe Refrigeration and the operatinglimits stated in this manual or in a writtenagreement with Sabroe Refrigeration.

S The compressor must only be used withthe following refrigerants: R717.Other refrigerants must only be used inaccordance with Sabroe Refrigeration’sinstructions.All other types of gas must only be usedwith a written permission from SabroeRefrigeration.

S Installation of the compressor in an ex-plosion-prone environment must onlytake place if the compressor is fitted withapproved explosion-proof equipment.The compressor will then be fitted withan EX-name plate, see Fig. 4.1.

Fig. 4.1

T2516273_0


4--20173--529--EN

The compressor must NOTbe used:S For evacuating the refriger-

ation plant of air and mois-ture.

S For putting the refrigerationplant under air pressure inview of a pressure testing.

S As an air compressor.

WARNING

Danger !

Sabroe Refrigeration is not liable for injuriesto personnel or damage to equipment result-ing from using the equipment for other pur-poses than the ones stated above.

Application of Combustion Engines

If combustion engines are installed in roomscontaining refrigeration machinery or roomswhere there are pipes and components con-taining refrigerant, make sure that in case ofleakage the combustion air for the enginecomes from an area in which there is no re-frigerant gas.

Failure to do so will involve a risk of lubricat-ing oil from the combustion engine mixingwith refrigerant; at worst this may lead to cor-rosion and damage of the engine.


4--3 0173--529--EN

Description of the Screw Compressor

Fig. 4.2 SAB 128RScrew Compressor Unit

CSM

OS

Fig. 4.3 SAB 163RScrew Compressor Unit

CSM

OS

Area of Application

The screw compressor unit is intended forhigh pressure operation and booster oper-ation. Since it is designed and constructed asa ready-to-operate unit, all that is required isexternal connections to the plant - suctionline, discharge line, etc.

Design/Construction

A description of the components which formpart of the unit is given below. More detaileddescriptions are included in separate docu-ments for the individual components.

The compressor (CS), the electric motor (M)and the oil separator (OS) are mounted on abase frame. The base frame also serves as afoundation for the other components of theunit.

The electric motor torque is transmitted tothe compressor via a flexible disc coupling.

When describing the individual components,the position numbers stated in the piping dia-gram later in this section will be used.


4--40173--529--EN

Compressor Description

Fig. 4.4 Compressor Block SAB 163R

The screw compressor series includes twocompressors. The compressors are identicalas regards their construction.

The drawing below illustrates how the com-pressor name is made up.

Screw Compressor: SAB 163 R

Rotor diameter

Rotatune

Section 6, Technical Data includes a list oftables indicating weight, dimensions, etc.

The compressor type and version can beread from the name plate shown below.Each compressor is fitted with a name plate.

Similarly, the serial number of each com-pressor has been stamped into the com-pressor block.

Whenever contacting Sabroe Refriger-ation regarding a compressor, pleasestate the compressor serial number.


4--5 0173--529--EN

Compressor

The unit is connected to the suction side viaa stop valve pos. 20, see the piping diagramlater in this section. The discharge gas issent to the oil separator (25) via the dis-charge line.

The Screw compressors have a wide rangeof application in the field of refrigeration.

The capacity of the compressor can be regu-lated automatically from approx. 16% to100% by changing the rotation speed of therotors from 1000 to 6000 rpm by means of afrequency controlled electromotor.

Moreover, the compressor has a built-involume regulating system Vi, by means ofwhich it is possible to regulate manually theinternal volume ratio of the compressor to thepressure ratio of the refrigeration plant. TheVi-regulating system is adjusted manually bymeans of an adjusting spindle on the com-pressor.

When the compressor has been adjustedcorrectly, it will obtain the highest efficiency.

The compressor has two rotors where thedriving rotor, the male rotor, has four lobesand the driven rotor, the female rotor, hassix lobes.

The rotors are constructed with an asym-metrical profile according to SRM licence. Atthe suction end the rotors are provided withroller bearings. The bearings at the dis-charge end consist of a combined set ofroller bearings, assimilating the radial load,and ball--bearings, assimilating the axialload. The axial forces are partly equalized byrotating balance piston mounted on the ro-tors.

The rotor shaft to wich the motor is con-nected is fitted with a shaft seal of the metal

below type. The purpose of this shaft seal isto seal between the interior volume of thecompressor and the atmosphere.

The shaft seal is equipped with multi--pointoil injection for more efficient cooling and lu-brication of sealing surfaces.

The compressor is provided with a largebuilt--in filter preventing dirt particles in therefrigeration plant from penetrating into thecompressor together with the suction gas.

Furthermore, the compressor is fitted with anon--return valve preventing the rotors fromrotating backwards when the power to themotor is cut off. The non--return valve is con-trolled by the compressor internal suctionpressure. Thus the valve is kept open duringoperation without causing unnecessary lossof pressure in the suction gas.

The compressor block is a very compactcontruction with internal oil channels, built--inoil filter and electric flow switch. Thus thenumber of piping connections can be re-duced considerably.

For the purpose of lubricating, cooling andsealing the movable parts in the compressor,large amounts of oil are sprayed into thecompressor compression chamber. The oil istaken from the oil separator. It is separatedfrom the discharge gas when passingthrough the oil separation filters in the oilseparator as described in the followingsection.

As the pressure in the oil separator is thesame as the pressure on the compressor dis-charge side, a stable lubricating pressure forthe bearings, the rotor injection and thecapacity regulating system is obtained.

When starting the compressor a prelubrica-tion pump - mounted on the unit - ensuresthat the unit lubrication system is filled withoil so that the bearings are lubricatedimmediately when the compressor is started.


4--60173--529--EN

Fig. 4.5 Sectional View of Compressor Block

110

160

The rotors, Fig. 4.5, pos. 110, are con-structed with an asymmetrical profile accord-ing to SRM licence. The male rotor has fourlobes whereas the female rotor has six, seeFig. 4.6. The compressors are only availablewith male drive.

Fig. 4.6

Fig. 4.5 shows a sectional view of the com-pressor block. A shaft seal of the slide type,Fig. 4.7, pos. 160, is mounted at the shaftend (driving shaft) of the male rotor.

The shaft seal has a rotating metal bellowand ensures complete tightness between the

compressor housing and the compressorshaft, thus preventing atmospheric air fromentering the compressor.

Fig. 4.7 Shaft seal with multi-point injection

160


4--7 0173--529--EN

Suction FilterThe suction filter is built into the compressorhousing above the rotors, Fig. 4.8, pos. 170.

The purpose of the filter is to collect theimpurities which are led around the refriger-ation system with the suction gas. Experi-

ence has shown that impurities will be col-lected in the filter especially after start-up ofa new plant. The filter must therefore becleaned after 200 operating hours at thelatest, see Section 11, Maintenance.

Fig. 4.8

SECTIONY--Y

260

170

4169--t12_4

Non-return ValveIn the suction filter housing a non-returnvalve is fitted. This valve prevents the returnof the rotors when the compressor stops,Fig. 4.8, pos. 260.


4--80173--529--EN

Oil FilterThe oil filter pos. 470, Fig. 4.9, is a replace-able filter cartridge mounted in the com-pressor block. As the capacity of the filtercartridge is used, the pressure loss acrossthe filter will increase, which will be regis-tered by the two pressure transducers, pos.752 and pos. 753.

It is therefore important to make sure that anew filter cartridge is available before remov-ing the used filter as it is not possible toclean the used filter.

Fig. 4.9

SECTIONG--GM--M

476 470 752 753

4169--t12_4

Fig. 4.10 Drain Valve

46

Before removing the filter cartridge from thecompressor block, stop the compressor andequalize the pressure to atmospheric pres-sure. Furthermore, drain the oil filter hous-ing of oil. This is done by unscrewing thethreaded plug, pos. 46, see Fig. 4.10.

Draining of the oil is best done whilethere is still an excess of pressure in thecompressor.


4--9 0173--529--EN

Flow Security

Fig. 4.11

476

To ensure a continuous lubrication of thecompressor, the compressor block has abuilt-in flow security, Fig. 4.9, pos. 476. For

detailed illustration see Fig. 4.11. The flowsecurity works as described in the following.

The float contains a permanent magnetwhich activates a built-in reed switch. Ifthere is no oil flow through the housing, thefloat will be in its lowest position, thus discon-necting the power supply through the reedswitch. If oil flows through the housing, thefloat will lift ifself to its highest position, thusestablishing a connection.

For compressor units with instrumentboard:If the float drops, thus disconnecting thepower supply, a time relay will stop the com-pressor after 10 seconds.

For compressor units with UNISAB II:The signal is transmitted to UNISAB II, whichwill stop the compressor once the encodedtime has expired and after the float has cutoff the flow connection.

For details, see the UNISAB II instructionmanual.


4--100173--529--EN

Systems for Regulating of Compressor Capacityand Vi-ratios SAB 128R and SAB 163R

This section describes the following two sub-jects:

1. Regulation of compressor capacity.

2. Manual regulation of the Vi-slide.

1. Regulation of Compressorcapacity

The compressor capacity can be regulatedfrom 16-100% by regulating the number ofrevolutions of the rotors from 1000-6000 rpm.This is done by means of a frequency trans-former, which controls the number of revol-utions of the electric motor driving the com-pressor.

The frequency transformer is located in theunit control box as shown in Fig. 4.12.

The operating data of the frequency trans-former is factory set. Any regulation of thecompressor capacity is carried out from theUNISAB II mounted on the unit.

Fig. 4.12Frequency regulatedmotor

Control box with frequency transformer

UNISAB II

4840--433--2--1

2. Manual Regulation of theVi-slide

For the purpose of obtaining the highestefficiency on the screw compressor, the com-pressor is fitted with a slide system by meansof which the built-in volume ratio Vi of thecompressor can be adjusted manually to thepressure ratio of the refrigeration plant(evaporating pressure/condensing pressure).

Fig. 4.13

4169--T12_0___1/5

SECTIONC--CA1--A1

180

Fig. 4.13 shows a section of the constructionof the manual system, which operates as de-scribed in the following.


4--11 0173--529--EN

FunctionThe regulating slide pos. 200 can be movedin the longitudinal direction of the rotors andcan thus change the size of the radial dis-charge port. Thus the built-in volume ratio ofthe compressor can be changed.

The regulating slide is moved by giving thespindle pos. 180 a predetermined number ofturns.

S If the spindle is turned clockwise, alower Vi is obtained.

S If the spindle is turned anti-clockwise ahigher Vi is obtained.

For correct adjustment of the Vi-slide posi-tion, use the following diagrams Fig. 4.14and Fig. 4.15 as explained below.

For the actual refrigerant and evaporationtemperature TE, follow the horizontal line tothe intersection with the curve for the actualcondensing temperature TC. From thispoint of intersection two readings can bemade by following the line either vertically upor down:

S vertically up, reading the Vi-ratio. Noticewhether the compressor is connected toan economizer or not.

S vertically down, reading the number ofrevolutions the spindle pos. 180 must beturned anti-clockwise - from itsextreme position - in order to achieveoptimum efficiency at the given tempera-tures TE and TC. Notice whether or notthe compressor is connected to an eco-nomizer.

Note:

S Due to the difference in pressure be-tween the suction side and the dis-charge side, adjustment of Vi must becarried out only when the compressoris stopped.

S Do not secure the Vi -slide against thelimit ends when adjusting the slide toits max. or min. position as this mayimpede the movement of the capacityslide.Consequently, when adjusting theVi -slide to max. or min. position, loosenthe spindle by turning it 1/2 to 1 turn inthe opposite direction from its extremeposition.


4--120173--529--EN

Fig. 4.14

--60

--50

0

0

10 20 30

10 20

--20--25

30

100

--10

33

--40

--30

--20

--10

0

10

20TE

403020

5055

TC

R717

2 2.5 3 3.5 4

2 2.5 3 3.5

4.5

4 4.5

SAB 128

T250810

Economizer

Volume ratioVi

ViEconomizer

Vi

C°

Adjustment

One stage

Evaporatingtemperature

Condensingtemperature

One stage

N turns of the adjusting screw

N omdr.

Adjusting the positionof the Vi-slide, R717,SAB 128 Mk3/4and SAB 128R Mk3/4

C°


4--13 0173--529--EN

Fig. 4.15

--60

--50

C°

2 2.5 3 3.5 4

2 2.5 3 3.5

--20--25

4.5

4 4.5

100

--10

SAB 163

--40

--30

--20

--10

0

10

20TE

403020

5055

C

TC

R717

0

0 10 20 30

10 20 30 40

40

42

42250812

°

Volume ratio Economizer

Economizer

Vi

Vi

Vi

Adjustment

One stageEvaporatingtemperature


One stage

N turns of the adjusting screw

N turns

Adjusting the positionof the Vi-slide, R717,SAB 163 Mk3/4and SAB 163R Mk3/4


4--140173--529--EN

Compressor Protecting System pos. 220 and 221

Fig. 4.16

Pilot valve, BSV8, pos. 221 Main valve, POV, pos. 220

Oil separator, condenser Condensing pressure Evaporating pressure

Evaporator

Compressor

In order to protect the compressor against aninadmissible high pressure (if the electricsystem has not already stopped the com-pressor), the compressor is fitted with a pro-tecting system with a main valve pos. 220and a pilot valve pos. 221, see piping dia-grams Fig. 4.35 and Fig. 4.36.

Functional Description

The pilot valve pos. 221 is actuated by thecompressor discharge pressure P1 and iskept closed by a built-in spring whose closingforce is adjusted to the pressure shown onthe valve plate. The reference pressure ofthe pilot valve is the atmospheric pressurePo, and the valve is dimensioned in such away that the pressure P2” does not affect theopening pressure of the valve.

If the pressure P1 rises above the set open-ing value on the valve plate, the pilot valvepos. 221 opens modulatingly and raises thepressure P2” below the piston pos. 5 in themain valve.

In the chamber above the piston pos. 5 thereis the same pressure P1 as under the valvecone pos. 2 since the piston rod pos. 3 ispierced. When the main valve is closed, thepressure P2” in the chamber pos. 6 belowthe piston will be the same as the com-pressor discharge pressure P2 since thepressure P2” is equalized through the nozzlepos. 7.

If the pilot valve pos. 221 opens due to a toohigh pressure P1, gas will flow from the pilotvalve to the main valve through the P2” line.If there is more gas that can flow through thenozzle pos. 7 the pressure will rise in thechamber pos. 6 and open the main valvemodulatingly.

Thus the way is open for a gas flow throughthe main valve from the compressordischarge side to the suction side.

When the pressure P1 again falls below theset pressure of the pilot valve, the pilot valvewill close. The pressure P2” in the chamberpos. 6 is equalized to the P2 pressure


4--15 0173--529--EN

through the nozzle pos. 7 and the main valvecloses in less than 50 seconds.The activation of the compressor protectingsystem will usually not result in valve leaks orin a need for regulation.

Oil System

As shown in the general piping diagrams,Fig. 4.35 and Fig. 4.36, a mixture of oil anddischarge gas is flowing from the compressorCS pos. 22 to the oil separator OS where theoil is separated from the discharge gas.

The main part of the oil is separated in thedemisters pos. B whereas the small dropswhich continue with the discharge gas areseparated in the fine separator elementpos. 55.

If necessary, the fine separator element canbe removed from the oil separator for inspec-tion by dismounting the flange at the end ofthe oil separator.

The gas, which is almost free of oil, leavesthe oil separator through the stop valve pos.204. From the demisters pos. B the oil isdrained to the bottom of the oil separatorwhere the oil level can be seen through thesight glasses pos. 31. A heating elementpos. 30 keeps the oil warm when the com-pressor is not in operation. The oil separatorcan be drained of oil through the valve pos.47. From the oil separator the oil is led to theoil cooler pos. 32/33 via the non-return valvepos. 210. Different oil coolers can be used asstandard where the secondary refrigerant iseither water or the refrigerant used in the re-frigeration plant.

For oil temperature regulation, a temperatureregulating valve can be mounted at point Aand B of the oil cooler.

The illustrated oil coolers can be drained ofoil through the valve pos. 34 and ofrefrigerant through the valve pos. 35.

From the oil separator the oil flows to thecompressor where it is filtered in the oil filterpos. 39 before it is led to the lubricatingplaces in the compressor.

As part of the starting procedure of the com-pressor, the secondary oil pump pos. 63starts first and fills the oil system with oil untilthe float switch pos. FT18 floats up and sig-nals that the compressor can be started.

The oil which is separated in the fineseparator element in the oil separator is re-turned separately to the compressor via theoil return valve pos. 52. See Fig. 4.17. Seealso the section Oil Return Valve where thevalve function is described in detail.

Fig. 4.17

pos. 524840--444--4--22

The piping diagrams, Fig. 4.35 and Fig. 4.36,for SAB 128R and SAB 163R respectivelyshow i.a. alternative choices of oil coolers.Note that SAB 163R is equipped with separ-ate oil vessel.


4--160173--529--EN

Oil Separator for SAB 128R and SAB 163R

Fig. 4.18 Oil Separator SAB 128R

Fig. 4.19 Oil Separator SAB 163R

The oil charged to the compressor forlubrication, sealing and cooling of the com-pressor block is mixed with the refrigerantgas and led to the oil separator collectively.

In the oil separator oil and gas areseparated whereupon the gas, which isalmost free of oil, leaves the compressor unitthrough the discharge connecting piecepos. A.

Two filter elements separate the oil from thegas. The main part of the oil is separated inthe demisters and drained to the bottom ofthe oil separators on SAB 128 and down intothe separate oil vessel on SAB 163 as shownin Fig. 4.20 and Fig. 4.21.

Fig. 4.20

del af T245755_0

Demister

Fine separator element pos. 55

Vessel

A

52

53

Fig. 4.21

Vessel

Demister

Fine separator element pos. 55

A

T245754_0

52

53


4--17 0173--529--EN

The remaining oil in the gas is separated inthe fine separator element pos. 55 and re-turned to the compressor through the oil re-turn valve pos. 52. See piping diagramsFig. 4.35 and Fig. 4.36.

Fine Separator ElementUsually it is superfluous to remove or re-place the fine separator element, but in caseof increasing oil consumption, it is possible toinspect the filter or remove it through flangepos. B.

The element can be removed through theends of the oil separator. This, however,must be done by Sabroe Refrigeration’s Ser-vice organization.

Nominal Oil Carry-over to Plant

Operatingconditions(6000 rpm)

SAB 128R SAB 163R

R717

--40/--10°C--10/35°C--40/35°C0/35°C

0.2 -- 0.60.7 -- 2.10.2 -- 0.60.9 -- 2.7

0.4 -- 1.21.4 -- 4.20.3 -- 0.92.0 -- 6.0

Oil carry-over in kg/100h

The above figures are based on a sepa-rator efficiency of 5-15 ppm

All figures are based on 100% compressorcapacity and no economizer loading.


4--180173--529--EN

Oil Level Glass

It must always be possible to see an oil levelin one of the two oil level glasses pos. 31,Fig. 4.35 and Fig. 4.36. The oil level will riseapprox 10 mm if the indicated amount of oilis charged:

Compressor typeAmount of oilper 10 mmLitres

SAB 128

SAB 163

6

4

10 mm

Section 6, Technical Data - Oil ChargeSAB128R/163R includes a list of the total oilcharge of the unit. However, the list does notinclude the amount of oil circulating in therefrigeration plant. In R22 systems with largequantities of refrigerant, special allowancemust be made for the amount of oil dissolvedin the refrigerant.

Consequently, it is important -- during the op-erating period after initial start-up -- to beaware that the oil level may sink rather quick-ly until the oil contents in the refrigerationsystem has stabilized.

Discharge Stop Valve andNon-return Valve

Discharge Stop ValveStandard units are supplied with a stopvalve welded on the oil separator dischargebranch. The discharge branch of the stopvalve is made for welding connection.

Non-return ValveIn addition to the discharge stop valve in thedischarge pipe, a non-return valve must befitted. This valve must close tightly wheneverthe pressure in the oil separator is reduced tosuction pressure during idle periods.

The non-return valve must be positioned onthe uppermost part of the discharge pipe asshown in Fig. 4.22. This prevents any con-densation that may have been created in thedischarge pipe during the standstill of the unitfrom running into the oil separator when theunit is restarted.

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

Fig. 4.22

Stop valve on unit

Common discharge pipe

Non-return valve

0174--407--EN

02.06


4--19 0173--529--EN

Oil Return Valve

Fig. 4.23

1

2

3

4

5

6

1: Inlet G1/4”2: Filter3: Stop valve, inlet side

4: Stop valve, outlet side5: Outlet G 1/4”6: Sight glass

1

5

Note:Valve inlet and outlet are marked on the valve housing with ”in” and “out”.

Function

The function of the oil return valve is to returnthe separated oil in the fine separator to thecompressor.

Oil and gas from the fine separator flow intothe oil return valve at pos. 1, through the filterpos. 2 and via the nozzles pos. 7 and 8 (seeFig. 4.24) back to the compressor throughthe outlet pos. 5.

The gas and oil flow through the nozzles pos.7 and 8 is adapted to the spring force of pos.9 as well as the viscosity difference betweenoil and gas. Consequently, the pressure lossof the gas flow through the nozzle pos. 7 isunable to move the piston pos. 7.

However, the pressure loss of the oil flowthrough the nozzle pos. 7 is able to move thepiston pos. 7.

Thus the spring force pos. 9 is equalized anda transverse bore pos. 10 with a consider-ably larger bore than pos. 7 will open.

The fact that the bore is larger makes it poss-ible quickly to remove oil collections at the oilreturn valve inlet.

When the oil has been removed, the gas flowwill rise and the piston pos. 7 will close thetransverse bore. The gas flow will be loweredto a minimum.

Through the sight glass pos. 6 it is possibleto watch the oil return. As a small amount ofgas will always pass through the nozzle pos.7, gas bubbles will be visible.

The valve can be serviced by closing thestop valves pos. 3 and 4.


4--200173--529--EN

Fig. 4.24

7

5

8 106 2

4 3

OutIn

1

9

Note:The sectional view shows the valve structure. Not all internal oil channels are visible.


4--21 0173--529--EN

Heating Rods, Element for Oil Heating

In order to keep the lubricating oil in the com-pressor warm during an idle period, the oilreceiver has one or two built-in heating rods.Before start-up, the heating rod must havebeen activated for six to eight hours in orderto ensure that there is only a minimum of re-frigerant in the oil. When containing muchrefrigerant, the oil will lose its lubricatingproperty and the following operational inter-ruptions may occur:

For screw compressors starting with muchrefrigerant dissolved in the oil, there is a riskof the compressor being stopped by the FlowSwitch. The reason for this is that the oil willfoam owing to the fall in pressure through oilpipe and oil filter.

As illustrated in the drawing Fig. 4.25, theheating rod consists of an electric heatingelement incorporated in a pipe with a diam-eter of 30 mm. The entire heating cartridge isscrewed on tight at the G 1 1/4” thread.

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

Fig. 4.25

Marking: Prod. no.

Watt

VoltageNV 50

G 1 1/4”

Fig. 4.26 Table of Power and Application

Heating Rods

PowerWatt

VoltageV

L1mm

L2mm

Used for:

270270270

250230115*

CMO--TCMO--SMC100--TSMC100

460460460

250230115*

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

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


4--220173--529--EN

Oil Cooling System

Various types of oil cooling systems can beapplied for cooling of the lubricating oil in thecompressor.

S Water-cooled oil cooler, type OWSGis designed for connection to a fresh-water system incorporating anti-cor-rosion and anti-scaling measures.

When the oil cooler is operating with acooling tower, algicides, rust and foulinginhibitors must be added to the water ac-cording to normal practice in connectionwith cooling tower systems.

S Water-cooled oil cooler, type OWRGis used where the water quality cannotbe guaranteed to be satisfactory andconstant.

S Refrigerant-cooled oil cooler, typeOOSIfor cooling of the oil with refrigerant.A closed, welded tubular heat exchangerof the OOSI type can be used.

S Other

Closed System

OWSGIf the oil cooler is connected to a closed sys-tem such as a heat recovery system, thewater flow can still be regulated.

OWRGOnly use the mentioned oil coolers for theprescribed water flow to minimize the risk ofcorrosion as a result of the combination ofhigh temperature and chloride content(Cl--) in the cooling water.

Therefore, Sabroe Refrigeration recom-mends the use of the regulating system de-scribed under Open System.

0171-561-EN

95.10


4--23 0173--529--EN

Water-cooled Oil Cooler, Type OWSG/OWRG pos. 33

Fig. 4.27

2

3

4 5

1

T0177037_0

No Used for12345

Hot oil inletCooled oil outletWater inletWater outletName plate

6

6 Air purging from water side

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

Design

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

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

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

Baffle plates are positioned between thetubes to extend the oil passage through thecooler, thus causing the oil to flow across thetubes. This improves the heat transmissionfrom oil to cooling water significantly.

The cooler end covers are designed to leadthe water back and forth a number of timesto ensure adequate water velocity.

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

Furthermore, the oil cooler can be fitted withend cover corrosion plugs. To ensure the cor-rosion resistance of the two oil cooler types,the pipes must never become overheated.Consequently, they must not be uncovered.

To avoid this, it is important that

S there are no air pockets on the waterside. Therefore, the oil cooler must befitted with a purge valve at the top of thecover without connections. This valvemay be omitted if the water discharge


4--240173--529--EN

pipe points upwards so that air can es-cape with the water.

S the water velocity through the oil cooleris never below the velocity stated bySabroe Refrigeration to prevent foulingand soiling.

For OWRG applies:

In the fresh water version the content of chlo-ride ions (Cl-) in the water must not exceed400 ppm at max outgoing water temperature= 35°C.

In case of chlorine treatment (sea water ver-sion), the amount of chlorine must not exce-ed 0.5 mg Cl2 per litre water for 30 minutesonce every 24 hours. Max outgoing watertemperature = 40°C.

Moreover, the oil cooler must be drained ofwater during idle periods of more than 1 or 2weeks.

Application

Oil cooler type OWSG is designed to be con-nected to a freshwater system where mea-sures have been taken to prevent corrosionand calcareous deposits.

When operating with an evaporating coolingtower, corrosion inhibitors and agents againstalgae growth and calcareous deposits mustbe added to the water according to commonpractice.

Oil cooler type OWRG is used where the wa-ter cannot be guaranteed to be of a good andconstant quality.

Cleaning

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

The cooler must therefore be checked andcleaned at regular intervals, depending onhow pure the cooling water is.

The OWSG/OWRG oil cooler can be cleanedby removing the end cover without branchesand scrubbing the tubing clean with a bronzebrush. The internal pipe diameter is 8 mm.

Finally, the tubing is rinsed with fresh water.Alternatively, ready-mixed inhibitive scouringacids can be used with subsequent neutrali-zation. Such agents must be intended for un-treated steel tube heat exchangers. The che-mical manufacturer’s instructions should befollowed precisely.


4--25 0173--529--EN

Oil Temperature Regulation

Open System

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

Decreasing water flow will result in foulingand perhaps clogged-up tubes, which willlead to tube corrosion.

Instead, the following is prescribed:

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

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 the oil cooler is connected in a closed sys-

tem such as a heat recovery system, the

water flow can still be regulated.

OWRG

Only use the mentioned oil coolers for the

prescribed water flow to minimize the risk of

corrosion as a result of the combination of

high temperature and chloride content

(Cl--) in the cooling water.

Therefore, Sabroe Refrigeration recom-

mends the use of the regulating system de-

scribed under Open System.

0178-261-EN

97.03


4--260173--529--EN

Refrigerant-cooled Oil Cooler, Type OOSI

Fig. 4.28

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

Description

The OOSI oil cooler, Fig. 4.28, is an all-welded tubular heat exchanger made ofsteel. On the inside the pipes are fitted with aspecial insert to improve the heat transfer.

The oil flows through the pipes while the re-frigerant evaporates outside the pipes. It is aflooded system, which means that the re-frigerant leaves the oil cooler as a mixture ofliquid and vapour. This ensures that, undernormal conditions, no oil is accumulated onthe refrigerant side.

Mounting

In order for the condenser to function correct-ly, it has to be mounted higher up than the oilcooler to ensure a natural circulation of therefrigerant. The draft on the following page isan example of a common pipe layout.

Ex. 1: The receiver is positioned above theoil cooler.

Ex. 2: In case the inlet height (H1) is insuffi-cient, a small priority vessel can bepositioned between condenser andreceiver as shown in the example.

If it proves quite impossible to obtaina satisfying inlet height, a pumpcould be mounted for the refrigerantsupply.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 thevertical pipe length or if executed,min 1 pipe dimension larger.

More detalied calculations andchoice of velocity are made bySabroe Refrigeration.


4--27 0173--529--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 therange of 35-60°C, depends on the actual op-erating conditions and oil cooler size.

The choice of oil cooler size also depends onthe chosen oil type. The calculated oil tem-peratures for the various oil types may beseen from Sabroe Refrigeration’s Oil Recom-mendation, see Section 6, Technical Data.The set points of the safety equipment areadjusted according to the calculated oil tem-peratures. Normally, the alarm limit is 10Kabove the calculated oil temperature for theoil type in question. See Section 9, Settings.

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 the condensing temperature, egduring cold periods, drops below 20°C duringoperation or below 10°C during standstill.

If this oil temperature regulating system isnot fitted and the condensing temperaturedrops below 10°C during standstill, theliquid supply line to the oil cooler must beclosed. For this purpose, a solenoid valvewith a low pressure drop, closing wheneverthe compressor stops, can be mounted. Thevalve will reopen once the compressor is

working again and the oil temperature hasreached min 20°C.

Before the compressor is started, the tem-perature of the oil in the piping system mustbe at least 10°C. In machine rooms withoutany heating it may be necessary to mount aheating rod. Oil separators are usuallymounted with heating rods as standard toensure a sufficiently high oil temperature inthe oil separator.

In case several oil coolers are mounted inparallel with a considerably different flow re-sistance due to the pipe lengths, etc, athrottle valve (R) (see Ex. 1) can be fitted inthe liquid supply line (A) so that the flow canbe equalized between the oil coolers, ensur-ing the full function of all oil coolers. Do notthrottle so much that the oil cooler does notremain flooded.

Do not regulate 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.

Thus oil will accumulate on the refrigerantside of the oil cooler, causing malfunctionand a heavy thermal loading of the oil cooler.This will increase the risk of breakdown.

0178-277-EN

98.05


4--280173--529--EN

Oil Temperature Regulating System

In screw compressor units where the oil sys-tem is cooled by means of either a refriger-ant-cooled oil cooler, type OOSI or a water-cooled oil cooler, type OWSG, the oiltemperature is usually regulated by athermostatic three-way valve as illustratedin Fig. 4.29.

Fig. 4.29

C

A

B

Function

The valve pos. 46, see general diagramFig. 4.35 and Fig. 4.36, is fitted in a by-passpiping system as shown in Fig. 4.30.

Fig. 4.30

To the compressor

Oil cooler

From oil receiver

Three-wayvalve

As shown in Fig. 4.31 and Fig. 4.32, thevalve works by letting a built-in thermo el-ement pos. 1 regulate a cone pos. 2 so thatcold and warm oil is mixed to the factory settemperature.

Note Pos. 3

Check that the Teflon ring is mounted andintact. If this is not the case, the thermo ele-ment will wear when it rotates, resulting inmalfunction.

In Fig. 4.31 the thermo element is shown inits cold position. It will try to raise the mixedtemperature of the oil at the outlet A. Thethermo element has thus shut off the flow ofcold oil, inlet C. However, the flow of warm oilis completely unobstructed.

Fig. 4.32 illustrates the opposite situationwhere the thermo element is in its warmposition, thus shutting off the flow of warmoil, inlet B, and opening for the flow of coldoil, inlet C.

During operation the thermo element will ad-just the regulating cone in a modulating wayso that the two oil flows are mixed to the setoil temperature and leave the valve throughconnecting branch A.


4--29 0173--529--EN

Fig. 4.31

BWarm oilfrom oilseparator

C

A

Cooledoil fromoil cooler

Thermo element in cold position

ServiceAs 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.

Fig. 4.32

B

A

Oil withcorrectmixed temp.

Thermo element in warm position

C

2

1

•

•

Warm oilfrom oilreceiver Cooled

oil fromoil cooler


4--300173--529--EN

Oil pump pos. 63

The gerotor is a positive displacement pump-ing unit consisting of just two elements. Theinner rotor has one less tooth than the outer

and has its centerline positioned at a fixedeccentricity from the centerline of the outerelement.

Fig. 4.33

Inlet

Outlet

Outlet

Inlet

Pumping Sector

Start-upThe pump must only run without oil flow forbrief periods.

Checking Rotating Directionof MotorBefore initial start-up of the oil pump, re-member to check the rotating direction of themotor. The rotating direction is indicated onthe electric motor with an arrow. Seenthrough the motor shield of the motor, themotor must rotate anti-clockwise.


4--31 0173--529--EN

Economizer

The compressor block is prepared for themounting of an economizer system.

By connecting the economizer port to an in-termediate cooler (economizer), gas of inter-mediate pressure can be fed to the com-pressor, thus superfeeding the grooves. Thefunction of the economizer is to cool theliquid refrigerant (subcooling) from the con-denser before it is led to the evaporator.

The economizer can be of the open flashtype as shown in Fig. 4.34.

Due to the lower liquid temperature createdby the economizer, there will be more en-thalpy available in the evaporator, and therefrigerating capacity will thus increase.

The power input will also increase due to thesuperfeed through the economizer inlet, butless than the refrigerating capacity in mosteconomizer arrangements.

The Coefficient Of Performance, i.e.

COP = Capacity/power (kW/kW)

will therefore usually increase by economizeroperation.

Selecting Economizer

The economizer is calculated by means ofthe COMP1 calculation program.

Fig. 4.34 Flash Economizer System

Suction

HV--2STR

VCK

Saturated liquidto evaporator

Gas of intermediate pressure tocompressor

Econo-mizervessel

Highpres-sureliquid

BPR

0171-564-EN

01.09


4--320173--529--EN

Refrigerant Injection into Discharge Pipe, type BLI(Booster Liquid Injection), Screw Compressors

For oil cooling a system may be used withrefrigerant injection into the compressor dis-charge pipe.

Function

During compression of refrigerant vapoursfrom evaporating pressure to intermediatepressure in the LP compressor of a two-stage system, a considerable amount of heatis generated. This heat must be dissipated tokeep the gas and oil temperatures at a suita-ble level. This is done by injecting liquid refri-gerant from the receiver into the dischargepipe immediately after the LP compressor.This process is controlled by a modulatinginjection valve of the TEAT type, pos. 83.

The liquid refrigerant evaporates in the hotmixture of oil and discharge gas, and themixture is thus cooled. The injection valvesize is chosen on the basis of the refrigerant,intermediate pressure temperature, conden-sing temperature and the cooling require-ments specified in the order. The thermo ele-ment of the valve has a working range of35-65°C.

The liquid supply to the BLI system must betaken from a point in the plant where there isalways refrigerant.

AdjustmentThe opening temperature of the injectionvalve is at the mid-temperature range of thethermo element.

Before starting the compressor, adjust theinjection valve opening temperature:

20K lower than the desired discharge gastemperature.

See Danfoss instructions regarding setting ofthe injection valve.

Fine adjust the valve once the installation isstable.

The solenoid valve, pos. 82, in front of theinjection valve must have an opening tem-perature of 15K below the desired dischargegas temperature.

In case of operation with BLI, a relativelylarge amount of foam may occur on the oil inthe oil separator.

0171-566-EN

02.09


4--33 0173--529--EN

Safety and monitoring devices

Compressor units with relay control or termi-nal strip for remote control are usually fittedwith the following instruments for safety andoperating control, depending on the specificorder.

Safety devicesPos. 28 Safety valve on oil separator

with exhaust to the atmosphere.The exhaust line must be routedfrom the engine room out intothe open air.

Pos. 43 Float switch pos. FT18 is fittedin an oil distributor chamber inthe compressor.The float switch consists of afloat with a built-in permanentmagnet activating a reed switchmounted in the float guide.When starting the compressor,oil will be pumped to the com-pressor lubricating system. Thefloat will then be lifted up, sig-nalling that the oil system hasbeen filled. A time relay must beset so that it will stop the start-ing signal if the float has notbeen lifted within 50 seconds.When the float switch sends outits signal within the 50 seconds,the system will wait for another10 seconds before the start sig-nal is accepted and the com-pressor starts.

Note: For Rotatune compressors SAB128R and SAB 163R the follow-ing start-up procedure applies:After the 50 second prelubricat-ing time the compressor mustbe started. A further 10 seconddelay must not take place as the

compressor lobes will then befilled with oil.

If the oil flow fails during opera-tion so that the float flows downand interrupts its control signal,the compressor will stop after 10seconds.

Pos. LIT1 The oil level transmitter ismounted in the oil dischargepipe.The transmitter is a capacitivelevel switch for measuring of oilflow. The switch consists of asensor pocket in which a sensoris mounted. The switch will reg-ister when the oil passes, and itwill send a signal to the control.When the compressor is started,the oil pump will start and fill thelubricating system with oil. If theoil flow is not satisfactory after50 seconds, a built-in timer willcancel the start-up. However, ifthe oil flow is satisfactory within50 seconds, another 10 sec-onds will pass before the com-pressor starts. If the level switchregisters a failing oil flow for aperiod of 10 seconds during op-eration, the compressor willstop.

Pos. PAZ1 Pressure cut-out KP1, whichstops the compressor in theevent of the suction pressurefalling below the set value. Thepressure cut-out is not equippedwith a reset, so the compressorstarts again when the pressurehas risen above the difference


4--340173--529--EN

between 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 11Differential oil pressure cut-outMP55. This pressure cut-out isdesigned to ensure sufficient lu-bricating pressure and oil pres-sure 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 excenssivedue 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 permissible

pressure 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 dischargepipe 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.

0171-575-EN

01.03


4--35 0173--529--EN

Key to Piping Diagrams/Component List

CS Screw compressor

OS Oil separator

M Electric motor

EC Electronic control system

240 Coupling

_______________ S _________________

PT1 Pressure transducer(suction pressure)

PT2 Pressure transducer(discharge pressure)

PT3 Pressure transducer(oil pressure after oil filter)

PT4 Pressure transducer(oil pressure before oil filter)

PT5 Pressure transducer(oil pressure after oil pump)

TT5 Temperature transducer(discharge gas temperature)

TT6 Temperature transducer(oil temperature in flow control)

TT7 Temperature transducer(suction gas temperature)

GT8 Position transmitter (capacityslide)

GT9 Position transmitter (Vi slide)

PAZ10 Safety pressure cut-out(for TÜV, SDM and SA only)

PAZ1 Low-pressure cut-out(only for classified systems)

PAZ2 High-pressure cut-out

PDAZ3 Differential pressure cut-out(pressure drop across oil filter)

TI5 Thermometer(discharge gas temperature)

TI6 Thermometer (oil temperature)

TI7 Thermometer (suction gas tem-perature) - only if specially or-dered

PDAZ10 Oil pressure difference cut-out(oil pressure - discharge pres-sure)

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


4--360173--529--EN

SC1 Throttle valve

SC2 Throttle valve

SC3 Throttle valve

SC4 Throttle valve

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


4--37 0173--529--EN

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%

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

77 Solenoid valve for suction sidethrottling system

78 Regulating valve forthrottling system

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


4--380173--529--EN

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

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 dischargepipe

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.


4--39 0173--529--EN

Fig. 4.35 General Piping Diagram for SAB 128R Mk4

DN25 60ø34/28

210 61

5BAR

63215

DN8

64

ø34/28

65

DN15

ø18/15

25

el.30

3131

OIL

55

DN50

DN65

204

AB32

ø34/28

ø34/28

F

ø76/70

DC

28 DN15

F

29

2828

FDN15

ECOCONNECTION

132

97140

SSTT

E

DN32

ø34/28

DN25

VALVE

SAFETY

(PED)

TWOSAFETY

VALVESWITH

VALVE

CHANGEOVER

OPTION

DN25

DN20

DN20

DN20

ø21/16

A

46H

J

C

TC

BAB

DG

COILTEMP.REG.

QDVDN15

DN15

35A

QDV

DN1534

A

AJJ

HH

TC

46

CB

DD

SAFETY

CUT--O

UT

ø6/4

10PRESSURE

DOUBLE

HIGHPZHH

4735

(PED)

47

47A

QDV

DN15

DN15

ADDITIONALEXTRA

BYSABROEAS

NON--R

ETURNVA

LVE

ONLY

DELIVERED

50

52

51

DN50/25

203

53

54

35

G

ø10/8

DN1534

ACG

CC

BOILTEMP.REG.

29

2828

DN15

DN32

TWOSAFETYVA

LVESWITH

CHANGEOVERVA

LVE

G28 DN15

VALVE

SAFETY

G

(ALL)--OPTION

(PED)--

OPTIONDN20

DN20

DN20

PT

PT 2

PT 3

34

4

--1--25B

AR

2PT

24

DN8

5TT

ø10/8

35A DN15

QDV

DN1534

ADN15

QDVDN15

35

JJ

32

DD

34

G\34/28

UICZA

UNISABII

1PT

21

d=3

20

PT 17TT

1--9BAR

ø48/43

HR DN 100

GRAPHICALSYMBOLS

ACC.TOEN1861

ANDISO3511

GRAPHICALSYMBOLS

ACC.TOEN1861

ANDISO3511

GRAPHICALSYMBOLS

ACC.TOEN1861

ANDISO3511

DN8

48

4238

DN8

48

CD

PT 4

48DN8

DN40

DN40

3PT

4238

DOUBLE

EXTERNALFILTER

106

3842

EXTERNALFILTER

106

DN40

DN40

DN40

DN40

DC

DN40/25

DN40/25

DN40/25

DN40/25

FF

EE

BB

OO

II

PP

DD JJ

AA

RR

CCQQ

KK

LL

Z

DN8

DN8

DN8

Eø6/4

102

90

9245

1BAR

959691

97

22

4PT

100 93

d=4

PT

NO

FT18

TT 6

3

23

220

39

POV40

221

BSV8

REFRIGERANT:R717

REV.

PID

IAGRAMSAB128MK4--PED

OILCOOLING:O

OSI1

&2A

CONTROL:UNISABII,ROTATUNE

4849--641

3

ø18/15


4--400173--529--EN

Fig. 4.36 General Piping Diagram for SAB 163R Mk4

REFRIGERANT:R717

REV.

PID

IAGRAMSAB163MK4--PED

OILCOOLING:O

OSI1

&2PA

SS

CONTROL:UNISABII,ROTATUNE

4849--639

3

el.

31

60

6163

ø34/28

DN25

65

DN15

210

ø18/15

5BAR

215

DN8

64

3031

OIL

2555

DN65

204

DN100

ø48/43

ø114/107

F

28 DN15

F

29

2828

FDN15

E

DN32

VALVE

SAFETY

TWOSAFETY

VALVESWITH

VALVE

CHANGEOVER

(PED)

DN15

QDV

DN15

47A

47

OPTIONDN20

DN20

DN20

ø21/16

A

46H

J

C

TC

BAB

DG

COILTEMP.REG.

DN15

QDV

A

TC

46

JJ

HH

DD

SAFETY

CUT--O

UT

ø6/410PRESSURE

DOUBLE

HIGH PZHH

4735

(PED)

50

52

ADDITIONALEXTRA

BYSABROEAS

203

ONLY

DELIVERED

NON--R

ETURNVA

LVE

DN65/40

5153

54

AB

ø48/43

32

DN15

35A

35G

ø10/8

DN15

DN15

QDV

34A

34CG

CBA

B

CCOILTEMP.REG.

DN15

QDV

29

2828

DN15

DN32

TWOSAFETYVA

LVESWITH

CHANGEOVERVA

LVEG

28 DN15

VALVE

SAFETY

G

(ALL)--OPTION

(PED)--

OPTIONDN20

DN20

DN20

PT 4PT 2

PT 3

34

24

DN8

5TT

ø10/8

2PT

--1--25B

AR

D

DN8

48

4238

DN8

48C

CD

PT 4

48DN8

DN40

DN40

35A

DN15

QDV

32

JJ

DN15

35

DD DN15

3434A

Gø48/43

UICZA

UNISABII 1PT

1--9BAR

ø48/43

3PT

4238

DOUBLE

EXTERNALFILTER

106

3842

GRAPHICALSYMBOLS

ACC.TOEN1861

ANDISO3511

EXTERNALFILTER

106

DN40

DN40

DN40

DN40

ECOCONNECTION

132

97140

SSTT

DN32

ø42/37

DN32

E

F

E

F

BB

OO

II

PP

DD JJ

AA

RRCC

QQ

LLKK

Z

DN8

DN8

DN8

Eø6/4

102

90

92d=6

45

1BAR

95964PT

99 100 9391

97

22

PT

NO

FT18

TT 6

3

23

220

39

21

d=3

20

PT 17TT

HR DN 125

POV40

221

BSV8

DC

ø18/15


4--41 0173--529--EN

Instrumentation

The screw compressor unit can be controlledby a UNISAB II regulation and control sys-tem, which is mounted on the unit and con-nected to a number of temperature and pres-sure sensors on the unit.

The UNISAB II control system is described inSection 10, Operating Instructions.

Fig. 4.37, Fig. 4.38, Fig. 4.39 and Fig. 4.40show the location of sensors, valves, etc.

See, moreover, the piping diagram in thissection.

The numbers refer to the Key to PipingDiagrams in this section.

Fig. 4.37 Location of Components SAB 128R

28 20

22

PT1 FT18

23

25

30 31 47

M EC 240

4840--444--4--2

TT7

PT3

PT4

TT6

PT2

24

TT5

2046063616564M1 OS

CS

TT7

PT1

PT2

24

TT5

B

A

Detail B

Detail A


4--420173--529--EN

Fig. 4.38 Location of Components SAB 163R

20

22

PT1

PT2

CS

TT6

23

6328 64 61 3031 47 204

FT18

60 65

M EC 240

M1

PT1

TT7

PT2

24

TT5

Detail B

24

PT4

PT3

TT7

Detail A

B

A

TT5

25

25


4--43 0173--529--EN

Fig. 4.39 Location of Components - Unit with OWSG Oil Cooler SAB 128R and SAB 163R

33

221220

4840--437--4--46

Fig. 4.40 Location of Components - Unit with OOSI Oil Cooler SAB 128R and SAB 163R

4840--435--4--47463534

32

6. Technical DataService Manual SAB 128R and SAB 163R Mk4

6--00173--529--EN

6. Technical Data

Table of Contents

Technical Data 6--1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Data for SAB 128R Compressor and Unit 6--2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Data for SAB 163R Compressor and Unit 6--3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Weight of Motor and Control Box with Frequency Converter 6--7. . . . . . . . . . . . . . . . . . . . . .Shipping Volume (Excluding Motor) 6--7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Planning the Machine Room 6--8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Operating Limits 6--9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Direction of Rotation 6--10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Electric Motor 6--11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Motor Dimension 6--12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Handling of Compressor and Unit 6--13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Mounting of Series of 52 Coupling 6--14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Laying of Unit Foundation 6--15. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Stationary Plant 6--17. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Marine Plant 6--17. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .The Influence of Piping Connections on the Unit 6--18. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Test Pressure Levels for Standard Compressors and Components 6--19. . . . . . . . . . . . . . . .Oil Charging 6--20. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Oil Charge SAB 128R and 163R 6--21. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Noise from Compressors and Units 6--23. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Sound data for compressor units 6--24. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Screw compressors 6--26. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Vibration Data for Compressors - All Compressor Types 6--27. . . . . . . . . . . . . . . . . . . . . . . . . . .Assessing the Oil 6--28. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Visual Assessment 6--28. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Analytical Evaluation 6--28. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Procedure 6--28. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Analysing the Oil 6--29. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Limiting Values 6--29. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Selecting Lubricating Oil for SABROE Screw CompressorsRefrigerant: R717 6--31. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Data Sheet for Listed Sabroe OilsTypical data for lubricating oils for Sabroe compressors 6--37. . . . . . . . . . . . . . . . . . . . . . . .

List of Major Oil Companies 6--40. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Selecting Lubricating Oil for SABROE Screw Compressors

Refrigerant: HFC/HCFC 6--41. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Data Sheet for Listed Sabroe Oils

Typical data for lubricating oils for Sabroe compressors 6--47. . . . . . . . . . . . . . . . . . . . . . . .List of Major Oil Companies 6--55. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .


6--1 0173--529--EN

Technical Data

The purpose of this document is to providethe technical data of the equipment. In thisdocument technical data is defined as:

S Data for compressor

S Data for unit

S Working range

S Handling the compressor

S Laying the foundation

S Noise level data

S Vibration data

S Test pressure for compressors

S Assessing the oil

S Selecting lubricating oil

This document is primarily intended fordesigners, service engineers, sales person-nel and prospective customers.






6--20173--529--EN

Data for SAB 128R Compressor and Unit

Fig. 6.1 Unit with OWSG Oil Cooler

4840 466

E

AF

C

B

Fig. 6.2 Unit with OOSI Oil Cooler

4840_442

E

AC

B

F


6--3 0173--529--EN

Data for SAB 163R Compressor and UnitFig. 6.3 Unit with OWSG Oil Cooler

4840_437

E

A

C

BF

Fig. 6.4 Unit with OOSI Oil Cooler

4840_433

E

AC

B

F


6--40173--529--EN

Fig. 6.5 Table SAB 128R / SAB 163R

Oil Dimensions Max.Compressor

TypeRefrige-rant

OilCoolingSytem

1)

Widthmm

Lengthmm

Heightmm

Max.NettoWeightk 2)

yp1)

B C A E F kg 2)

SAB 128RR717 OWSG 575 1222 2140 3042 2062 2295

SAB 128RR717 OOSI 575 1232 2140 3186 2062 2265

SAB 163RR717 OWSG 640 1680 2507 3554 2527 2950

SAB 163RR717 OOSI 640 1515 2507 3554 2527 2950

Fig. 6.6 Table SAB 128R / SAB 163R (US system)

Oil Dimensions Max.Compressor

TypeRefrige-rant

OilCoolingSytem

1)

Widthinch

Lengthinch

Heightinch

Max.NettoWeightlb 2)

yp1)

B C A E F lbs 2)

SAB 128RR717 OWSG 23 48 84 120 81 5060

SAB 128RR717 OOSI 23 49 84 125 81 4995

SAB 163RR717 OWSG 25 66 99 140 99 6505

SAB 163RR717 OOSI 25 60 99 140 99 6505

1) OWSG = Heat exchanger with shell (water)OOSI = Heat exchanger with shell (refrigerant)BLI = Refrigerant injection in discharge pipe

2) Excluding motor, oil and water


6--5 0173--529--EN

Fig. 6.7 Table SAB 128R / SAB 163R

C R tInternal Rotor

L/DP Motor at

1000Motor at6000Compressor

TypeRotorDrive

InternalVol. Ratio

V

RotorDia.mm

L/D1)

max.bar

1000 rpmSwept Volume

6000 rpmSwept VolumeType Drive Vi mm

1) bar2)

Swept Volume

m3/hSwept Volume

m3/h

SAB 128R MALE 2 0--4 5 127 5 1 7 20 103 615SAB 128R MALE 2,0--4,5 127,5 1,7 20 103 615

SAB 163R MALE 2 0--4 5 163 2 1 7 20 215 1292SAB 163R MALE 2,0--4,5 163,2 1,7 20 215 1292

Table SAB 128R / SAB 163R (US system)

C R tInternal Rotor

L/DP Motor at

1000Motor at6000Compressor

TypeRotorDrive

InternalVol. Ratio

V

RotorDia.mm

L/D1)

max.psi

1000 rpmSwept Volume

6000 rpmSwept VolumeType Drive Vi mm

1) psi2)

Swept Volume

cfmSwept Volume

cfm

SAB 128R MALE 2 0--4 5 127 5 1 7 290 61 362SAB 128R MALE 2.0--4.5 127.5 1.7 290 61 362

SAB 163R MALE 2 0--4 5 163 2 1 7 290 127 760SAB 163R MALE 2.0--4.5 163.2 1.7 290 127 760

1) Rotor length L divided by rotor diameter D

2) Discharge pressure less suction pressure

See, however, permissible operating limits in the following diagrams.

Fig. 6.8 Block Weight and Center Height

Block Weight Center Height

Kg lb mm

SAB 128R 290 639 200

SAB 163R 460 1014 245


6--60173--529--EN

Fig. 6.9 Weight (excluding motor, refrigerant, oil and water)

Oil CoolerType

Kg Basic UnitKg

CompressorBlockKg

Total, UnitKg

TypeSAB128

SAB163

SAB128

SAB163

SAB128

SAB163

SAB128

SAB163

OOSI 1614OOSI 2114OOSI 2714OOSI 3214

78130180

78130180215

100810601110

1528158016301665

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

120

185210

130

210310

700 950 230 500

1050

11151140

1580

16601760

Fig. 6.10 Weight (excluding motor, refrigerant, oil and water) (US system)

Oil CoolerType

Basic Unitlb

CompressorBlocklb

Total, Unitlb

TypeSAB128

SAB163

SAB128

SAB163

SAB128

SAB163

SAB128

SAB163

OOSI 1614OOSI 2114OOSI 2714OOSI 3214

170290400

170290400475

222523352450

3670348535953450

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

265

410465

290

465685

1545 4300 510 1105

2315

24602515

3485

36603880


6--7 0173--529--EN

Weight of Motor and Control Box with Frequency Converter

Fig. 6.11

PowerkW

MotorSize

Weight of Motorand Control Boxwith Frequency

ConverterKg

IEC SAB 128 SAB 163

90110132160200250315400

225225225225280280315315

5655705806959501155

580695950115516501700

Fig. 6.12 (US system)

PowerkW

MotorSize

Weight of Motorand Control Boxwith Frequency

Converterlb

IEC SAB 128 SAB 163

90110132160200250315400

225225225225280280315315

124512551280153020952545

128015302095254536403750

Shipping Volume (Excluding Motor)

Fig. 6.13

Oil CoolerType

Compressor Typem3

TypeSAB 128 SAB 163

OOSI 2114OOSI 3214

811

OWSG 2115OWSG 2719

912

Fig. 6.14 (US system)

Oil CoolerType

Compressor Typeft3

TypeSAB 128 SAB 163

OOSI 2114OOSI 3214

285390

OWSG 2115OWSG 2719

320425


6--80173--529--EN

Planning the Machine Room

When planning the machine room, it is im-portant to make sure that there is enoughspace around the plant so that repairs and

maintenance tasks can be carried out withoutproblems. Fig. 6.15 shows the minimumspacing in millimetre.

Fig. 6.15

SAB 128R SAB 163RA) Removal of fine oil separator element 600 800B) Cleaning of oil cooler OWSG 1500 1900C) Access to control box and pipe arrangement 1000 1000

B

A

C

C C

4840_466


6--9 0173--529--EN

Operating Limits

The following diagram for R717 shows theoperating limits within which the compressoris permitted to operate.

Please note the following:

S Use of economizer is permitted withinthe entire working range of the compres-sor.

Fig. 6.16 Operating Limits R717

Evaporating temperature


(T250835_0)

---30

---20

---10

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

0

10

---20 ---10 0 10 20 °C

20

30

40

50

60C°

R717

SAB 128R, SAB 163R


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Direction of Rotation

The direction of rotation of the compressor isindicated by an arrow cast into the compres-sor cover as shown in the following sketch.

Fig. 6.17 Direction of rotation of compressorseen from A

Seen towards shaft ends

Note:The electromotor must only be connectedto the compressor male rotor.

Fig. 6.18 Screw Compressor

A


6--11 0173--529--EN

Electric MotorThe electric motor is a purpose-made high-speed motor with protection class IP23(IP = Index of Protection).By means of a frequency converter it is poss-ible to adjust the number of revolutions from1000 to 6000 rpm (17-100 Hz).

The motor is mounted on a fan.The separately mounted fan lowers at thesame time the noise level of the motor.

The design of the motor ensures a far betterefficiency characteristic than that of a stan-dard motor both at full load and part load,see Fig. 6.19.

Fig. 6.19

0.70

0.75

0.80

0.85

0.90

0.95

1.00

20 50 100

High Speed MotorStandard Motor

Speed%

COP

Efficiency of the new high-speed motors ver-sus the relative speed n. compared withstandard motors.

Finally, the motor has a power factor which ispractically the same within the whole speedrange Fig. 6.20. This combined with the highefficiency of the converter ensure low lossesfor the drive system. The reactive power ispractically zero, resulting in a substantial costreduction as expensive power factor com-pensation is not required.

Fig. 6.20

0.80

0.85

0.90

0.95

1.00

50 100

RotatuneConventional

Speed%

Cos ϕ

Fig. 6.20 shows the power factor as a func-tion of the relative capacity of a conventionalscrew compressor and a compressor withthe new frequency controlled drive. Thepower factor of the latter is almost 1, whichshows that practically no reactive power istaken from the network.


6--120173--529--EN

Motor Dimension

The size of the motor is determined on thebasis of the power requirements of the com-pressor under the current operating condi-tions calculated by means of the SabroeCOMP1 PC program. The motor effect canalso be determined by using the tablesFig. 6.21 and Fig. 6.22 for SAB 128R andSAB 163R respectively.

The min. nominal effect of the motor is calcu-lated as the power consumption at 6000 rpmmultiplied with 1.05, thus ensuring that themotor is able to neutralise any variations inthe refrigeration plant.

Fig. 6.21 Power Consumption SAB 128RN(CT,ET)

200

180

160

140

120

100

80

60

40

20

0

CT=20CT=15

CT=25

CT=35

CT=30

CT=40

CT=45

CT=50

Deg. Cel.

Evap. temp. Deg. C

Power

ConsumptionkW

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

Fig. 6.22 Power Consumption SAB 163RN(CT,ET)

350

300

250

200

150

100

50

0

CT=20CT=15

CT=25CT=30

CT=40CT=35

CT=45

CT=50

Deg. Cel.

Evap. temp. Deg. C

Power

ConsumptionkW

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

Note:

It is essential that the drive system is di-

mensioned for the worst possible situ-

ation.

As previously mentioned, it is possible to ad-

just the speed of the motor to max. 6000

rpm. For this purpose a frequency converter

is used.

The converter allows soft starting and stop-

ping with controlled acceleration and dece-

laration of the compressor

Fig. 6.23

Current

Time

Convention

Rotatune

Fig. 6.23 shows motor current compared to

time for a conventional screw compressor

and a compressor with the new frequency

controlled drive. As regards the rotatune

compressor, soft start is obtained and no cur-

rent peaks occur.


6--13 0173--529--EN

Handling of Compressor and UnitThe compressor is equipped with a threadedhole into which the lifting eye is fitted. As tothe weight of the compressor, see table onCompressor Data.

Note:Only the compressor block alone must belifted in the lifting eye. The same appliesto the motor.

The weight of the unit is shown on the unitname plate.

When transporting and handling the com-pressor, care should be taken not to damageany of the components, piping or wiring con-nections.

Fig. 6.24

4840--437--2--2


6--140173--529--EN

Mounting of Series of 52 Coupling

Series 52, Fig. 6.25, is a coupling of the flex-ible disc type which is torsionally stable, andas such does not cause any torsional fluctua-tions between motor and compressor.

The flexible discs and the intermediatesection provide the coupling with the neces-sary radial and axial flexibility to absorb

the minor radial and axial displacementsbetween motor and compressor.

These displacements occur as a conse-quence of the heat and power impactsduring operation.

Procedure for alignment of the coupling isdescribed in detail in Section 7, InstallationInstructions.

Fig. 6.25

CT0177120_0/V1

E

CompressorType

Coupling Type Bolt DimensionSpanner

Cmm

Emm

SAB 128R

SAB 163R

225

262

1/2”

9/16”127±0.5

14±0.510 +1.0

0


6--15 0173--529--EN

Laying of Unit Foundation

Standard units for stationary purposes havetheir foundations laid in one of the followingtwo ways:

a: The unit is fixed directly on the concretefoundation.

b: The unit is mounted on vibration dampers.

Both ways are described in the following.

a: Mounting directly on foundation

When installing a unit directly on a concretefoundation, the foundation should be cast inaccordance with the foundation drawings dis-patched.

In principle the foundation is designed asshown in Fig. 6.26.

Fig. 6.26 Foundation Sketch

alignment of base framebolt; is moulded afterHole for foundation

Foundation bolt

Concrete foundationFoundation plate

Base frameFoot plate

245308All dimensions are in mm

When the foundation has been cast with theholes set out (see foundation drawing) andhas hardened, the unit is placed on woodenbeams in a flush position. Adjust the heightof the beams so that the foundation plate is

slightly recessed into the foundation, seeFig. 6.26.

To make sure that the foundation plates arekept close to the base frame during the cast-ing process, secure the foundation plates tothe base frame by means of steel wire.

The concrete which is used for the founda-tion bolts must be dry, i.e. it must have a lowwater content. Stamp down the concretearound the bolts and the foundation plate.

It is important that the concrete has a lowwater content as this prevents the hardeningconcrete to shrink.

10-14 days should pass before tighteningthe foundation bolts. Remove the steel wireand the wooden beams beforehand andcheck that there is no air space between thefoot plate of the base frame and the founda-tion plate. Otherwise, shims must be insertedbetween the plates before tightening themdown.

As shown in Fig. 6.26 the foundation hasbeen cast as part of the machine floor and --as indicated -- it is 100 mm above the floorsurface.

With this type of foundation vibrations can betransferred from the unit to the building.

However, the vibrations can be reduced byisolating the concrete foundation from thebuilding as described in section b or byplacing the unit on vibration dampers as de-scribed in section c.

b: Isolating the unit foundation from thebuilding

In order to avoid that vibrations from the unitare transferred to the building, the compres-


6--160173--529--EN

sor unit can be mounted directly on a founda-tion block that is isolated from the building

The foundation block is cast as an indepen-dent unit as shown in Fig. 6.27.

Fig. 6.27

H

Y

B

InsulationMachine floor

Foundation block

Firm bedding

This foundation block is cast directly on afirm and supporting bedding and is iso-lated from the machine floor by means ofapprox. 20 mm thick plates made of eitherhigh density polystyrene or cork.

If the bedding is part of the cast buildingconstruction, the foundation block can becast on a vibration mat with a suitable bear-ing capacity. This should be taken into ac-count by the supplier.

The dead weight of the foundation blockmust be in accordance with the weight of theunit. Consequently, the block is cast with anouter length and width as indicated in thefoundation drawing accompanying the order.

The height H of the block must be 450 mmfor all units provided that concrete with adensity of approx. 2.2 tonnes per m3 is beingused.

When mounting the compressor unit on topof the block, follow the description in sectiona. The general values for vibrations emitted

from the unit are stated in the section SoundData.

c: Mounting on vibration dampers

In view of reducing the transmission of vibra-tions from the compressor unit to the build-ing, the unit is often placed on vibrationdampers. In this way reductions can be ob-tained as indicated in the section SoundData.

On delivery of a unit from SabroeRefrigeration, the vibration dampers have notbeen mounted. They are included in the de-livery and marked with a code.

Similar codes are written in the drawingindicating the position of the vibrationdampers, which will be forwarded foreach specific order and which must onlybe used for that order.

It is very important that the vibration dampersare fitted correctly as shown in the drawingas the load on the foot plates varies.Fig. 6.28 illustrates the different types ofvibration dampers for stationary and marineunits.

The vibration dampers for stationary unitsare made with a rubber surface underneathso that they can be positioned directly on theconcrete foundation without having to befixed, which means that pockets in thefoundation are not required.

Further, vibration dampers for stationary usecan be adjusted in height and thus equalizeminor deviations that may occur in the levelof the foundation. Vibration dampers for ma-rine use, however, cannot be adjusted,which makes a level foundation even moreimportant. Read more about this in the fol-lowing.


6--17 0173--529--EN

Fig. 6.28

A

T0177040_0

A

A

Stationarytype

Marine type

A

Unloaded state Loaded state

Lock nut

Stationary Plant

The machine room floor or foundation onwhich the unit is to be placed must have thenecessary bearing strength. The floor mustbe plane within a maximum of 5 mm fromthe horizontal level so that the difference inheight between the foundation plates doesnot exceed the scope for adjustment on thevibration dampers.

The vibration dampers are installed on theunit in their unloaded state while it is sus-pended from the crane; the unit is thenplaced in its final position. The unit is alignedwith the aid of wedges placed close to thevibration dampers.

When the unit is horizontal, both longitudinal-ly and laterally, the screws in the vibrationdampers are tightened exactly enough to re-lease the wedges.

The vibration dampers have been selected tocompress between 1.0 and 2.0 mm underthe expected load calculated at the point ofsupport in question.

To check that the vibration dampers are adju-sted for the correct load, make a note ofmeasurement “A” in the unloaded state for

each individual damper. After loading of thevibration dampers, “A” should be reduced by1 to 2 mm. When the adjustment is correct,tighten down the lock nut. The alignment ofthe unit against the foundation is now com-pleted.

Marine Plant

As mentioned earlier the vibration dampersfor marine use cannot be adjusted in height.This means that the foundation must beplane and horizontal within a max. deviationof 2 mm.

As the loads on the supporting surfaces ofthe unit vary, different vibrations dampers areused on the same unit. Consequently, it isimportant to position them in the right placesin compliance with the drawing forwardedfor the unit in question.

In order to check the deflection of the vibra-tion dampers while loaded, measure ”A” (seeFig. 6.28) while the unit is still suspended inthe crane. After the unit has been installed,measure ”A” once more. The difference(deflection) must be between 3 and 5 mm forall vibration dampers.


6--180173--529--EN

If this is not the case, liner plates must beinserted under the vibration dampers until theabove deflection has been obtained.

As the vibration dampers for marine use alsohave to dampen the vibrations coming fromthe foundation caused by the main and auxil-iary engine, vibration dampers are selectedon the basis of the information table andthe mentioned descriptions, etc. This tableincluding appendices are sent to the personin charge at Sabroe Refrigeration, who willthen select the appropriate dampers.

The Influence of PipingConnections on the Unit

To prevent transmission of stress in the pip-ing connections between unit and plant, caremust be taken that the pipes are positionedso as not to cause tensile or compressivestress during expansion or contraction due to

temperature changes. Steel pipes will ex-pand approx. 1 mm per metre per 100°C.

Thus, we recommend the pipe layout shownin Fig. 6.29 with a free length of min. 1.5 m intwo directions which are at right angles toeach other.

On some elevated point on the compressorunit discharge pipe, mount a non-return valveto prevent condensed refrigerant from return-ing to the oil separator.

Fig. 6.29

min. 1.5 m.

min.1.5 m.

Connection tocompressor unit

A non-returnvalve must befitted in the dis-charge pipe


6--19 0173--529--EN

Test Pressure Levels for Standard Compressors and Components

All components for refrigeration plants whichare under the influence of gas pressure mustbe pressure tested to prove their strengthand tightness.

The approving authorities determine the testpressure levels on the basis of various cri-teria. The test pressure requirements can,however, be summarized into a number ofstandard pressure levels, which in practicemeet the requirements set up, and which cantherefore be approved by all the authoritiesinvolved.

The table, Fig. 6.30, shows the standardpressure levels used by Sabroe Refriger-ation. In case of specific applications, theauthorities may, however, demand a highertest pressure level. Within certain limits suchrequirements can be met for SABROE com-pressors - against an additional price.Please, contact Sabroe Refrigeration forfurther information.

When pressure testing compressors andvessels, components must first prove theirstrength by resisting the test pressure of thestrength test. This test is carried out with air.Afterwards the leak test is carried out alsowith air at the prescribed pressure and withthe component soaked in a water basin for30 minutes.

Units consist of components which havebeen pressure tested as described in thetable. This means that it is only necessary toleak test the unit. Dwelling time is 20 min-utes. Leak testing is carried out with pressur-ized air at the pressure stated in the table. Allweldings and connections are covered witha frothing liquid which will start foaming incase of a leak.

Fig. 6.30

Standard Test Pressure Levels

Compressor Type Compressor SideStrength Testing Leak Testing with

Pressurized AirCompressor Type Compressor Sidebar [psi] bar [psi]

CMOSMC 100

High pressure side 42 [609] 25 [363]SMC 100SMC 180 Low pressure side 27 [392] 14 [203]

High pressure side 42 [609] 25 [363]TCMOTSMC

Low pressure side 27 [392] 14 [203]TSMC

Intermediate pressure side 42 [609] 25 [363]

HPO High pressure side 80 [1160] 40 [580]HPOHPC Low pressure side 45 [653] 22 [319]

SAB 110SAB 128SAB 163SAB 202

The entirecompressor block

42 [609] 21 [305]

SAB 283L/Ecompressor block

39 [566] 26 [377]SAB 283L/ESAB 355 L

39 [566] 26 [377]

CompressorUnit

All typesThe entire unit

7 [102]

Vesselsin general

Individual pressure testing in accordance with local rules and regulations.Consequently, no table can be set up.


6--200173--529--EN

Oil Charging

Oil charging is carried out by means of a por-table oil charging pump, see Fig. 6.31.

Oil charging is carried out in the followingway: The high-pressure hose pos. 7, seeFig. 6.31, is connected to the charge valvepos. 24 on the unit via the non-return valvepos. 12 and the correct reduction nipple. Seealso Fig. 6.32. The free end of the suctionhose from the pump pos. 1 is positioned to-gether with the by-pass hose pos. 2 in the oilbarrel. The ball valve pos. 9 and the chargevalve pos. 24 will open whereupon the pump

pos. 5 will start. The oil will now circulate untilthe system is free from air bubbles whereup-on the ball valve pos. 9 will close. The oil willnow be charged to the unit.

When the desired amount of oil has beencharged, the pump will stop and the chargevalve pos. 24 close. Open the ball valve pos.9 carefully so that the pressure is equalized.The hoses can now be dismounted. Loosenthe non-return valve carefully so that the re-maining pressure is equalized. Remember tomount the cap nut on the charge valve and toseal the oil barrel if there is any oil left.

Fig. 6.31

LENGTH: 460

1

5

7

DETAIL A

9 2

20

1/4” RG

DETAIL A

3/8” RG

1/2” RG

7/8” RG

HEIGHT: 350

WIDTH: 340

WEIGHT: 22

(RG = PIPETHREAD)


6--21 0173--529--EN

Fig. 6.32 Piping Diagram for Oil Charging

COMPRESSOR UNITA24

12

7

9

5

20

1

B

2

Oil Charge SAB 128R and 163RCharging the unit with oil is carried out bymeans of a portable oil charging pump. See

description in this section -- Oil Charging.Fig. 6.33 shows all oil charges.

Fig. 6.33 Oil Charge (Oil level at the middle of upper sight glass during operation)

Oil CoolerLitres Oil Separator

LitresCompr. Pipes

LitresTotal, UnitLitresOil Cooler

Type SAB128

SAB163

SAB128

SAB163

SAB128

SAB163

SAB128

SAB163

OOSI 1614 11 11 80 103

OOSI 2114 20 2060 80 9 12

89 112

OOSI 2714 3160 80 9 12

123

OOSI 3214 48 140

OWSG 1615 20 89

OWSG 1619 25 117

OWSG 2115 31 60 80 9 12 100

OWSG 2119 39 131

OWSG 2719 63 155


6--220173--529--EN

Oil Charge (US gal)

Oil CoolerUS gal Oil Separator

US galCompr. Pipes

US galTotal, UnitUS galOil Cooler

Type SAB128

SAB163

SAB128

SAB163

SAB128

SAB163

SAB128

SAB163

OOSI 1614 2.9 2.9 21.1 27.2

OOSI 2114 5.3 5.3 23.5 29.6

OOSI 2714 6.2 32.5

OOSI 3214 12.7 37.0

OWSG 1615 6.6 23.0

OWSG 1619 6.6 30.7

OWSG 2115 10.3 15.8 21.1 2.4 3.2 25.6

OWSG 2119 10.3 34.6

OWSG 2719 16.6 40.9

Comment: Be sure always to have approx 25% extra oil available to refill at first start-up.


6--23 0173--529--EN

Noise from Compressors and UnitsNoise will be inevitable when a compressoror unit is operating. However, by taking thisfact into consideration during the projectphase, it is possible to reduce noise pollutionof the environment considerably.

Over the years Sabroe Refrigeration hasbeen aware of this problem. Consequently,we have designed the compressors and unitswith a view to meeting market demands asregards maximum noise levels.

Of course, modern compressor units are loudand must be expected to issue noise. Thismakes it extremely important that the sounddata stated for a compressor or unit is evalu-ated correctly.

The above issue will be discussed in the fol-lowing. In this connection we would like topoint out that at a failrly low cost it is possibleto make the machine room a pleasant workplace. The use of noise absorbing materialscould be one solution to the problem.

0170-114--EN

02.07


6--240173--529--EN

Sound data for compressor units

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 ofa large number of measurings on variousunits. The measurings have been carried outin accordance 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 can

be calculated provided that the acoustic dataof the machine room is known.

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

Dimension tolerances are :

1 ±3 dB for SAB, SV and FV screw com-pressors±5 dB for SAB 283 L/E and SAB 355 Lscrew compressors

As to the reciprocating compressors thevalues are stated for the compressor blockonly. The dimensional values are stated for100% capacity.

Fig. 6.34

Fictional frame

Reflecting plane1 meter

Dimensional plane

1 meter


6--25 0173--529--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 asanother motor type can increase the noiselevel in the machine room.

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 ones

stated -- e.g. 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 Refrigeration youcan have sound data calculated for otheroperating conditions.

Tables for Noise Data

The following tables show the operatingconditions of the compressor during thenoise measurements as well as the appliedrefrigerant.

0170-164--EN

02.07


6--260173--529--EN

Screw compressors

Evaporating temperature = --15°CCondensing temperature = +35°CRefrigerant = R22/R717Number of revolutions = 2950 rpm.*Number of revolutions = 6000 rpm.

Compressor block LW LP

SAB 110 SM 98 81

Mk1SAB 110 SF 98 81

Mk1SAB 110 LM 98 81

SAB 110 LF 98 81

SAB 110 SM

SAB 110 SF

Mk 2SAB 110 LM

Mk 2SAB 110 LF

SAB 110 LR

SAB 110 SR

SAB 128 M 100 82

Mk 3 SAB 128 F 104 86

SAB 128 R* 104 86

SAB 128 M

Mk 4 SAB 128 F

SAB 128 R*

SAB 163 M 103 85

Mk3 SAB 163 F 105 87

SAB 163 R* 105 87

SAB 163 M

Mk 4 SAB 163 F

SAB 163 R*

Compressor block LW LP

SAB 202 SM 105 86

SAB 202 SF 106 87

SAB 202 LM 105 86

SAB 202 LF 107 88

SAB 283 L 107 87

SAB 283 E 108 88

SAB 355 L 109 89

SAB 81 103 84

SAB 83 104 85

SAB 85 105 86

SV 87 106 86

SV 89 108 87

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

Compressor unit LW LP

SAB 163 BM

SAB 163 BF

106110

8892

0170-115-EN

01.01


6--27 0173--529--EN

Vibration Data for Compressors - All Compressor Types

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

Vibration data for Sabroe 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 vibrationdampers supplied by Sabroe Refrigeration(additional), the vibrations against thefoundation are reduced by:

-- 85-95% for screw compressor units

-- 80% for recip. compressor units

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

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

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

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

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


6--280173--529--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 Assessment

If 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 EvaluationNaturally, the oil sample can be analysed bythe oil company which supplies the oil.As a special offer to our customersSabroe 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.

ProcedureS A form set with a plastic sampling bottle

and a dispatching envelope can be re-quested from the local SabroeRefrigeration representative.


6--29 0173--529--EN

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 in

which the address of the laboratory in Hol-land are also mentioned.

Analysing the OilThe 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 Oil PAO 68 Sabroe Oil AP 68 Sabroe Oil A 100

Parameter Unit Method TargetSpec. Max Min

TargetSpec. Max Min

TargetSpec. Max Min

Viscosity @ 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 0.02 -- 0.05 0.02 --

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

Water ppm Karl Fisher -- 100 -- -- 100 -- -- 100 --

Appearance -- -- report report report

Colour -- ASTM D1500

report report report

Pentane Insolubles W% MM 490(Sum)

-- 0.05 -- 0.05 -- -- 0.05 --

Oxidation abs/cm IR,1700-1720/cm

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

Nitration abs/cm IR,1627-1637/cm

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

Nitro Compounds abs/cm IR,1547-1557/cm

-- 0.5 -- -- 0.5 -- -- 0.5 --

Maximum values for metal content in the oil

Lead ppm ICP -- 10 -- -- 10 -- -- 10 --

Copper ppm ICP -- 10 -- -- 10 -- -- 10 --

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

Iron ppm ICP -- 100 -- -- 100 -- -- 100 --

Chromium ppm ICP -- 5 -- -- 5 -- -- 5 --

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

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

1) TAN (Total Acid Number) is only reported for non-ammoniaapplications

2) SAN (Strong Acid Number) is only reported for non-ammo-nia applications


6--300173--529--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.

S 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 Sabroe Refri-geration so that we are in a position to adviseyou, if required.

0170-154--EN

02.11


6--31 0173--529--EN

Selecting Lubricating Oil for SABROE ScrewCompressorsRefrigerant: R717

In a period from 1990 to 1995 SabroeRefrigeration experienced a rising number ofproblems with the use of mineral oils, es-pecially in R717 plants. The problems can bedivided into two groups:

a: The oil changes viscosity within a fewoperating hours.

b: The oil dissolves(becomes very black).

The problems have been observed in con-nection with several different types of mineraloil and often occur within only a fewoperating hours. The consequences havebeen severe for both compressors andplants.

On the basis of the thorough investigationsubsequently carried out by SabroeRefrigeration, it was decided to introduce aseries of synthetic oils complying with therequirements of modern refrigeration plants.

Mineral oils can, however, still be used inrefrigeration plants, provided the lubricatingquality is carefully monitored. For modernhigh-capacity refrigeration plants where along service life for both lubricant and movingparts is expected, Sabroe Refrigerationrecommends the use of synthetic oils.

Areas of application and specifications forthe synthetic oils mentioned are described inthe following pages. Supervisors and/orusers of plants are at liberty to choose be-

tween Sabroe Refrigeration’s own oil brandsand alternative oil brands, provided theycomply with the specifications required.

General

This recommendation will only deal with thelubrication of the compressor. The perform-ance of the lubricant in the plant (receiver,evaporator, etc.) must, however, also be con-sidered.

Lubricating oils with relatively high viscositymust be used to ensure a satisfactory lu-brication of refrigeration compressors.

To achieve the best lubrication, the oil must:

S possess the correct viscosity under alloperating conditions.

S possess acceptable viscosity at start-up.

S possess sufficient oxidation stability (theoil must be free of moisture whencharged to the system).

S possess sufficient chemical stabilitywhen used together with R717.

Moreover, the extent to which different re-frigerants dissolve in the oil must be deter-mined so that the oil return system, etc. canbe designed to perform at its optimum.

Stratification

Note that the oil in some plants is layered inrefrigerant receivers and evaporators undercertain operating conditions and at certain oilconcentrations.


6--320173--529--EN

Plants with Several Different CompressorTypes/Makes

In plants where several different compressortypes/makes are connected, it is stronglyrecommended to use the same type of oil inall the compressors. This is very importantwhere automatic oil return systems are used.

If you consider changing the type of oil,please read the section Oil Changing onSABROE Compressors carefully.

Selecting Lubricating Oil

The correct oil is selected by means of thefollowing diagrams. When the general condi-tions concerning the lubrication of the com-pressor have been considered, the specificconditions of the plant must be taken intoaccount.

Use the oil recommendation diagrams to se-lect the correct oil code number.

The oil code number consists of letters indi-cating the oil type and viscosity number.

Codedesign Oil Types

M Mineral oil

A Synthetic oil based onAlkylbenzene

PAO Synthetic oil based onPolyalphaolefin

AP Mixture of A and PAO oils

E Synthetic ester-based lubricants

In the oil recommendation diagrams it ispossible to find the code number best suitedfor the operating conditions in question. Withthe code number it is possible to select thecorrect Sabroe oil for the application in ques-tion.

Oil Types and Oil Companies

Due to the large number of oil companiesoffering oil for refrigeration plants, it has notbeen possible for Sabroe Refrigeration totest all the different oil brands on the globalmarket.

It is our experience that certain oil brandscan change character during use and thus nolonger correspond to the specificationsstated by the oil companies on delivery. Wehave thus experienced changes in specifica-tions as well as formula and performancewithout having received information on thisbeforehand from the oil company. Thismakes it extremely difficult for Sabroe Refrig-eration to give a general approval of other oilbrands.

In co-operation with a large, respected oilcompany Sabroe Refrigeration has thereforedeveloped a series of three different oilscovering most demands. Furthermore, a listof the oils which can be supplied throughSabroe Refrigeration has been prepared.Data for these oils is included in the tableData for Sabroe Oils. We recommend thatyou use these oils, which can be delivered in20 litre pails or 208 litre drums. When order-ing, use the part no. stated in List of PartNumbers for Available Sabroe Oils.

It is of course possible to use similar oilsfrom other oil companies. If this is the case,use the table Data for Sabroe Oils.

Please note that Sabroe Refrigeration hasnot tested other oils than our own brand.Thus we cannot guarantee the quality, stabil-ity or suitability of other oils. The respectiveoil companies are thus responsible for thequality and suitability of the oil delivered, andif there are any problems with these oils in


6--33 0173--529--EN

the compressor or the refrigeration plant,contact the oil supplier directly.

When selecting oils from other oil com-panies, special attention should be paid tothe suitability of the oil in the compressor andthe refrigeration plant as a whole.

Please note in particular the following points:

S Oil type

S Compressor type

S Miscibility between refrigerant and oil

S Operating data for the compressor

-- Discharge gas temperature

-- Oil temperature

-- Oil temperature before injection intocompressor, but after oil cooler

-- Max. permitted oil temperature =set point for alarm.

-- Min. permitted oil temperature =set point for alarm.

-- Condensing pressure

-- Evaporating pressure

S The viscosity of the oil in the compressorduring operation:

-- Solubility of refrigerant in the oil

-- Operating temperatures

-- Vapour pressure in the oil reservoir

-- Discharge pressure and gastemperature

-- Compatibility with neoprene O-rings:The aniline point indicates how theO-ring material reacts to the oil.

At an aniline point less than approx.100°C the material has a tendency toswell, and at an aniline point higher

than approx. 120°C it has a tendencyto shrink.

Thus it cannot be recommended tochange the oil type from M to PAOwithout changing the O-rings at thesame time as a leak may otherwiseeasily occur in the compressor or theplant. Sabroe Refrigerationrecommends therefore the use of theSabroe AP68 oil since this type of oilin this case reduces considerably therisk of leaks.

Sabroe Refrigeration can supply a listof operating data on request.

S Please note the viscosity limits duringoperation:

• Optimum viscosity limits= 20 to 50 cSt

• Max. permitted viscosity = 100 cSt

• Min. permitted viscosity = 10 cSt

• Max. permitted viscosity during start-upof the compressor = 500 cSt

• Max. refrigerant concentration in the oilduring operation: 25% - also in casethe viscosity requirements have beenmet.

Use of Mineral Oil

As described in the introduction, mineral oilin particular causes serious problems es-pecially in R717 plants.

When using mineral oil, it is important tomonitor the plant closely. The condition/co-lour of the oil must therefore be checked on aweekly basis and for each 1,000 to 2,000 op-erating hours oil samples must be taken forfurther analysis.

Sabroe Refrigeration recommends there-fore only to use M oil under moderateoperating conditions - see the followingoil recommendation diagrams.


6--340173--529--EN

Sabroe Refrigeration is aware that severalcustomers have used mineral oils for manyyears without any problems. The customerswho wish to continue using mineral oil inexisting as well as new compressors can doso, provided that the compressor type andthe operating conditions are similar to theexisting ones.

Sabroe Refrigeration has thus decided tomarket one brand of mineral oil which hasbeen tested and found suitable for most ofthe general refrigeration purposes.

In case another brand of mineral oil is used,follow the specifications on the data pages inthis recommendation as a guideline.

Mineral oil can be used in refrigerationplants, provided the lubricating quality iscarefully monitored. Sabroe Refrigerationrecommends, however, that you use syn-thetic oils for modern high-capacity plantswhere a long service life for both lubricantand moving parts is expected.

The advantage of using synthetic lubricatingoils is a much lower oil consumption andlonger oil changing intervals. Improvedviscosity at low temperatures facilitates fur-thermore drainage at the cold parts of theplants.

How to Use the Diagrams in the OilRecommendation:

To find the correct code number, selectrefrigerant and compressor type in the oilrecommendation diagram. Then insert theestimated operating conditions in the dia-gram.

Example (screw compressors):

Refrigerant: R717Condensing temperature: TC +35 °CEvaporating temperature: TE -20 °C

Please observe !Sometimes plants operate under differentconditions, e.g. different evaporating tem-peratures due to variations in the plant, ordifferent condensing temperatures as aresult of seasonal changes.By inserting TC and TE in the oil recom-mendation diagram, the recommendedarea is found. In this case it is oil area 1. Ifthe intersection is outside the area, con-tact Sabroe Refrigeration for a detailedcalculation by means of the calculationprogram COMP1.



-60 -50 -40 -30-30

-20

-10

0

10

-20 -10 0 10 20

20

30

40

50C°

C°

F122

104

86

68

50

32

14

-4

-22

°

TC

F°68503214-4-22-40-58-76TE

1

c

R717

By using the table which is situated next tothe oil recommendation diagram, select therecommended code number and thus therecommended oil. In the example abovethere are thus 3 possibilities: PAO3, AP1 orM1. However, M1 is only recommended formoderately loaded compressors.


6--35 0173--529--EN

PAO3 YAP1 l/Y

1Code no.

Areano.

M1 Seenote

Oil Change on Sabroe Compressors

Never change to another oil type withoutcontacting the oil supplier. Nor is it advisableto recharge a compressor with another oiltype than the one already used for the plantor compressor in question.

Mixing different oils may result in operatingproblems in the refrigeration plant or damageto the compressor. Incompatibility betweendifferent oil types may reduce the lubricatingproperties considerably and may cause oilresidues to form in the compressor, oilseparator or plant. Oil residues may blockfilters and damage the moving parts of thecompressor.

Changing the oil type or brand should onlybe done following a thorough procedure in-volving drainage and evacuation of the refrig-

eration plant. Information on a suitable pro-cedure can be obtained from SabroeRefrigeration as well as a number of oil com-panies.

It is extremely important that the new unusedoil is taken directly from its original containerand that both the brand and the type corre-spond to the specifications of the plant.

Make sure that the original oil container issealed properly during storage so that mois-ture from the air is not absorbed by the oil.Many oils, particularly polyolester oils, areextremely hygroscopic. It is therefore recom-mended only to buy the oil in containerswhose size correspond to the amount to beused.

In case all of the oil is not used, make surethat the rest of the oil is sealed in the originalcontainer and stored in a warm, dry place. Itis recommended to charge nitrogen to keepthe water content below 50 ppm.

Ideally, oil containers should be equippedwith a barrel tap to ensure an effective, air-tight seal.


6--360173--529--EN

Oil Changing IntervalsA list of the recommended oil changing inter-vals is included in the instruction manuals ofthe compressors. This list is for guidanceonly. The actual oil changing intervals areoften determined by a number of operatingparameters in the plant.

It is strongly recommended to monitor thequality of the oil by performing oil analyseson a regular basis. This will also give an in-dication of the condition of the plant. Thisservice can be supplied by SabroeRefrigeration or the oil supplier.

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 Sabroe 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 Sabroe Refrigeration.

SH : Suction gas superheat, K (Kelvin).

: Zone in which both oils are useable.: Calculation must be performed using COMP1.

A

B

C


6--37 0173--529--EN

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 great difference between polyolester-based lubricants from various suppliers it is

E5Due to the great difference between polyolester-based lubricants from various suppliers, it isnot possible to present any typical data for these oils. When using other oil brands than the

E9p p y yp g

ones recommended by Sabroe Refrigeration, please contact the oil supplier to select thecorrect oil type

E11correct oil type.

The listed data are typical values and are only intended as a guideline when selecting a similaroil from a different oil company. Data equivalence does not necessarily qualify the oil for use inSabroe Refrigeration’s Sabroe compressors.


6--380173--529--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 barrel

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 0001) 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)


6--39 0173--529--EN

R717screw compressors

Area no.Code 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

Y : In case of a new plant. Very suitable.

l : In case you wish to change from mineral oil.: Min suction temperature --50°C: at TE< --50°C superheating must be introduced.

: Calculation must be performed using COMP1.

Note: Sabroe Refrigeration recommends that the use of M oils is restricted to moderately loaded compressorsand that the oil quality is monitored carefully via regular oil analyses.

HLI: Calculation must be performed using COMP1.

C


6--400173--529--EN

List of Major Oil Companies

The oil from the companies listed below are not tested by Sabroe Refrigeration and are there-fore not approved by Sabroe Refrigeration. The following list includes the information providedby the oil companies. The oil companies are responsible for the information concerning thedurability and suitability of their oils for specific purposes. Oils tested and approved by SabroeRefrigeration are included 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 • •

0170-156--EN

01.06


6--41 0173--529--EN

Selecting Lubricating Oil for SABROE ScrewCompressorsRefrigerant: HFC/HCFC

In a period from 1990 to 1995 SabroeRefrigeration experienced a rising number ofproblems with the use of mineral oils, es-pecially in R717 plants. The problems can bedivided into two groups:

a: The oil changes viscosity within a fewoperating hours.

b: The oil dissolves(becomes very black).

The problems have been observed in con-nection with several different types of mineraloil and often occur within only a fewoperating hours. The consequences havebeen severe for both compressors andplants.

On the basis of the thorough investigationsubsequently carried out by SabroeRefrigeration, it was decided to introduce aseries of synthetic oils complying with therequirements of modern refrigeration plants.

Mineral oils can, however, still be used inrefrigeration plants, provided the lubricatingquality is carefully monitored. For modernhigh-capacity refrigeration plants where along service life for both lubricant and movingparts is expected, Sabroe Refrigerationrecommends the use of synthetic oils.

Areas of application and specifications forthe synthetic oils mentioned are described inthe following pages. Supervisors and/orusers of plants are at liberty to choose be-

tween Sabroe Refrigeration’s own oil brandsand alternative oil brands, provided theycomply with the specifications required.

General

This recommendation will only deal with thelubrication of the compressor. The perform-ance of the lubricant in the plant (receiver,evaporator, etc.) must, however, also be con-sidered.

Lubricating oils with relatively high viscositymust be used to ensure a satisfactory lu-brication of refrigeration compressors.

To achieve the best lubrication, the oil must:

S possess the correct viscosity under alloperating conditions.

S possess acceptable viscosity at start-up.

S possess sufficient oxidation stability (theoil must be free of moisture whencharged to the system).

S possess sufficient chemical stabilitywhen used together with HFC/HCFC.

Moreover, the extent to which different re-frigerants dissolve in the oil must be deter-mined so that the oil return system, etc. canbe designed to perform at its optimum.

Stratification

Note that the oil in some plants is layered inrefrigerant receivers and evaporators undercertain operating conditions and at certain oilconcentrations. This applies in particular toHFC/HCFC plants.


6--420173--529--EN

The oil recommendation diagrams forSABROE compressors with HFC and HCFCrefrigerants indicate the limits for Sabroe oilswhere stratification occurs. The oil con-centrations stated in these diagrams mustnot be exceeded. This makes it possible toadjust the oil rectification/return systems tothe oil consumption of the compressor sothat the maximum concentration is not ex-ceeded. For area A in the diagrams, the oilconcentration in the liquid phase must notexceed 2%. For the other areas, the oil con-centration must not exceed 5%. For area B,please contact Sabroe Refrigeration.

Plants with Several Different CompressorTypes/Makes

In plants where several different compressortypes/makes are connected, it is stronglyrecommended to use the same type of oil inall the compressors. This is very importantwhere automatic oil return systems are used.

If you consider changing the type of oil,please read the section Oil Changing onSABROE Compressors carefully.

Selecting Lubricating Oil

The correct oil is selected by means of thefollowing diagrams. When the general condi-tions concerning the lubrication of the com-pressor have been considered, the specificconditions of the plant must be taken intoaccount.

Use the oil recommendation diagrams to se-lect the correct oil code number.

The oil code number consists of letters indi-cating the oil type and viscosity number.

Codedesign Oil Types

M Mineral oil

A Synthetic oil based onAlkylbenzene

PAO Synthetic oil based onPolyalphaolefin

AP Mixture of A and PAO oils

E Synthetic ester-based lubricants

In the oil recommendation diagrams it ispossible to find the code number best suitedfor the operating conditions in question. Withthe code number it is possible to select thecorrect Sabroe oil for the application in ques-tion.

Oil Types and Oil Companies

Due to the large number of oil companiesoffering oil for refrigeration plants, it has notbeen possible for Sabroe Refrigeration totest all the different oil brands on the globalmarket.

It is our experience that certain oil brandscan change character during use and thus nolonger correspond to the specificationsstated by the oil companies on delivery. Wehave thus experienced changes in specifica-tions as well as formula and performancewithout having received information on thisbeforehand from the oil company. Thismakes it extremely difficult for Sabroe Refrig-eration to give a general approval of other oilbrands.

In co-operation with a large, respected oilcompany Sabroe Refrigeration has thereforedeveloped a series of three different oilscovering most demands. Furthermore, a listof the oils which can be supplied throughSabroe Refrigeration has been prepared.Data for these oils is included in the tableData for Sabroe Oils. We recommend thatyou use these oils, which can be delivered in20 litre pails or 208 litre drums. When order-


6--43 0173--529--EN

ing, use the part no. stated in List of PartNumbers for Available Sabroe Oils.

It is of course possible to use similar oilsfrom other oil companies. If this is the case,use the table Data for Sabroe Oils.

Please note that Sabroe Refrigeration hasnot tested other oils than our own brand.Thus we cannot guarantee the quality, stabil-ity or suitability of other oils. The respectiveoil companies are thus responsible for thequality and suitability of the oil delivered, andif there are any problems with these oils inthe compressor or the refrigeration plant,contact the oil supplier directly.

When selecting oils from other oil com-panies, special attention should be paid tothe suitability of the oil in the compressor andthe refrigeration plant as a whole.

Please note in particular the following points:

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 temperature

-- Oil temperature before injection intocompressor, but after oil cooler

-- Max. permitted oil temperature =set point for alarm.

-- Min. permitted oil temperature =set point for alarm.


-- Evaporating pressure

S The viscosity of the oil in the compressorduring operation and under the influenceof:

-- Solubility of refrigerant in the oil

-- Operating temperatures

-- Vapour pressure in the oil reservoir

-- Discharge pressure and gastemperature

-- Compatibility with neoprene O-rings:The aniline point indicates how theO-ring material reacts to the oil.

At an aniline point less than approx.100°C the material has a tendency toswell, and at an aniline point higherthan approx. 120°C it has a tendencyto shrink.

Thus it cannot be recommended tochange the oil type from M to PAOwithout changing the O-rings at thesame time as a leak may otherwiseeasily occur in the compressor or theplant. Sabroe Refrigerationrecommends therefore the use of theSabroe AP68 oil since this type of oilin this case reduces considerably therisk of leaks.

Sabroe Refrigeration can supply a listof operating data on request.

S Please note the viscosity limits duringoperation:

• Optimum viscosity limits= 20 to 50 cSt

• Max. permitted viscosity = 100 cSt

• Min. permitted viscosity = 10 cSt

• Max. permitted viscosity during start-upof the compressor = 500 cSt

• Max. refrigerant concentration in the oilduring operation: 25% - also in casethe viscosity requirements have beenmet.


6--440173--529--EN

Use of Mineral Oil

As described in the introduction, mineral oilin particular causes serious problems es-pecially in R717 plants.

When using mineral oil, it is important tomonitor the plant closely. The condition/co-lour of the oil must therefore be checked on aweekly basis and for each 1,000 to 2,000 op-erating hours oil samples must be taken forfurther analysis.

Sabroe Refrigeration recommends there-fore only to use M oil under moderateoperating conditions - see the followingoil recommendation diagrams.

Sabroe Refrigeration is aware that severalcustomers have used mineral oils for manyyears without any problems. The customerswho wish to continue using mineral oil inexisting as well as new compressors can doso, provided that the compressor type andthe operating conditions are similar to theexisting ones.

Sabroe Refrigeration has thus decided tomarket one brand of mineral oil which hasbeen tested and found suitable for most ofthe general refrigeration purposes.

In case another brand of mineral oil is used,follow the specifications on the data pages inthis recommendation as a guideline.

Mineral oil can be used in refrigerationplants, provided the lubricating quality iscarefully monitored. Sabroe Refrigerationrecommends, however, that you use syn-

thetic oils for modern high-capacity plantswhere a long service life for both lubricantand moving parts is expected.

The advantage of using synthetic lubricatingoils is a much lower oil consumption andlonger oil changing intervals. Improvedviscosity at low temperatures facilitates fur-thermore drainage at the cold parts of theplants.

How to Use the Diagrams in the OilRecommendation:

To find the correct code number, selectrefrigerant and compressor type in the oilrecommendation diagram. Then insert theestimated operating conditions in the dia-gram.

Example (screw compressors):

Refrigerant: R134aCondensing temperature: TC +35°CEvaporating temperature: TE -3°C

Please observe !Sometimes plants operate under differentconditions, e.g. different evaporating tem-peratures due to variations in the plant, ordifferent condensing temperatures as aresult of seasonal changes.By inserting TC and TE in the oil recom-mendation diagram, the recommendedarea is found. In this case it is oil area 2. IfTE should change, e.g. from --10°C to--30°C, oil area 1 should be used. Since--30°C is within the marked area, oil area2 can, however, also be used at this TE.


6--45 0173--529--EN

C°



-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

SH5

SH10

SH20

SH30

SH20

R134a

1

2

By using the table which is situated next tothe oil recommendation diagram, select therecommended code number and thus therecommended oil. In the example above anoil with the code number E9 can be used.

E5 Y

E9 Y

1 2

Code no.Areano.

(See note)

Oil Change on Sabroe Compressors

Never change to another oil type withoutcontacting the oil supplier. Nor is it advisableto recharge a compressor with another oiltype than the one already used for the plantor compressor in question.

Mixing different oils may result in operatingproblems in the refrigeration plant or damage

to the compressor. Incompatibility betweendifferent oil types may reduce the lubricatingproperties considerably and may cause oilresidues to form in the compressor, oilseparator or plant. Oil residues may blockfilters and damage the moving parts of thecompressor.

Changing the oil type or brand should onlybe done following a thorough procedure in-volving drainage and evacuation of the refrig-eration plant. Information on a suitable pro-cedure can be obtained from SabroeRefrigeration as well as a number of oil com-panies.

It is extremely important that the new unusedoil is taken directly from its original containerand that both the brand and the type corre-spond to the specifications of the plant.

Make sure that the original oil container issealed properly during storage so that mois-ture from the air is not absorbed by the oil.Many oils, particularly polyolester oils, areextremely hygroscopic. It is therefore recom-mended only to buy the oil in containerswhose size correspond to the amount to beused.

In case all of the oil is not used, make surethat the rest of the oil is sealed in the originalcontainer and stored in a warm, dry place. Itis recommended to charge nitrogen to keepthe water content below 50 ppm.

Ideally, oil containers should be equippedwith a barrel tap to ensure an effective, air-tight seal.


6--460173--529--EN

Oil Changing IntervalsA list of the recommended oil changing inter-vals is included in the instruction manuals ofthe compressors. This list is for guidanceonly. The actual oil changing intervals areoften determined by a number of operatingparameters in the plant.

It is strongly recommended to monitor thequality of the oil by performing oil analyseson a regular basis. This will also give an in-dication of the condition of the plant. Thisservice can be supplied by SabroeRefrigeration or the oil supplier.

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 Sabroe 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 Sabroe Refrigeration.

SH : Suction gas superheat, K (Kelvin).

: Zone in which both oils are useable.: Calculation must be performed using COMP1.

A

B

C


6--47 0173--529--EN

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 great difference between polyolester-based lubricants from various suppliers it is

E5Due to the great difference between polyolester-based lubricants from various suppliers, it isnot possible to present any typical data for these oils. When using other oil brands than the

E9p p y yp g

ones recommended by Sabroe Refrigeration, please contact the oil supplier to select thecorrect oil type

E11correct oil type.

The listed data are typical values and are only intended as a guideline when selecting a similaroil from a different oil company. Data equivalence does not necessarily qualify the oil for use inSabroe Refrigeration’s Sabroe compressors.


6--480173--529--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 barrel

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 0001) 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)


6--49 0173--529--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 Sabroe Refrigeration for an update on the requirement for superheat.

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.

* : Dry expansion systems only. Flooded systems to be considered individually: contact Sabroe Refrigeration

SH : Suction gas superheat, K (Kelvin): Calculation must be performed using COMP1

A

C


SH20

SH5

SH10 SH20 SH10SH5SH25

2


6--500173--529--EN

-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 Sabroe Refrigeration for an update on the requirement for superheat.

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.

* : Dry expansion systems only. Flooded systems to be considered individually: contact Sabroe Refrigeration

SH : Suction gas superheat, K (Kelvin): Calculation must be performed using COMP1

A

C


SH20


6--51 0173--529--EN

C°



R134ascrew compressors

Area no.Code 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 Sabroe 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.


6--520173--529--EN

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 no.Code no.

1 2

F

104

86

68

50

32

14

-4

-22

°

F°503214-4-22-40-58-76TE

-94

TC

B

C



Y : In case of a new plant. Very suitable.: Max oil concentration in liquid phase: contact Sabroe Refrigeration: 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: Calculation must be performed using COMP1

B

C

1

2 (3)

3 SH15

SH10

SH15

(See note)


(2)


6--53 0173--529--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


Y : In case of a new plant. Very suitable.: Max oil concentration in liquid phase: contact Sabroe Refrigeration: 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: Calculation must be performed using COMP1

B

C

SH5

SH5

SH10

(See note)



6--540173--529--EN




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: Calculation must be performed using COMP1

C

2

SH30

SH15

SH5

SH5


(See note)


6--55 0173--529--EN

List of Major Oil Companies

The oil from the companies listed below are not tested by Sabroe Refrigeration and are there-fore not approved by Sabroe Refrigeration. The following list includes the information providedby the oil companies. The oil companies are responsible for the information concerning thedurability and suitability of their oils for specific purposes. Oils tested and approved by SabroeRefrigeration are included 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 • •

9. SettingsService Manual SAB 128R and SAB 163R Mk4

9--00173--529--EN

9. Settings

Table of Contents

Settings 9--1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Safety Precautions 9--1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Qualification Requirements 9--1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Screw Compressors -- Measured and Calculated Pressure Levels 9--2. . . . . . . . . . . . . . . . . .Screw Compressors -- Measured and Calculated Temperatures 9--3. . . . . . . . . . . . . . . . . . . .Notes 9--4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .


9--1 0173--529--EN

Settings

The purpose of this document is to provideinformation about the factory settings of thesafety and control equipment, how to changethe settings and the effect of a change.

This document is primarily intended for in-stallation and service engineers.




This document must not be copied without awritten permission from Sabroe Refrigerationand the contents hereof must not be im-parted to a third party, nor be used for anyunauthorised purpose. Contravention will beprosecuted.

Safety Precautions

Danger !

Risk of injury to personnel and damage toequipment! In addition to the safety precau-tions in this document, always read thesafety precautions belonging to this equip-ment before changing the settings. Failure tocomply with safety precautions may causedeath or injury to personnel. It may alsocause damage to or destruction of the equip-ment.

Qualification RequirementsChanges in the factory settings must only becarried out by an authorised refrigerationcompany. Moreover, it is required that thepersonnel is able to follow a detailed descrip-tion in English.

The setting of pressure and temperaturesmust be made in accordance with the tablesFig. 9.1 and Fig. 9.2 supplemented by thenumbered notes.


9--20173--529--EN

Fig. 9.1 Screw compressors -- Measured and Calculated Pressure Levels

Measuring Min Max Factory Note

Suction pressure(bar)

High alarmHigh warningLow warningLow alarm

--1.5--1.0--1.0

--9.06.06.0

--5.01.51.0

3+4+53+4+53+4+5

Discharge pressure(bar)

High alarmHigh warningLow warningLow alarm

4.03.0--

--1.0

24.022.0--

--1.0

16.015.0--

--1.0

1+61+6

1+5

Oil pressure (bar)Calculated value

SAB Mk 1 compressors

Low warningLow alarm

1.51.0

6.05.0

4.02.5

2+72+7


SAB Mk 2 compressors


0.00.0

6.05.0

0.00.0

2+92+9

Oil pressure (bar)Calculated valueSAB Mk 3 compressorsSAB 202, SAB 250, SAB 330FV 19, SV 24/26, FV 24/26


Set point 1Set point 2

1.00.5

0.00.0

6.05.0

10.010.0

1.51.2

2.54.0

2+92+9

2121


VMY Mk 2--2.5 compressor


1.51.0

6.05.0

2.01.5

2+9+172+9+17

Oil pressure(bar)Calculated value

VMY Mk 3 compressors



1.51.0

0.00.0

6.05.0

10.010.0

4.03.0

5.57.0

2+92+9

2222


SAB 80



1.51.0

0.00.0

6.05.0

10.020.0

2.01.5

0.516.0

2+92+9

2020

Diff. pressureacross oil filter (bar)Calculated valueAll types but SAB 80

High alarmLow warning

0.00.0

1.51.3

1.00.7

2+112+11

Diff. pressureacross oil filter (bar)Calculated value

SAB 80

High alarmHigh warning

0.00.0

2.52.2

1.61.4

2+11+192+11+19


9--3 0173--529--EN

Fig. 9.2 Screw Compressors -- Measured and calculated temperatures

Measuring Min Max Factory Note

Discharge temp.(°C)

High alarmHigh warningLow warning.Low alarm.

60.050.0--65.0--

130.0120.0--65.0--

100.090.0--65.0--

1+61+6

Oil temperature(°C)


40.030.010.00.0

80.070.050.040.0

60.055.025.020.0

2+72+72+72+7

Brine temperature(°C)


--60.0--60.0--100.0--100.0

100.0100.0100.0100.0

60.050.04.02.0

1+61+61+61+6

Suction gas superheat(°C)

Calculated value


6.05.00.00.0

120.0120.040.040.0

110.0100.02.00.0

2+7+122+7+122+7+102+7+10

Disch. gas superheat(°C)Calculated value

Low warning.Low alarm.

5.00.0

40.040.0

10.00.0

2+7+102+7+10

4-20 m Auxiliary input signalMeasuring Min Max Factory Note

Auxiliary input(4-20 mA)


--999.9--999.9--999.9--999.9

999.9999.9999.9999.9

0.00.00.00.0

3+183+183+183+18


9--40173--529--EN

Notes

Note 1 The alarm cannot be switched off until the problem has been solved.

Note 2 The alarm can be switched off immediately (RESET key).

Note 3 The alarm is switched off automatically.

Note 4 The safety limits can be entered in bar or °C/R.

Note 5 Alarm monitoring active when digital output ”compressor starting signal” has beenchosen.

Note 6 Alarm monitoring always active -- except when ”BLOCKED” has been selected inthe picture COMPRESSOR CTRL MODE.

Note 7 Alarm monitoring 300 sec delayed after compressor start.



Note 10 A setting of 0.0 hinders monitoring.

Note 11 Delay of 300 sec, regardless of when the limits are exceeded.

Note 12 The compressor must have been above 5% capacity. Below 5% capacity monitor-ing is hindered.


Note 14 Delay of 60 sec, regardless of when the limits are exceeded.

Note 15 Only applies to HPO and HPC compressors.


Note 17 For VMY Mk 2-2.5, calculate the following (see Fig. 6 below):

Oil pressure = Oil pressure 3 (after oil filter) -- Discharge pressure 2 .For all other compressor types (except for SAB 80, see Note 20), calculate the fol-

lowing: Oil pressure = Oil pressure 3 (after oil filter) -- Suction pressure 1 .

Note 18 The limits are not active until AUX. INPUT SIGNAL has been selected in theCALIBRATION 4-20 mA menu.

Note 19 For SAB 80 the differential pressure across the oil filter is calculated as follows (see

Fig. 6 below): Oil filter diff. pressure = Discharge pressure 2 - Oil pressure 4 (af-ter oil filter).

The shown oil filter pressure will thus be 0.1 to 0.7 bar higher than the actual pres-sure loss across the filter due to the pressure loss across the oil separator and theoil cooler.

The maximum allowed pressure drop across the oil filter is 1.2 bar. Consequently,the warning limit should be set between 0.8 and 1.4 bar or lower. The alarm limitshould be set between 1.1 and 1.7 bar or lower.


9--5 0173--529--EN

Note 20: Set points 1 and 2 are used for alarm monitoring of the mechanical oil pump.Cf. the description of the alarm under ”Oil pump error” in the section Other Alarms.For SAB 80, the oil pressure is calculated as follows (see Fig. 6 below):

Oil pressure = Oil pressure 3 (after pump) - Suction pressure 1 .

Note 21: The set points are used to control the oil pump. When the pressure falls below setpoint 1, the oil pump will start. When the pressure exceeds set point 2 for 60 se-conds, the oil pump will stop.

Note 22: The set points are used to control the full flow pump. When the pressure falls belowset point 1, the full flow pump will start. When the pressure exceeds set point 2 for60 seconds, the full flow pump will stop.

Fig. 6

Oilseparator

Oilseparator

Oil filter

Compressor

Others

CompressorOil pump

Oil filter

Oil cooler

Suction pressure

Oil pressure(before compressor)

Oil pressure 2(between pump and filter)

Discharge pressure

SAB 80

Oil pump

Oil cooler

10. Operating InstructionsService Manual SAB 128R and SAB 163R Mk4

10--00173--529--EN

10. Operating Instructions

Table of Contents

Operating Instructions 10--1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Safety Precautions 10--1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Ventilation 10--1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Pressure 10--1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Hot and Cold Surfaces 10--2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Qualification Requirements 10--2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Compressor Control and Alarm Functions 10--3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Operator’s Panel, UNISAB II Control 10--3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Display 10--3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Front Panel 10--4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Control Section 10--4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Recording Section 10--5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Menu Structure 10--5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Compressor Unit 10--6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Functions 10--6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Preparations for Starting 10--6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Starting 10--8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Operating Mode UNISAB II 10--8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Checks to be Performed during Operation 10--13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Operations Log 10--14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Stopping Routine 10--15. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .


10--1 0173--529--EN

Operating Instructions


S Dangers resulting from failure to complywith safety precautions when operatingthe equipment.

S How to start, operate, and stop thisequipment in a safe way.

S How to act when problems occur duringoperation.

This document is primarily intended for oper-ators and service engineers.





Danger !

Risk of injury to personnel and damage toequipment! Always read the safety precau-tions belonging to this equipment beforestart. Failure to comply with safety precau-tions may cause death or injury to personnel.It may also cause damage to or destructionof the equipment.

Safety Precautions

Danger !

A number of safety considerations whichmust be read before operating the unit inquestion are presented in the following.General safety instructions/regulations mustbe studied carefully. Failure to do so may re-sult in personal injury or even death. More-over, the equipment may be damaged ordestroyed.

Ventilation

Before operating the unit, always check tosee that the ventilation system used in thearea where the screw compressor unit is lo-cated (machine room) is functional and oper-ating at full capacity.

The safety instructions explain the risks as-sociated with the refrigerant and oil beingused. Pay close attention to the fact thatlarge amounts of escaped (or released) re-frigerant entail risk of suffocation.

The safety instructions also explain the risksgenerally associated with refrigerants. Bodycontact with leaking liquid refrigerant entailshigh risk of injuries caused by intense cold.

Pressure

A screw compressor unit comprises a pres-surized system. Never loosen threaded joints(such as a union nut) while the system isunder pressure and never open pressurizedparts of the system.


10--20173--529--EN

Hot and Cold Surfaces

A screw compressor unit contains both hotand cold system parts. Always wear and usethe recommended safety items.

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

Qualification RequirementsBefore carrying out the measures set forth inthis document, all personnel must have care-fully studied the instructions issued for thescrew compressor unit.

The personnel must also fulfil all national re-quirements for authorization.


10--3 0173--529--EN

Compressor Control and Alarm Functions

Operator’s Panel, UNISAB IIControlAll control operations for the screw com-pressor unit are carried out from the oper-ator’s panel and its keys. The following pagegives a brief explanation of what the keys onthe operator’s panel are used for.

A detailed description of the control system,its functions and its use is presented in the

Instruction Manual for UNISAB II Control.

The following points deal with daily operationof the screw compressor unit.

1. The emergency stop button on the sideof the control cabinet can always beused to stop the compressor unit quickly.

2. When voltage is applied to UNISAB II,the following main picture will appear onthe display, and UNISAB II is ready foroperation.

SUCT. PRESS. 0.0 BARDISCH. PRESS. 0.0 BARMOTOR CURR. 0 ASTOPPED 0%

Values for warning limits, alarm limits and setpoints, etc are programmed into UNISAB II.This makes it possible to start the com-pressor immediately.

However, some of the values must always beadapted to the actual operating situation. Forthis purpose use the table Quick Reference,see Fig. 10.6 and Fig. 10.7.

It is also recommended to read theInstruction Manual UNISAB II Control care-fully to acquire a thorough knowledge of howto operate the control system.

UNISAB II is operated exclusively by meansof the keys shown in Fig. 10.2. Reading ofoperating conditions as well as changing limitvalues and set points are carried out via thedisplay.

The control panel is normally closed andlocked with a screw at each end of the panel.

By turning the screws half a turn the controlpanel is loosened and can be lifted to openposition whereupon it is secured to the cabi-net as shown in Fig. 10.1.

Fig. 10.1 Opening the Cabinet

In this way it is still easy to operate the con-trol panel. At the same time easy access tothe cabinet interior is obtained.

When UNISAB II is open, it is still fully op-erational.


10--40173--529--EN

Display

Pos. 1 Has a constant background illumina-tion and displays 4 lines, each with20 characters. The contrast hasbeen factory set, but can be ad-justed if required. See subsectionContrast (display) in the sectionLanguages in the UNISAB instruc-tion manual.

In the display pressure levels, tem-peratures as well as all set pointsand warning and alarm limits can beread.

Front Panel

The UNISAB II front panel is divided into twosections:

S the control section, pos. 2-10, bymeans of which the compressor is con-trolled.

S the recording section, pos. 11-15, bymeans of which menu pictures are se-lected and values changed.

Control Section

Pos. 2 Green lamp indicating whether thecompressor is running. At start-upthis lamp will flash until UNISAB IIhas received feedback from themotor starter. At the same time the

text ”STARTING” (lamp flashes) and”OPERATING” (lamp light steady)can be seen in the bottom line of anoperating picture.

Pos. 3 Yellow lamp indicating whether thestate of operation is automatic ormanual. Yellow light = manualoperation.

Pos. 4 Red lamp indicating warning oralarm.Slow flashes = warningQuick flashes = alarm

Pos. 5 I Compressor start at manualoperation by pressing the key once.Works only if yellow lamp pos. 3is lit.

Pos. 6 0 Compressor stop at manualoperation by pressing the key once.Works only if yellow lamp pos. 3is lit.

Pos. 7 A change between manual(yellow lamp on) and automatic(yellow lamp off) takes place bypressing the key once.Please note that if manual was se-lected from the CONTROL menu, itis not possible to change to auto-matic. See section Control Mode inthe UNISAB instruction manual.

Pos. 8 R Key used to acknowledgealarms.


10--5 0173--529--EN

Fig. 10.2 UNISAB II Front Panel

UNISAB II

R O

I Set

10 3 4789 2 5 6 1 11 1213 14 15

Suct.temp. -25°CDisch.temp. 38°COil press. 4.3 barReady 0%

Pos. 9 Loading of capacity during man-ual operation. On screw com-pressors the slide moves towardshigher capacity as long as the key isheld down.

Pos. 10 Unloading of capacity duringmanual operation. On screw com-pressors the slide moves towardslower capacity as long as the key isheld down.

Recording Section

Pos. 11 The Set key has several functions.

-- When pressing the Set key, a changewill take place between Bar (PSI) and°C/R (°F/R) for saturated vapours whenthe display shows a suction or dischargepressure.

-- Changing the set values can only be car-ried out by using the password shown onpage 1 in the UNISAB instruction manual.As to the encoding of a password, seesection Changing of Set Values in theUNISAB instruction manual.

Pos. 12 A Used for moving left in the menusystem. Used for selecting picturesor a digit when changing a value.

Pos. 13 " Used for moving right in themenu system. Used for selectingpictures or a digit when changing avalue.

Pos. 14 Y Used for moving upwards in apicture in order to point at a certainvalue, or when changing to a highervalue.

Pos. 15 B Used for moving downwards in apicture in order to point at a certainvalue, or when changing to a lowervalue.

Menu StructureUNISAB II features a number of different pic-tures on compressor operation, set va-lues, configuration, etc and these picturesare built up in a menu system in which a cer-tain picture can be selected by means of thearrow keys. See Fig. 10.6 and Fig. 10.7.


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Compressor Unit

Functions

The compressor unit functions are descibedin Section 4, Technical Description.

Preparations for Starting

1. Turn on the control voltage. The emerg-ency stop button on the side of the con-trol equipment cabinet must be in the ONposition (pulled out). See Fig. 10.3. If thesystem fails to start, check the fuses.See Fig. 10.4.

Fig. 10.3 Operator’s Panel

Fig. 10.4 Drawing of Fuses and their Position

UNISAB II

1 2 33 Amp

2. Check the oil level in the oil separator. Itmust not be higher than the upper sightglass. Oil must be added when the levelreaches the lower sight glass.

The correct level appears only when theunit is in operation.

If the oil level is too low, the reason mustbe found.

The oil level switch FT209 will stop thecompressor if the level drops too low.

3. Check that all valves are positioned inaccordance with the following tableFig. 10.5 -- Position during Operation.


10--7 0173--529--EN

Fig. 10.5 Position during Operation

Pos.no. Qty Designation Position during operation20 1 Stop valve suction line Open

21 1 Non-return valve suction line Is opened by thesuction gas flow

24 1 Air purge valve/oil charging Closed34 1 Drain valve (oil side) Closed35 1 Drain valve (refrigerant side) Closed47 1 Service valve for oil drainage Closed

52 2 Oil return valvePartly open

(See Section 4, TechnicalDescription

60 1 Stop valveUsually open

Is also used for oil chargingSee Section 11, Maintenance

64 1 Stop valve for air purging of pump Usually closedSee Section 11, Maintenance

65 1 Stop valve Usually openSee pos. 60

203 2 Non-return valve in discharge pipe Is opened by thesuction gas flow

204 2 Stop valve after oil separator Open210 1 Non-return valve Is opened by the oil flow220 1 Compressor protection valve Closed221 1 Pilot valve for pos. 220 Closed


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StartingBefore starting the screw compressor unit,always read the section Preparations forStarting in this document.

Reset any alarms in accordance with the in-structions for the control system.

Modes of Operation, UNISAB IIThe compressor can be adjusted to differentmodes of operation. These are found in

SETUP " CONTROL ".

COMPRESSOR CTRL. MODE

STOPPED

When selecting this picture, the cursor will be

in the top line. Press Set and the cursormoves to the second line.

Select the desired mode of operation with the

keys Y B.

There are the following possibilities:

S STOPPED

S MANUAL

S AUTO

S REMOTE

STOPPED means that the compressor isblocked and thus cannot start.

MANUAL means that the compressor onlyoperates manually, ie it is not possible tochange to another mode of operation by

means of the key .

However, the compressor can be started with

I and stopped with 0 and capacity in-

creased/decreased with .

AUTO means that the compressor runs inlocal automatic operation according to theform of regulation chosen (suction pressure,brine, etc). It is possible to change to MAN-

UAL with the key .

REMOTE means that the compressor runs inremote regulation. Choose REMOTE whena number of compressors are workingtogether in a common MULTISABregulating system.

Regulators

In UNISAB II it is possible to regulate thecompressor according to different pressurelevels and temperatures. These forms ofregulation are found in CONFIG CONTROLON.

If placing the cursor on CONTROL ON and

pressing Set until the cursor moves to theright side of the picture, it is now possible toselect different types of regulation with the

keys Y B.

Choose between the following regulators:

S SUCTION SIDE

S BRINE

S DISCH. SIDE

S HOT WATER

S EXT. COOL

S EXT. HEAT

Each regulator has its own set of parame-ters. This means that when changing theCONTROL ON setting from one regulator toanother and back again, the original parame-ters are kept.

The common regulator parameter set in-cludes: Set point (Sp), Neutral zone (Nz) andProportional band (Pb or P Band). On screwcompressors PID parameters are also used,see the section PID Controller below.


10--9 0173--529--EN

Set point Sp is the pressure or the tempera-ture desired in the plant.

Neutral zone Nz indicates how much thepressure or the temperature is allowed tofluctuate in relation to the Sp without thecompressor changing its capacity. The setvalue of Nz is positioned symmetricallyaround the set point (Sp +/– 1/2 Nz).

Proportional band Pb indicates how power-ful the regulating signal to the compressorcapacity regulation is going to be, dependingon the difference between the desired value(Sp) and the actual value.

In case the measured value is just outsidethe Nz, the regulating impulses will be verybrief, whereas they will be very long if themeasured value is outside the P band. The Pband is positioned symmetrically around Spoutside the Nz.

PID Controller

On screw compressors a PID controller isused for capacity and Vi control. The theoryof PID controllers is described in numerousbooks on automatic control. Methods of opti-mizing the parameters are also included inthese books.


10--100173--529--EN

Fig. 10.6

Sabroe Refrigeration Tel.: +45 8736 7000Chr. X’s Vej 201, DK-8270 Højbjerg Fax: +45 8736 7705DENMARK

”QUICK REFERENCE”LEAFLET FOR

UNISAB II -- Ver. 2.01Screw Compressor

0178-218-EN2001.07.01

1. MAIN PICTURE

Press A until the picture remains unchanged and this is your MAIN PICTURE. Factory--setting

2. SELECT THE ”CONFIGURATION” MENU

Main picture -" suction -B setup -" config. -" control -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- "Check whether UNISAB II is set correctly for the compressor.Press A until the Main picture appears.

CONTROL ON XXXXAUTO START YESAUTO STOP

XXXXXXXCOLD STORE

B3. SELECT THE ”TIMER SETUP” MENU

Main picture -" suction -B setup -" control-B timers -" timers -- B timer setup -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- "

Check the set times in Timer setupPress A until the Main picture appears in the display.

START START XXXSTOP START XXX

START DELAY XXX

XXXSTOP DELAYB4. READ SUCTION PRESSURE OR DISCHARGE PRESSURE IN BAR OR °C/R.

Place cursor on suct. press or disch. pres and press ”SET” (once).

5. SELECT THE MENU FOR SUCTION PRESSURE REGULATION

Main picture -" suction -" suct. press -press ”SET” for changing to °C/R -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- "

Press A until the Main picture appears.

HIGH ALARM XXXHIGH WARNING XXX

LOW WARNING XXX

XXXLOWALARMB

-- B SETPOINT 1 XXXSETPOINT 2 XXX

NEUTRAL ZONE XXX

XXXPROP. BAND6. CHANGING THE SET VALUES

In order to be able to change a set value, a password must be encoded as described:Press ”SET” for 2 seconds [Standard code number 1234].Find the right password in the instruction manualWith A " and YB the correct password is encodedPress ”SET” and the password is kept open for 60 mins.

7. SETTING OF VALUES, f. inst. SUCTION PRESSURE (LOW ALARM)

Main picture -" suction -" suct. press -" high alarm -- B low alarmEncode password (see pt. 6) -YB andA" changing of set values - ”SET” for confirmation.

8. SELECT FUNCTION, f.inst. REGULATOR MODE

Main picture -" suction -B setup -" control -B config. -" type -B control onEncode password (see pt. 6) -YB for selection of regulator - ”SET” for confirmation.

9. SELECT COMPRESSOR CONTROL MODE

Main picture -" suction -B setup -" control -" compressor control mode - ”SET” (the cursor is now in line 2)-YB for selection of control type (manual / auto / remote / stopped) - ”SET” for confirmation.

10. CHANGING BETWEEN MANUAL- AND AUTOMATIC / REMOTE CONTROL MODE

Press - . to swith between manual - auto/remote

The light diode above . lights up at manual control mode.It is always possible to change between manual and auto/remote -- also during operation.

SUCT.PRESS XXXXDISCH.PRESMOTOR CURR

XXXXXXXREADY


10--11 0173--529--EN

11. MANUAL START (THE I-KEY):

By READY in the main picture or in any other monitoring picture: Press ”I” to start the compressor.The ready-line changes to Prelubrication or Starting or Operating. (Text depending on compressor type)During the Starting period the green light diode flashes above the I-key.After feedback from the motor starter, the light diode changes to a steady light.

12. MANUAL STOP (THE 0-KEY)

By pressing the ”0”-key during operation, the compressor is stopped immediately.

13. MANUAL LOADING/UNLOADING OF CAPACITY (the keys)

regulates the compressor capacity upwards - regulates the compressor capacity downwards.The immediate compressor capacity can be seen in the main picture or in any of the other monitoring pictures.

14. CONFIRMATION OF ALARMS (THE R-KEY)

Slow flashes from the red light diode = The warning limit has been exceeded.Quick flashes from the red light diode = Alarm and compressor will stop.The alarm may be confirmed by means of the R-key, and the quick flashes will stop once the situation is back to normal.


10--120173--529--EN

Fig. 10.7

CONTRASTLANGUAGE GB

AUXILIARY OUTPUTACTIVATE WHEN

AT MAX.CAP

4 MA20 MA

PRESS TRANSDUCER

CAPACITY

NOWARNINGS

NOALARMS

CONTROLMULTISABTIMERSDIAGNOSIS

PRESS INP 1PT 100 INP 1

EXT.

ON TIME HOURSINCE START

INSPECT OLD ALARMSMISC. FUNCTIONSSOFTWARE VERSION

SERVICE TIMERS

MULTISAB STATEALL COMPRESSORSPARALLEL CONTR.

D.OUTPUTD.OUTPUTD.OUTPUTD.OUTPUT

D.INPUTD.INPUTD.INPUTD.INPUT

HOURMINSECDAY

START STARTSTOP STARTSTART DELAYSTOP DELAY

BRINE TEMPSUCT.PRESSEXT.INPUT

DISCH. TEMPDISC.SUPERH.

OIL PRESS

OIL TEMP

MOTOR CURR ACAPACITYVI--POSITION

SUCTIONDISCHARGEOILMOTOR

SUCT.PRESSDISCH.PRESMOTOR CURR ARUNNING

SETPOINT 2NEUTRALZONEPROP.BAND

START NO.SYSTEM NO.SYS. CONTROLLER

SUCT.PRESS.SUCT.TEMP.SUCT.SUPERH

UNISAB II Ver. 2.01

HIGH ALARMHIGH WARN.LOW WARN.LOWALARMACTUAL SP.SETPOINT 1

°C/R°C/R°C/R°C/R°C/R°C/R°C/R°C/R°C/R

DISCH. PRES

°C/R°C°C

°C/R°C

DIFF. PRESS BAR°C

BAR

°C/R°C/R

BRINEALARMWARNINGSETUP °C

°C/R

SECSECSECSEC

Screw compressor

RUNNING 100%

RUNNING 100%

RUNNING 100%

RUNNING 100%

RUNNING 100%

100%

Main picture

"

Y

A

0178-218

Main menu

Suction

PARAMETER SETTING

Discharge

Oil

Motor

Multisab state

%

Brine

Alarms

Warnings

Setup

COMPRESSOR CTRL.

MANUAL

Control

MultisabMULTISAB

Timers

Timers

Service timers

Analog. input

Date-time

Dig. input

Dig. output

Diagnosis

Calibrate

Config.CONTROLCOMPRESSOROIL SYSTEM

Language

°C

All compressorsCOMPR. #01 MANUALSYSTEM # 01START # 01RUNNING 100%

TIMERS

4-20 MA input

Auxiliary output

LANGUAGECONFIG.

CALIBRATE

BRINE TEMP

%

TIMER SETUP

B

T.INT.T.DIFF.P.PARTI.PARTD.PARTREG.OUTPUT

SECSEC%%%%

CAPACITY SETPOINT

Menu Tree

RUNS BY ITSELF

ControlCONTROL ONAUTO START YESAUTO STOPCOLD STORE

ECONOMIZER


10--13 0173--529--EN

Checks to be Performed duringOperation

1. Choose a suitable picture from the dis-play to follow the data which are to bechecked. After setup, check that oil pres-sure is obtained and that the evaporatingand condensing pressure lie within thepermissible ranges shown in the Operat-ing Limits diagrams as described in Sec-tion 6, Technical Data.

2. Check the other operating data.

3. Listen for knocking valves or other ab-normal noises indicating that pipes arepoorly clamped or vibrating for someother reason. If necessary, submit a re-port so that remedial measures can betaken.

4. Check the pressure drop across the oilfilter. If it exceeds 0.7 bar, replace thefilter as soon as possible to prevent thecompressor unit from being stopped.

5. Check the oil level in the oil separator.

6. Perform what is described in Section 11,Maintenance -- Daily Maintenance.

Monitoring of Operation

To ensure an unproblematic operation, it isrecommended to enter the following routinesin a logbook. The service engineer will needthis information in connection with eg anerror report.

Daily reading of:

-- Suction pressure


-- Oil differential pressure

-- Oil level

-- Suction gas superheating

-- Discharge pipe temperature

-- Condition of the oil (check colour, whetherthe oil foams, whether the temperature isnormal)

-- kW consumption

-- Oil collection from shaft seal

It is also recommended that a logbook bemade for the entire refrigeration plant, seeexample in Fig. 10.8.


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Operations LogCompr. type ____________________Compressor no ____________________Refrigerant ____________________Compr. local no ____________________Oil type ____________________

Fig. 10.8 Monitoring of Operation

Machine room or system designation Date:

Normal level Data registered at

ChecklistFrom To

04.00am

08.00am

12.00am

04.00pm

08.00pm

12.00pm

Suction pressure

Suction temperature

Superheating, suction gas

Discharge pressure

Discharge temperature

Oil pressure, compressor

Oil pressure, filter

Oil temperature

Oil temperature, separator

Oil level

Charged oil, ltr.

Operation time (hours)

Capacity piston position (%)

Motor 1/1-load amp.

Volume ratio

Capacity load (%)


10--15 0173--529--EN

Stopping RoutineBrief stop

The compressor can be stopped at any ca-pacity setting. However, under normal condi-tions it is recommended to reduce the capac-ity to a minimum before stopping thecompressor.

Leave all valves in their in-operation posi-tions as stated in the table in Fig. 10.5 --Position during Operation, unless servicingor repair work is to be performed.

Do not turn off power to the screw com-pressor unit since the oil heater must be con-nected to keep the correct oil temperature.

Shutting Down for Long Idle Period

The compressor can be stopped at any ca-pacity setting. However, under normal condi-tions it is recommended to reduce the capac-ity to a minimum before stopping thecompressor.

The valves can be left in their in-operationpositions. However, to permit servicing andrepair work, the necessary valves must beclosed.

If necessary, the refrigerant can be moved toparts of the system where no intervention willtake place. Note that the parts of the systemwhich are shut down must not be filled to thetop with liquid refrigerant.

If the screw compressor unit is exposed tovibrations during a long idle period, the com-pressor and motor bearings may be dam-aged. To prevent this, the motor and the

compressor should be started for a shortperiod once a week, ie in operation forapprox 30-60 min.

Problems

Some frequently encountered errors that canbe remedied by the operator are describedbelow.

In more difficult situations, call in skilled per-sonnel, who have access to the appropriatedocumentation.

Fault-findingCompressor does not start.

1. No demand for chilling (refrigeration).Wait until the temperature rises where-upon the compressor will start automati-cally.

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

3. One of the following digital entries has notbeen activated:

• External start permission/immediatestop and/or

• External start/Normal stop.

4. Restarting delay.

5. Emergency stop activated.

If an alarm caused by a tripped monitor oc-curs, call in experienced personnel who haveaccess to the document entitled Fault-findingInstructions.

11. Maintenance InstructionsService Manual SAB 128R and SAB 163R Mk4

11--00173--529--EN

11. Maintenance Instructions

Table of Contents

Maintenance Instructions 11--1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Safety Precautions 11--1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Safety Measures 11--1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Maintenance of Screw Compressor Unit 11--2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Measures to be Taken 11--3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .General Rules for Use of Lubricating Oil in Refrigeration Compressors 11--5. . . . . . . . . . . .Oil Charging 11--5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Oil Change 11--5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Searching for Leaks 11--6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Motor Lubrication 11--6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Major Service Intervals 11--9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Checking the Oil 11--10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .


11--1 0173--529--EN

Maintenance Instructions



S Scheduled maintenance tasks for thisequipment and how to carry them outsafely.

S When these scheduled maintenancetasks should be performed.

This document is primarily intended for oper-ators and service engineers.





Danger !

Risk of injury to personnel and damage toequipment! Always read the safety precau-tions belonging to this equipment beforestart. Failure to comply with safety precau-tions may cause death or injury to personnel.It may also cause damage to or destructionof the equipment.

Safety Precautions

Danger !

Risk of injury to personnel and damage toequipment! In addition to the safety precau-tions in this document, always read thesafety precautions belonging to this equip-ment before start. Failure to comply withsafety precautions may cause death or injuryto personnel. It may also cause damage to ordestruction of the equipment.

Safety Measures

Danger !

The paragraphs that follow present some im-portant safety considerations for this type ofscrew compressor unit. Before starting main-tenance work, study carefully the generalsafety instructions/regulations that apply tothis series of screw compressor units. Failureto follow these instructions/regulations canlead to personal injury and even death.Moreover, the equipment can be damaged ordestroyed.


11--20173--529--EN

Maintenance of ScrewCompressor Unit

General

To make certain that the screw compressorunit operates without problems throughout along service life, follow the system of main-tenance presented in the following instruc-tions.

Maintenance can be divided into threegroups:

1. Daily MaintenanceThis point consists of visual inspections.When familiar with the normal noise andvibration of the unit, compare the perform-ance of each day with previous observa-tions. Make comparisons with the avail-able diagrams, etc. to make certain thatthe operating data lie within permissibleranges.

• Inspect the screw compressor unit andcheck that both noise and vibration arenormal.

• Enter the observed operating data intothe operations log, see the table Moni-toring of Operation in Section 10, Oper-ating Instructions. Check that all oper-ating values are within the permissibleranges. Compare them with previousvalues to detect trends. If necessary,submit a report so that a closer checkcan be made.

• Check the oil level in the oil separator.

• Check oil pressure.

• Check the refrigerant charge.

• Search for leaks if there is even theslightest suspicion that there may be aleak. Conducting a manual check rightat the screw compressor unit itself isalways the best way to check for:

a) leakage of oil and/or refrigerant,

b) leakage of cooling water or brine,

c) abnormal vibrations.

• Do not wait for the monitoring equip-ment to issue an alarm. Searching forleaks is explained in greater detail laterin this section.

Warning!

Daily maintenance is normally conducted bythe operating personnel. Other maintenanceand service tasks which require the refriger-ation system to be opened must only be con-ducted by authorized personnel.

2. Periodic maintenanceMotor lubrication and other routine main-tenance tasks are usually based on run-ning time. Note, however, that these canbe conducted more frequently if necess-ary.

3. Major overhaulFor major maintenance tasks such ascompressor overhauls, the usual pro-cedure is to call in the supplier’s servicepersonnel.

The different parts of the screw compressorunit that require regular periodical mainten-ance are shown under Activities during Ser-vice Inspection in this document.


11--3 0173--529--EN

Measures to be TakenThe following sections describe themeasures which must be taken. They includeinformation about tools, materials, prepara-tions and implementation.

Noise and Vibration

No special requirements are imposed regard-ing equipment and materials. Inspect theunit and check that there is no abnormalnoise and vibration. Listen for any knockingor other abnormal noise caused by e.g. poor-ly clamped pipes or defective valves.

Evaporating Pressure and Con-densing Pressure

No special requirements are imposed regard-ing equipment and materials. Check on theoperator’s panel that the different kinds ofpressure comply with what the specificationsissued for the screw compressor unit inquestion prescribes and that they are withinthe permissible operating ranges.

Evaporating Pressure

The terms “evaporating pressure” and “suc-tion pressure” refer to the pressure that pre-vails on the suction side of the compressor.

Usually the pressure is the same at the evap-orator outlet as at the compressor inlet. Theonly difference is the pressure drop in theline. Because of this pressure drop, the pres-

sure at the evaporator outlet is a little higherthan at the compressor. The non-return valvein the suction line will also contribute to thepressure drop.

Normal Evaporating Pressure

According to fundamental refrigeration engin-eering principles, the refrigerant absorbsheat from the medium that is being chilled.

In order for heat to be transferred to the re-frigerant, it must boil at a lower temperaturethan the temperature of the medium beingchilled in the evaporator. A basic rule is thusthat the evaporating temperature is lowerthan the temperature of the medium beingchilled in the evaporator. This rule sets amaximum value for the suction pressure.

Condensing Pressure

The terms “condensing pressure” or ”highpressure” as used here refer to the pressurethat prevails at the outlet side of the com-pressor. Usually the pressure is the same atthe condenser inlet as at the compressoroutlet. The only difference is the pressuredrop in the line.

Because of this pressure drop in the line, thepressure is a little higher at the compressorthan at the condenser inlet. The oil separator,the stop valve and the non-return valvemounted in the discharge line will also con-tribute to the pressure drop.


11--40173--529--EN

Normal Condensing Pressure

In the condenser the absorbed heat energyin the refrigerant is released to the surround-ings. The heat energy in the refrigerant is thesum of the heat energy absorbed in theevaporator and the energy supplied to thecompressor via the electric motor taking oilcooling system in account.

During the condensing process the refriger-ant vapours are again transformed into liquid.To give off the energy (heat) from the con-denser, the temperature of the medium (air,water) to which the heat is to be transferredmust be lower than the condensing tempera-ture. Since there is a connection between thetemperature and the pressure in the con-denser, there is a minimum value for howmuch the condensing temperature must fall;a too low condensing pressure level will re-sult in operational failures.

Visual Inspection

Inspect the screw compressor unit to makesure that there are no refrigerant or oil leaks.

Oil Level

The oil separator in the screw compressorunit has an oil receiver. The oil pump takesthe oil used for lubrication, cooling, sealingand regulation of the compressor from thisreceiver. It is thus very important to havesufficient oil available in the oil receiver.

Check the oil level in the oil reservoir. It mustnot be higher than the upper sight glass. Oilmust be added when the level reaches thelower sight glass. The correct level appearsonly when the unit is in operation.

The section Oil Level Glass, in Section 4,Technical Description states how much oilmust be charged to raise the oil level 10 mm.

If the oil level is too low, the reason must befound. For this purpose use Section 12,Fault-finding Instructions. The oil level switch209 (additional equipment) will stop the com-pressor if the level drops too low.

If the oil level is too low, check for leaks. Ifthere is no leakage, the oil can still be col-lected in the system.

Call in a service company to investigate theproblem.


11--5 0173--529--EN

General Rules for Use ofLubricating Oil in RefrigerationCompressors

S Only fresh, clean refrigeration machineoil may be charged. Oil tapped from theevaporator system in an ammoniaplant must not be reused in the com-pressor.

S Use grade of oil originally prescribed forcompressor.

S As far as possible, avoid mixing differenttypes of oil. Mixed oil is generally inferiorto the two original oils. Mixing varioustypes of oil may give rise to formation ofsludge, which will lodge in valves andfilters.

S If it is necessary to switch to anotherbrand of oil, remember to change the oilin both the compressor and the plant.

S The refrigeration oil must be free ofmoisture, which may give rise to operat-ing malfunctions and attacks of cor-rosion.

The oil should, therefore, be purchased incontainers corresponding to the quantity tobe used for a single, or at most, two top-ups.The oil containers must be kept carefullysealed. If all the oil in a container is not usedat the same time, the container should betightly sealed and stored in a warm place toprevent the absorption of moisture.

Note:It is not recommended to reuse oil whichhas been drawn from a compressor orplant. This oil will have absorbed moisturefrom the air and may cause operating

problems. Always switch off the power tothe heating rod before drawing off the oil.

Section 6, Technical Data - Charging theCompressor with Oil includes a detailed de-scription of lubricating oils as well as direc-tions for selecting the correct oil.

Caution!

Never add oil until the reason for the drop inthe oil level has been found and remedied.

Oil ChargingSee section 6, Technical Data.

Oil ChangeAs stated in the tables placed at the end ofthis document the oil in the unit must bechanged after a specific number of operatinghours or when an oil analysis shows that theoil needs to be changed.

Let Sabroe Refrigeration’s service organiz-ation change the oil as it is recommended toreplace all the filters in the unit at the sametime.

Warning!

Corrosive oil is a hazardous substance,which can cause irritation and other injuries.

If the oil in the oil separator appears abnor-mal or if its condition is in any way question-able, take an oil sample via valve pos. 47 foranalysis.

Valve pos. 47 is placed at the bottom of theoil receiver. See the piping diagram in Sec-tion 4, Technical Description.

Take the sample while the unit is running. Donot use the first 100 ml. Empty the sample


11--60173--529--EN

into a clean and dry sample bottle and followthe description in Section 6, Technical Data,Assessing the Oil.

Note:The postion numbers above refer to Gen-eral Piping Diagram in Section 4, Techni-cal Description.

Caution!

Leave the sample bottle open for an hourafter filling it so that the refrigerant dissolvedin the oil will have time to evaporate and dis-appear. Otherwise the sample bottle may ex-plode.

Searching for Leaks

Leak searching can be performed in manyways. The most frequently used method is touse a leak detector. When finding a leak, agood way to find its exact location is to applysoapy water.

When searching for large leaks, divide thesystem into sections to prevent needlessamounts of refrigerant from leaking out.

Proceed as follows:

S Ascertain whether there is a refrigerantshortage by checking the refrigerant levelin the condenser or the receiver.

S Search for drops of oil at couplings,flanged joints, valve spindles, shaft seals,safety valves and the like.

S Ventilate in advance to remove any gas-eous refrigerant from the leak searchingarea.

S Check that the required refrigerant pres-sure is present in the part of the system inquestion.

S Conduct the search systematically to en-sure that all possible sources of leaks arechecked.

Do not forget the following:

S Threaded joints and flanged joints

S Valve spindles

S Shaft seals

S Relief equipment

S Expansion valves

S Pressure transducers and pressuregauges

S Safety valves

Motor LubricationFor electric motors, it is absolutely essentialto lubricate the bearings correctly and usethe correct type of grease.

For correct service, please follow theinstructions of the motor manufacturer.

Replacing Motor Bearings

Contact Sabroe Refrigeration’s serviceorganization.

Major Overhaul of the Compressor

Contact Sabroe Refrigeration’s serviceorganization.


11--7 0173--529--EN

Activities during Service Inspection

Daily

Periodic service Activity

1.1 External inspection and leak check.

1.2 Check oil level in oil separator.

1.3 Check pressure and temperatures.

1.4 Check for unusual vibrations or noise.

1.5 Record operating data in log book.

1

5.1 Clean compressor suction filter. **

5.2 Take oil sample from oil separator and send it to laboratoryfor analysis as described in Assessing the Oil.

5.3 Fit new oil filter cartridge. **

5.4 Clean all other oil filters and connections to and fromcompressor. **

5.5 Check coupling and alignment of coupling **

5.6 Check that pressure switches and thermostats areworking correctly (see set values in instruction manual).If UNISAB II computerized control is fitted, check transdu-cers (see instruction manual for UNISAB II).

After 2500 hours’operation

5

2.1 Clean suction filter. **After 50 hours’ operation2


3.2 Take oil sample from oil separator and appraise it visuallyor send sample to laboratory for anlysis.Both methods are described in section entitled Assessingthe Oil.

3.3 Replace filter cartridge in oil filter unless replacedearlier. **


3.5 Check coupling and alignment of coupling. **3.6 Check that all screws and nuts have been tightened to

correct torque. **


3


4.2 Take oil sample from oil separator and appraise it visually-or send sample to laboratory for analysis.Both methods are described in section entitled Assessingthe Oil.


4


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Periodic service Activity




6.4 Check coupling and alignment of coupling (SAB 110*) **

6.5 Check that pressure switches and thermostats areworking correctly (see set values in instruction manual).If UNISAB II computerized control is fitted, check transdu-cers (see instruction manual for UNISAB II).

6.6 Take oil sample from oil separator and send sample tolaboratory for analysis as described in section entitledAssessing the Oil. Please see table entitledChecking the Oil.

After 5000 hours.operation

This service should berepeated after every5000 hours of operation

6

7.1 Total compressor overhaul, including fitting newgaskets. As compressor is already open, inspect be-arings and, if necessary, fit new ones. Check regulatingsystem. **

7.2 Overhaul and clean compressor motor. **NBFollow service schedule specified bymotor manufacturer.


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

7.5 Check coupling and alignment of coupling(SAB 110*) **

7.6 Check that pressure switches and thermostats are wor-king correctly (see set values in instruction manual).If UNISAB II computerized control is fitted, check trans-ducers (see instruction manual for UNISAB II).

Major service

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

7

* Check elastic intermediate part for visible oblique cracks in rubber part.In case of cracks, replace intermediate part.

** Recommended to be carried out by Sabroe Refrigeration’s service organization.


11--9 0173--529--EN

Major Service IntervalsSAB 110, SAB 128/163 Mk3/4, SAB 128/163R, SAB 202

R22

R717

--50 --50

--50 --30 --20 --10 --5

--30 --20 --10 --5 0--50

0 10 15 20

5 10 15 20

5 25

25

T0177068_0

--10--505

10

20

25

30

35

15

--20--30

35

30

25

20

15

50

10

--5--10--15--20--30

40

45

50

55

55

50

45

40

40,000 hour interval

TE (°C)

TC (°C) ”Extreme” operating conditions20,000 hour interval

Normal operating conditions30,000 hour interval

Condensing temp.

Evaporating temp.

“Booster” conditions


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Checking the Oil

20,000h 30,000h 40,000h

5020010002500

500010000150002000025000

300003500040000

•••

•×•×•

×•⊕

•••

••×••

×•⊕

•••

•×•×•

⊕

•••

••×••

⊕

•••

•×•⊕

•••

••×⊕

•

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

• It is advisable to assess the oil.

× It is advisable to assess the oil.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 compressor start-up.

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)HCFC R717HCFC R717HCFC 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.


11--11 0173--529--EN

12. Fault-finding InstructionsService Manual SAB 128R and SAB 163R Mk4

12--00173--529--EN

12. Fault-finding Instructions

Table of Contents

Fault-finding Instructions 12--1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Safety Precautions 12--1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .How to Carry Out Fault Tracing 12--2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Example 12--3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Remedying Malfunctions 12--5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .


12--1 0173--529--EN

Fault-finding Instructions

The purpose of this document is to:

S Describe the dangers resulting from fail-ure to comply with instructions and safetyprecautions during the fault-finding pro-cess.

S Provide a list of common problems.

S Suggest cause(s) and recommend actionsto solve each problem.

This document is primarily intended forservice engineers.




This document must not be copied withoutthe written permission of SabroeRefrigeration, and the contents hereof mustnot be imparted to a third party nor be usedfor any unauthorised purpose. Contraventionwill be prosecuted.

Danger !

Risk of injury to personnel and damage toequipment! Always read the safetyprecautions belonging to this equipmentbefore start. Failure to comply with safetyprecautions may cause death or injury topersonnel. It may also cause damage to ordestruction of the equipment.

Safety Precautions

Danger !

Risk of injury to personnel and damage toequipment! In addition to the safetyprecautions in this document, always readthe general safety precautions belonging tothis equipment before starting thefault-finding process. Failure to comply withsafety precautions may cause death or injuryto personnel. It may also cause damage to ordestruction of the equipment.

Qualification Requirements

Fault-finding requires highly skilled, qualifiedpersonnel with extensive knowledge of thesystem in question. The formal requirementsinclude knowledge of refrigeration engineer-ing and familiarity with the system in ques-tion.


12--20173--529--EN

How to Carry Out Fault-finding

Fault-finding is necessary in three generalsituations:

S When acute problems ariseTo find out what caused the screw com-pressor unit to malfunction.

S MaintenanceDuring scheduled maintenance to detectoperational deficiencies that can lead tofuture disturbances or uneconomicaloperation.

S Starting up after repairsAfter a damaged component has been re-placed (for example) to find external rea-sons why the component failed.

Screw Compressor Unit as Part ofOverall System

The functions performed by a screw com-pressor unit – and thus the errors that mayoccur – are often linked to the overall system(plant) in which the unit is operating.

On the low pressure side the screw compres-sor unit is connected to an evaporator as wellas to a system used for distributing thechilled medium.

On the high pressure side it is connected to acondenser as well as to a system used forthe coolant.

A control system is responsible for monitor-ing, control and regulation. Most of the errorswhich occur are indicated by the control sys-tem.

Personnel who carry out fault-finding musttake into account all of the above mentionedthe system parts to obtain a clear picture ofwhat is happening.

Systematic Fault-finding

Fault-finding should be carried out systemati-cally. The personnel will often know what theproblem is and find the error immediately. Ifthe personnel has a thorough knowledge ofthe unit in question, they will often know thecause of the problem.

If this is not the case, however, consider thesituation carefully. Do not change any set-tings immediately. Spend some time workingout a systematic approach.

Operating ConditionExperience shows that pressure and temper-ature variations in a refrigeration system canprovide information about the refrigerationplant operating conditions.

In particular, the suction and condensingpressure as well as the temperatures of suc-tion and discharge gases may provide impor-tant information as to the plant operatingconditions.

Considerable changes in the operating con-ditions can often be produced by only verysmall changes in the variable pressure 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 error isindicated by a code number in the left handcolumn, with the error briefly described in thesecond column. The third column statescode numbers for the possible causes oferror.

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.


12--3 0173--529--EN

Example

Observed 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, 53, 5414 Insufficient capacity -- aut. controls out of order 3,4, 53, 5415 Falling oil level in reservoir 15, 16, 17.

16 Oil foams vigorously during idle period 31, 32.17 Oil reservoir sweating during idle period 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, 47, 53, 5420 Compressor runs continuously 2, 4, 42, 48, 49.21 Liquid in suction line 1, 31, 32.


12--40173--529--EN

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 when

decreasing temperature

6 Capacity regulation not set for 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 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 line53 Motor defect54 Error in frequency transformer

Code CodeCause Cause


12--5 0173--529--EN

Remedying Malfunctions

1. Excessive suction temperature

1.2 Inadequate capacity Increase capacity

Safety valve leaky or opening pre-maturely

Check condensing 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 positioned cor-rectly

3. Suction pressure 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 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 liquid from receiver through dryingfilter

Note:Never add methanol to system to avoid freezing,as this will give rise to corrosion and chemicalattacks in compressor, etc.

3.42 Insufficient charge Charge more refrigerant to plant

3.30 Thermostatic expansion valve haslost its charge

Valve fails to open - change valve

3.33 Solenoid valve in liquid or suctionline not opening

Coil may have blown - change coil


12--60173--529--EN

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


12--7 0173--529--EN

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

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


12--80173--529--EN

9. Oil pressure too low

9.5 Excessive capacity duringtemperature decrease

Excessive capacity during temperature decrease(run-down) may result in liquid being suckedalong in suction line. This liquid may cause oil inoil reservoir to foam vigorously so that oil pres-sure drops, thus stopping machine. Before re-starting, check whether there is liquid in oil reser-voir.

This liquid must be boiled off using heating ele-ment or by heating oil reservoir with hot water orsteam. The plant must therefore be run- down atreduced capacity.

9.11 Oil pressure regulator set too low The regulator is set for 2.5 kp/cm as 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.

10. Oil temperature too high

10.13 Thermostat cut out See section Pressure and temperature settingsfor set point. The reason for the oil overheatingmust be found in the following points

10.18 Valve in oil line being throttled 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--9 0173--529--EN

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 compressor stops, auxiliary pump mustensure capacity regulation is set for 0% capacityso that compressor is ready for restart.

Check whether pump is energized or whetherpump or motor is out of order.

13.53 Replace or repair.Motor defective

13.54 In case of error in frequency transformer thecombined lamp/push-button positioned on theoutside of the control board will be activatedTry to reset frequency transformer by pushingbutton. If this does not help, please contact Sa-broe Refrigeration.

Error in frequency transformer

14. Insufficient capacity - automatic controls out of order

14.3 See point 13.4

14.53 See point 13.53

14.54 See point 13.54


12--100173--529--EN

15. Falling oil level in reservoir

15.15 Filter for solenoid valve in oil-re-turn line clogged

Clean filter

15.16 Solenoid valve in oil return out oforder

Oil return line must be hot during operation.

15.17 During initial start-up, some of theoil will be let out into the plant

Particularly on HCFC plants 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 compressor is stopped and current interruptedat main switch, any refrigerant in oil reservoir willevaporate. As heating element in oil reservoirhas also been cut off, heat needed for evapora-tion must be taken from surroundings. The oilwill therefore go very cold and will requireheating up before restarting.

17.50 Heating element blown See point 17.47


12--11 0173--529--EN

18. Abnormal noise from compressor

If any abnormal noise is coming from the compressor, the machine must be stopped immediately,and the cause found and remedied before restarting.

18.5 Excessive capacity duringrun-down

Excessive capacity during run-down may resultin liquid being sucked along into 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 compressor. Open and repair.

18.10 Loose bolts in coupling Stop compressor and tighten bolts

18.31 Liquid in suction line Check and adjust valves with excess through-flow

18.32 Loose or misplaced sensor Check sensor positioning


12--120173--529--EN

19. Compressor motor will not start

19.6 Capacity regulation not set for 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 Compressor will restart after rise in suction pres-sure sufficient to re-activate pressure cut-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

19.53 See point 13.53

19.54 See point 13.54

20. Compressor runs continuously

20.49 Evaporator soiled or iced up Clean or defrost evaporators

20.2 Compressor lacks capacity See under point 13.54

20.4 Timer or other automatic controlout of order

See under point 13.54

20.42 Insufficient charge on plant Top plant up with refrigerant


See point 10.48


12--13 0173--529--EN

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

13. Service InstructionsService Manual SAB 128R and SAB 163R Mk4

13--00173--529--EN

13. Service Instructions

Table of Contents

Service Instructions 13--1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .General Preparations before Service 13--2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Service Schedules for Screw Compressors SAB 128/163 Mk3 13--3. . . . . . . . . . . . . . . . . . . . .Preparations before Compressor Inspection 13--3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Replacement of Oil Filter 13--3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Cleansing of Oil in the Unit 13--3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Oil Charge SAB 128/163 HR 13--5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Servicing the Refrigeration Plant 13--6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Maintenance of Compressor Disassembly and Assembly 13--8. . . . . . . . . . . . . . . . . . . . . . . . . .1. Oil Filter 13--10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2. Suction Filter 13--11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3. Shaft Seal for SAB 128 and SAB 163 Mk4 13--12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4. Slide for Vi Regulation 13--16. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5. Suction Cover and Bearing in Compressor Shaft End 13--18. . . . . . . . . . . . . . . . . . . . . . . . .6. Rotors and Bearings in Compressor Discharge End 13--20. . . . . . . . . . . . . . . . . . . . . . . . . .7. Compressor Protection System 13--28. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Oil temperature regulating system SAB 110, 128, 163, 202 and VMY 536 13--31. . . . . . . . . . . .Oil pump pos. 63 13--33. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Start-up 13--33. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Checking Rotating Direction of Motor 13--33. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Service 13--34. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Disassembly of Seal 13--34. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Disassembly of Pump 13--34. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Inspection 13--35. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Reassembly of Pump 13--35. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Mounting and Dismounting of Coupling 13--37. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Dismounting of Coupling Flange 13--39. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Refrigeration Plant Maintenance 13--43. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Operational Reliability 13--43. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Pumping down the Refrigeration Plant 13--43. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Dismantling Plant 13--43. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Tightness Testing and Pumping down the Refrigeration Plant 13--44. . . . . . . . . . . . . . . . . . . .

Ordering Spare Parts 13--45. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Spare Part Sets for Screw Compressor and Unit. 13--46. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .


13--1 0173--529--EN

Service Instructions



S Scheduled maintenance tasks for thisequipment and how to carry them outsafely.

This document is primarily intended for ser-vice engineers.




This document must not be copied without awritten permission from Sabroe Refrigerationand the contents hereof must not be im-parted to a third party, nor be used for anyunauthorised purpose. Contravention will beprosecuted.

Danger !

Risk of injury to personnel and damage toequipment! Always read the safety precau-tions belonging to this equipment beforestart. Failure to comply with safety precau-

tions may cause death or injury to personnel.It may also cause damage to or destructionof the equipment.

Safety Precautions

Danger !

Risk of injury to personnel and damage toequipment! In addition to the safety precau-tions in this document, always read thesafety precautions belonging to this equip-ment before changing the settings. Failure tocomply with safety precautions may causedeath or injury to personnel. It may alsocause damage to or destruction of the equip-ment.

Safety Measures

Danger !

The paragraphs that follow present some im-portant safety considerations for this type ofscrew compressor unit. Before starting ser-vice work, study carefully the general safetyinstructions/regulations that apply to thisseries of screw compressor units. Failure tofollow these instructions/regulations can leadto personal injury and even death. Moreover,the equipment can be damaged or de-stroyed.


13--20173--529--EN

General Preparations beforeService

Ventilation

Before servicing the unit, always check thatthe ventilation system used in the area wherethe screw compressor unit is located (ma-chine room) is functional and operating at fullcapacity.

The safety instructions explain the risks as-sociated with the refrigerant and oil beingused. Pay close attention to the fact thatlarge amounts of escaped (or released) re-frigerant entail risk of suffocation.

The safety instructions also explain the risksgenerally associated with refrigerants. Bodycontact with leaking liquid refrigerant entailshigh risk of injuries caused by intense cold.

Pressure

A screw compressor unit comprises a pres-surized system. Never loosen threaded joints(such as a union nut) while the system isunder pressure and never open pressurizedparts of the system.

Hot and Cold SurfacesA screw compressor unit contains both hotand cold system parts. Always wear and usethe recommended safety items.

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

Qualification RequirementsBefore carrying out the measures set forth inthis document, all personnel must have care-fully studied the instructions issued for thescrew compressor unit.

The personnel must also fulfil all national re-quirements for authorization.

Main Power SupplyBefore servicing the compressor, switch offthe power on the main disconnect switch ofthe plant. To prevent the compressor fromstarting up inadvertently, dismantle the mainfuses of the plant.

Tools and AccessoriesServicing the compressor correctly requires alot of special tools. The tools can be orderedfrom Sabroe Refrigeration and are describedin detail in:

S Document 0662--734 for SAB 128 Mk4

S Document 0662--744 for SAB 163 Mk4

0178-028-EN

99.05


13--3 0173--529--EN

Service Schedules for Screw Compressors

Good and careful servicing of the com-pressor and 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, these instructionsindicate the service tasks to be carried out.

Preparations before CompressorInspection

Before dismantling any part of the com-pressor or unit for inspection or repair, thepressure must be reduced to atmosphericpressure. This is done as follows:

S Regulate the compressor down to itslowest capacity stage and stop it.

S Close all stop valves in the piping connec-tions to the unit except for suction stopvalve pos. 20, which must remain openuntil the pressure in the unit has beenequalized to suction pressure.

S Close suction stop valve pos. 20.

S Any excess pressure in the unit is equal-ized to atmospheric pressure through stopvalve pos. 24. See Key to Piping Dia-grams in Section 4, Technical Descriptionand Section 3, Safety Precautions -- Pro-tecting the Environment.The heating element in the oil separatormust remain connected until the pressureis completely equalized, thus boiling therefrigerant out of the oil.

S Remove the main fuses for the com-pressor motor in order to prevent it fromstarting up inadvertently.

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

Replacement of Oil Filter

In case only the oil filter has to be replaced,follow the procedure described in Prepara-tions before Compressor Inspection as wellas the description under Oil Filter later in thissection.

Cleansing of Oil in UnitThe most critical time for an oil filter is rightafter initial start-up of the compressor.

Although an effort should be made to keepthe plant free of any impurities when as-sembled, experience shows that it is difficultto avoid impurities in tubes and vessels.

These impurities will be conveyed by thesuction gas to the suction filter, where largeimpurities are intercepted. Small impuritieswill pass through the filter and be conveyedto the oil separator where they are sus-pended in the oil. From here they are takento the unit lubricating system and absorbedby the oil filter.

These impurities may necessitate a replace-ment of the oil filter cartridge shortly afterinitial start-up.

It is equally important to check the oil regu-larly as specified in Section 6, Technical Data-- Assessing the Oil.

Oil purification may be done by using a threemicron filter in a closed system. During this


13--40173--529--EN

process the oil must not come into contact

with oxygen and moisture in the air.

In addition, it is important that all pressure

and temperature levels be kept within the

specified values and that filters be kept

clean. Provided inspection is carried out ac-

cording to the schedules prescribed in Sec-

tion 11, Maintenance Instructions -- Activities

during Service Inspection, the compressor

and unit will work efficiently and have a longservice life.

Checking the Oil

See Section 11, Maintenance Instructions.

Major Service Intervals


Activities during Service Inspection



13--5 0173--529--EN

Oil Charge SAB 128/163RFig. 13.1

Oil CoolerLitres Oil Separator

LitresCompr. Pipes

LitresTotal, UnitLitresOil Cooler

Type SAB128

SAB163

SAB128

SAB163

SAB128

SAB163

SAB128

SAB163

OOSI 1614 11 11 80 103

OOSI 2114 20 20 89 112

OOSI 2714 31 123

OOSI 3214 48 140

OWSG 1615 25 87

OWSG 1619 25 117

OWSG 2115 39 60 80 9 12 97

OWSG 2119 39 131

OWSG 2719 63 155

Oil Charge (US gal)

Oil CoolerUS gal Oil Separator

US galCompr. Pipes

US galTotal, UnitUS galOil Cooler

Type SAB128

SAB163

SAB128

SAB163

SAB128

SAB163

SAB128

SAB163

OOSI 1614 2.9 2.9 21.1 27.2

OOSI 2114 5.3 5.3 23.5 29.6

OOSI 2714 6.2 32.5

OOSI 3214 12.7 37.0

OWSG 1615 6.6 23.0

OWSG 1619 6.6 30.7

OWSG 2115 10.3 15.8 21.1 2.4 3.2 25.6

OWSG 2119 10.3 34.6

OWSG 2719 16.6 40.9

Comment: Be sure always to have approx. 25% extra oil available to refill at first start-up.

0171-470-EN

97.07


13--60173--529--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 functionunder load, ie:

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 instruction man-ual. The service instructions should thereforebe 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.

Replace 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


13--7 0173--529--EN

Check Interval Activity

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

Periodically

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

Periodically

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

Safety pressure controlsAutomatic operating controlsAlarms

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

Automaticcontrols

Periodically

Lubrication of electric mo-tors

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

Electricmotor

PeriodicallyAlignment of couplingV belt drive

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

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

Condenser Periodically-- normallymin. 4times ayear

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

EvaporatorWhen re-quired

Check in accordance with the in-structions of the instruction manual.Tighten loose V belts or replacewith new ones.


13--80173--529--EN

Maintenance of CompressorDisassembly and Assembly

Service work on the screw compressor mustbe carried out by professional, well-trainedstaff acquainted with the compressor.

These instructions describe complete com-pressor disassembly and assembly, althoughthis will not always be required.

When dismantling the compressor, the partsshould be marked to ensure that they can beremounted in the same position as before.

The torque moments for screws and boltsstated in Section 21 -- Appendices must bestrictly observed.

Preparations before Disassembly

A description is given below of completecompressor disassembly, inspection and re-assembly.

Partial disassembly and inspection can beundertaken while the compressor is securedto the base frame. To allow a complete disas-sembly, however, the compressor must belifted off the base frame. For further details,see Sequence of Disassembling the Com-pressor later in this section.

It is important that dismantling and handlingof the various parts is carried out as de-scribed in these instructions in order to avoiddamage when restarting the compressor.

Therefore, read the instructions carefullybefore commencing the work.

As O-ring gaskets have a tendency to ex-pand when exposed to oil and refrigerant, itis useful to have an extra set of gasketsready before starting the work. See the list ofspare part sets in this instruction manual.

Tools

Apart from having the necessary tools athand, see document 0662--734 and0662--744, it is an advantage to place thecompressor on an iron plate when dismantl-ing it completely. This will allow for easy re-moval of oil leaking from the compressor dur-ing the dismantling process.

It is also recommended to position the com-pressor in a spacious room, which is cleanand free of dust.

Elimination of Refrigerant Gas

Shut off the suction and discharge stopvalves and eliminate the refrigerant gas asdescribed in Section 3, Safety Precautions --Protecting the Operator as well as the Envi-ronment.

Removal of Various Accessories

When working on the compressor, the powerto the compressor motor must be cut off andit must be ensured that the compressor can-not start inadvertently (if necessary, removethe main switches).


13--9 0173--529--EN

Dismantling of Following Parts

1. Coupling between compressor andmotor.

2. Flanges connecting the compressorsuction and discharge sides to plantand oil separator(in case of total disassembling).

3. Oil piping connected to the compressor.

There may be oil in these pipes. Theyshould therefore be loosened carefully toallow for collection of this oil.

When the oil pipes have been removed,they must be stored without being bentor damaged.

4. Electrical connections to the compressorblock.

The position numbers in the following sec-tions refer to the spare parts drawing.

Draining Oil from Compressor

After the oil pipes have been dismantled,there may still be quite a large amount of oilin the compressor. Most of the oil can beremoved by unscrewing the threaded plug

pos. 24 on the lower side of the compressorwhile this is suspended eg in a crane.

Note:For cleaning and drying compressor parts,do not use twist or any other fluffy cloth.

Disassembling of Compressor

Sequence of disassembling:

Parts to be disassembled

234

1Oil filterSuction filterShaft seal

Suction cover and bearingsin compressor shaft endRotors and bearings incompressor discharge end

76

5

Compressor Protecting System

Slide for Vi regulation

Point

The individual points are described below.

Reassembling of Compressor

Clean all parts carefully before reassembling.Examine the parts for damage and wear andreplace with new parts, if necessary.Examine all gasket rings to see if they can bereused. If in doubt, replace with new parts.

Before remounting, lubricate all parts, includ-ing screws, with clean fresh refrigeration oil.


13--100173--529--EN

1. Oil Filter

The oil filter pos. 470 is a replaceable filtercartridge fitted in the compressor block asshown in the spare parts drawing.Along with the consumption of the filteringcapacity of the filter cartridge, the pressureloss across the filter will increase. This is reg-istered by two pressure transducers pos. 752and pos. 753.

Make sure that a new filter cartridge is avail-able as the replaced oil filter cannot becleaned.

Before removing the filter cartridge from thecompressor block, stop the compressor.E-qualize the pressure to atmospheric pres-sure. Furthermore, empty the oil filterhousing of oil. This is done by unscrewingthe threaded plug pos. 46 -- see piping dia-gram as well as Fig. 13.2.

This drainage is best carried out whenthere is still excess pressure in the com-pressor.

Fig. 13.2

46

47

470

.

..

1.1. Removal and Cleaning

After the pressure in the com-pressor has been equalized to at-mospheric pressure, dismantle oilpipe pos. A at flanges B and C as il-lustrated in Fig. 13.3.

Fig. 13.3

B

A

C

456450753

761

.

.

.

. .

1.1.1. Next, dismantle the electrical connec-tion pos. 753 and the temperaturetransmitter pos. 761.

1.1.2. By removing the screws pos. 456, thecover pos. 450 with the oil cartridgepos. 470 and the O-ring pos. 452 canbe extracted from the oil filter housing.

1.1.3. By dismantling the nut pos. 455, thefilter cartridge pos. 470 can be pulledout across the spindle pos. 458.

1.1.4. Do not dismantle the magnetic filterpos. 460, but wipe it with a cleanpiece of cloth.


13--11 0173--529--EN

1.2. Mounting of Oil Filter Cartridge

1.2.1. After cleaning the cover pos. 450 and471 on the inside, mount the filtercartridge pos. 470 and the O-ringpos. 453 and 472. Secure the partswith the nut pos. 455.

1.2.2. Position the complete cover pos. 450with the O-ring pos. 452 in the com-pressor and tighten with the screwspos. 456.

1.2.3. Mount the oil pipe pos. A and secureit to the flanges B and C as illustratedin Fig. 13.3. If considered necessary,replace the O-ring in flange B and thegasket in flange C. See part numbersin Spare Parts List - Document0662--731/741 in the section on OilSystem -- Flange Connection.

1.2.4. Next, fit the electrical connection cou-pling to the pressure transducer pos.753 and the temperature transmitterpos. 761.

2. Suction FilterThe suction filter is built into the compressorhousing above the rotors.

The purpose of the filter is to collect theimpurities conveyed from the evaporator sys-tem with the suction gas.

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

Consequently, it is important to clean thesuction filter after 200 hours of operationfrom the initial start-up of the compressor.

In case this is not done, there is a risk thatthe suction filter may burst due to an excess-ive differential pressure across the filter.

2.1 Removal of Suction Filter

Before removal of the suction filter, the com-pressor protection system must be dis-mounted. The protection system is fitted onthe compressor block with two flange con-nections.

2.1.1. Remove the screws pos. 702 and 716and dismount the protection system.

2.1.2. Dismount the suction filter cover pos.718 by removing the eight screwspos. 734.

2.1.3. Pull out the suction filter pos. 170.Take care when removing the filterso dirt from the filter does not enterthe compressor.

2.1.4. Clean the suction filter in an oil deter-gent. Blow dry and clean it with com-pressed air.

2.2 Mounting of Suction FilterAfter cleaning the suction filterpos. 170, check that the filtermesh is undamaged.Mount suction filter as follows:

2.2.1. Before mounting the suction filter,check that the non-return valve workscorrectly. Check that the suctionchamber is clean.Replace O-ring pos. 719.

2.2.2. Mount the filter insert in the suctionchamber. Mount the cover pos. 718with the screws pos. 734.


13--120173--529--EN

3. Shaft Seal for SAB 128 and SAB 163 Mk4Fig. 13.4

81 82

83

113

118

160

165B

165E165F 165G 165I

165A

AB CDE

165C165D 165K165L165J

Fig. 13.5 SAB 128

Pos. no. Designation Quantity

165AA Shaft seal cover, Male 1

165AB Shaft seal cover, Female 1

165B Balance piston 1

165C Slide ring with wearbushing

1

165D Radial shaft seal 1

165E Inner ring 1

165F O-ring, 39.34 x 2.62 1

165G O-ring, 59.99 x 2.62 1

165I Countersunk screwM4 x 10

4

165J O-ring, 14 x 1.78 1

165K Oil distribution ring 1

165L Spirolox ring 1

Fig. 13.6 SAB 163

Pos. no. Designation Quantity

165AA Shaft seal cover, Male 1

165AB Shaft seal cover, Female 1

165B Balance piston 1

165C Slide ring with wearbushing

1

165D Radial shaft seal 1

165E Inner ring 1

165F O-ring 50.52 x 1.78 1

165G O-ring 69.52 x 2.62 1

165I Countersunk screwM6 x 12

4

165J O-ring, 14 x 1.78 1

165K Oil distribution ring 1

165L Spirolox ring 1


13--13 0173--529--EN

The shaft seal pos. 160 as illustrated inFig. 13.4 is mounted at the compressor shaft.The shaft seal must ensure that refrigerantand oil from the inside of the compressor donot escape into the atmosphere both whenthe shaft is rotating and when it is standingstill. The shaft seal has therefore two sealingsystems, the primary shaft seal and the lipseal arrangement as described in the follow-ing.

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. B. It rotates together with the shaftand slides against a steel ring pos. A, whichis inserted in the shaft seal cover pos. 165A.The sliding surfaces of the two rings are sur-face-ground and lapped together, thus ensur-ing the desired tightness both when the com-pressor 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. B is secured to the compressorshaft by means of three pointed screws pos.E. The outer and inner O-rings pos. C and Densure tightness between the shaft seal andthe shaft seal cover pos. 165A and the com-pressor 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 the

chamber, making it possible for smallamounts of refrigerant to leak from the shaftseal.

To avoid this situation, a sealing ring pos.165D 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. 165D is mounted in theshaft seal cover pos. 165A and seals againstthe sliding ring pos. 165C, as illustrated inFig. 13.4.

Dismounting of Shaft Seal and Lip SealArrangement

S Depressurize the compressor - as de-scribed in the instruction manual - and dis-mantle the coupling.

S Remove all the screws pos. 82 and pullout the shaft seal cover. If the coversticks, it can be pushed out by mountingtwo of the screws pos. 82 in the twothreaded holes of the cover.

Note: Only SAB 128The two threaded holes are notthreaded all the way through. It istherefore advisable to insert a steel pin(diameter 8 x 40 mm) before mountingthe screw.

S The steel slide ring pos. A and the sealingring pos. 165D will come out with thecover and can then with great care bepressed out of the cover. The oil splashring will also come out with the cover andcan be removed manually.


13--140173--529--EN

S Dismount the four countersunk screwspos 165I.

S Pull out the slide ring 165C by means oftwo long M4 screws (SAB128) or M6screws (SAB 163), which are mounted inthe two threaded holes in the flange. TheO-ring pos. 165G can now be removedmanually.

S Now there is enough space to loosen thethree pointed screws pos. E approx oneturn by means of the shortened Allen key -size 3 mm - which is included in the shaftseal 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 By fitting the above-mentioned two longscrews (M4 or M6) in the threaded holesof the balance piston pos. 165B, the pis-ton can now be pulled out manually. Theinner ring pos. 165E and the O-ring pos.165F will come out with the piston andcan then be removed manually.

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. 165B(see Fig. 13.4) on the compressor shaftand turn it so that the pin pos. 118 catchesthe key groove of the balance piston.

S Mount the O-ring pos. 165F in the innerring pos. 165E. Press the inner ring on tothe compressor shaft. Keep pressing untilthe ring rests on the balance piston.

S Fit the O-ring pos. 165G in the inner ring,eg by means of a little grease.

S Mount the rotating part of the shaft seal(the one with the carbon ring) and push itall the way to the recess on the shaft. Donot put any pressure on the carbon ring.Use instead two screwdrivers as illus-trated in Fig. 13.7. Tighten the rotatingpart by means of the three pointed screwspos. E. Check that the O-ring pos. D hasbeen mounted in the rotating part.

Fig. 13.7

S Mount the slide ring pos. 165C and tightenit by means of the four countersunkscrews pos. 165I.

Before mounting the shaft seal cover pos.165A on the compressor block, carry out thefollowing:

• Press the sealing ring pos. 165D intothe shaft seal cover. It must be turnedas illustrated in the drawing Fig. 13.8and must only be pressed so far intothe shaft seal cover that the two sur-faces are flush with each other asshown in Fig. 13.8.


13--15 0173--529--EN

Fig. 13.8

165A

165D

Plane

..

• Mount the O-ring pos. C on the castiron seat pos. A and place the cast ironseat in the shaft seal cover so that thepin pos. 83 catches the key groove ofthe seat.

• Fix the O-ring pos. 81 to the shaft sealcover and the O-ring pos. 165J in theinternal oil channel.

S Place the shaft seal cover on the com-pressor shaft and move it carefully for-ward until it touches the rotating part. Be-fore the screws pos. 82 are tightened,there must be a gap of 3-4 mm betweenthe two flanges as shown in Fig. 13.9.

It is recommended to cross-tighten thescrews pos. 82 so that the shaft seal isnot damaged due to uneven tightening.Tighten the screws to the torques indi-cated in the instruction manual.

S Mount the oil splash ring pos. 113. 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. 92, dis-mount the cap cover pos. 90 by fitting two ofthe screws in the threaded holes in the capcover flange. Thus the cap cover can bepushed out. Remounting of the cap cover iscarried out in the same way as the shaft sealcover.

Before mounting the cover, clean the nozzlepos. 95 with compressed air. Check O-ringpos. 96 and replace it if necessary.

Fig. 13.9

82

3--4 mm beforetightning of screws.


13--160173--529--EN

4. Slide for Vi Regulation

The purpose of the Vi regulating system is toregulate the built-in compressor volume ratioso that the compression ratio is equal to thepressure ratio between the condensing pres-sure and the evaporating pressure in the re-frigeration plant. The system works by dislo-cating the slide pos. 200, thus changing thesize of the compressor discharge port. Thischange increases - or decreases - the com-pression chamber and consequently thecompression ratio.

Vi Adjustment

Adjustment of the Vi slide position is de-scribed in Section 4, Technical Description.The pos. numbers in Fig. 13.10 refer to thespare parts drawing.

Fig. 13.10

184

183

180

105

182

104

102

100200 193 2524 103186 101

Dismantling

After dismantling of the screws pos. 102, un-screw the slide cover pos. 100 and the bear-ing housing pos. 103 by turning the spindlepos. 180 anti-clockwise.

S When the spindle has been unscrewedcompletely from the thread in the slidepos. 200, the arrangement can be re-moved manually.

S By dismantling the screws pos. 104, thecover pos. 100 is dismantled from thebearing housing pos. 103. The sealingrings pos. 182, 183 and 184 can be re-moved by hand.

S Push the spindle pos. 180 and the ballbearings pos. 186 out of the bearing hous-ing, pos. 103.

S Do not remove the arrangement from thecompressor until the suction cover pos. 20has been dismantled.

S The screw pos. 193 functions as a slidestop and should usually not be dis-mantled.

Mounting

Assembly is carried out in reverse order andattention must be paid to the following:

S Insert the ball bearings, which must bewell greased with ball-bearing grease, inthe bearing housing pos. 103 with thespindle collar pos. 180 in between. Avoidknocking on the bearings.


13--17 0173--529--EN

S Before assembling of the slide cover pos.100 and the bearing housing pos. 103,place the sealing rings pos. 182, 183 and184 as shown in the drawing. The openside of the sealing ring pos. 183 must facethe ball bearing. Assembling is carried outby means of the screws pos. 104.

-- Check that the spindle is easily turned.

S Mount the whole unit in position by screw-ing the spindle into the slide pos. 200 untilthe slide cover pos. 100 rests against thesuction cover pos. 20.

Pay attention to the O-ring pos. 101.Secure with the screws pos. 102.


13--180173--529--EN

5. Suction Cover and Bearing in Compressor Shaft End

Before the suction cover pos. 20 can be dis-mantled, the following parts must be re-moved as described earlier:

-- Shaft seal cover pos. 80 and shaft seal

-- Cap cover pos. 90

-- Slide stop cover pos. 100Fig. 13.11

22.4 T0177135_0 V12

9 5 2

21.2

Dismantling

S Knock out the guide pins pos. 22 with thetools nos. 55 and 56,.

S Dismantle the screws pos. 23.

S Carefully pull out the suction cover abovethe shaft ends. The outer rings of the roll-er bearings pos. 111 will come out with thecover.

S Knock the outer rings with the rollers outof the cover with a punch. They cannotbe reused.

S After dismantling the retention pin pos.118, pull out the roller bearing inner ring ofthe rotors as shown in Fig. 13.11. Thenumbers in the drawing refer to the toolslist.

S Mount punch pos. 15 on the short shaftend (rotor end).

S Lock the rotors as shown in Fig. 13.15.

Fig. 13.12

24

20.2

23.3

1

7

T0177135_0 V11

15


13--19 0173--529--EN

Mounting

S Mount locking tool no. 11 on the rotor endwhere the roller bearing inner ring is to bepositioned as shown in Fig. 13.13.

Fig. 13.13

T0177135_0 V21

11

22.7

S Press on the roller bearing inner ring withthe tools as shown in Fig. 13.12. Remem-ber to grease the shafts with Molykotegrease. Tighten to 70 Nm.

Always mount new roller bearings.

S Mount driving pin pos. 118 on the rotorshaft in which the shaft seal is to bemounted.

S Mount the suction cover pos. 20 with theguide pins pos. 22 and tighten the screwspos. 23. Pay attention to the O-ring pos.21 as well as the two small O-rings pos.26 for internal oil channels.

S Press the outer rings with rollers into posi-tion as shown in Fig. 13.14. Remember touse tool no. 4 as shown in the drawing.

S Dismantle locking tool no. 11.

S Now mount the remaining parts as men-tioned at the beginning of this section.

Fig. 13.14

24.1

20.2

23.3

1

7

4

T0177135_0 V20


13--200173--529--EN

6. Rotors and Bearings in Com-pressor Discharge End

Before the rotors can be removed from thecompressor, the parts mentioned under point5 must be disassembled. Proceed as follows:

6.1 Dismantling

6.1.1. Loosen the four locking screws pos.45 and slacken the two adjustingscrews pos. 44 three to four turns.

6.1.2. Dismantle the cover pos. 40 byremoving the screws pos. 43.

6.1.3. Pull out the two inner covers pos. 151and 153 by means of the screws no.22.3, which must be mounted in thethreaded holes of the covers.

Be careful not to lose the two lock-ing pins pos. 119.

6.1.4. Now dismantle the screws pos. 115and remove the clamps pos. 114.

When dismantling the screws pos.115, lock the rotors in order to preventthem from rotating. For this purposeuse arrangement Fig. 13.15 in the ro-tor shaft end.

Fig. 13.15

31

22.6

110

30

15

Remember to dismantle the toolsagain before pressing out the ro-tors.

6.1.5. It is now possible to push out therotors - one at a time - by means ofthe tools shown in Fig. 13.16.

Screw the four long threaded journalsno. 20.1 from the tools set into thethreaded holes used for securing thecover pos. 40.

Fig. 13.16

T0177135_0 V14

21.1

6 1

10 20.1 23.2


13--21 0173--529--EN

Press the rotors loose - one at a timewith screw no. 21.1 and remove themmanually. The bearing inner rings willalso be loosened from the rotors asthey cannot pass the discharge portspos. 140 and 141.

6.1.6 Loosen the discharge ports pos. 140and 141 by removing the screws pos.142.

• The discharge ports are adjusted bymeans of the adjusting screw pos.148 and the locking screw pos. 147(see spare parts drawing).

Fig. 13.17

146149147148

Start by dismantling the blank-offscrew pos. 146 together with thegasket pos. 149. Next, dismantlepos. 147 and loosen pos. 148 withkey no. 51.2. There is only one setof screws pos. 146/147/148 per dis-charge port.

Note:It is essential to loosen the screwspos. 148 before pressing out thedischarge ports as described in thefollowing.

6.1.7 Press out the outer rings of the mainbearings and the discharge portspos.140 and 141 by means of thetools shown in Fig. 13.18.Normally, the bearings should notbe reused.Note, that O-rings pos. 152 and 154are not mounted.

6.1.8 Remove the balance piston pos. 130and 135 from the discharge portmanually.


13--220173--529--EN

Fig. 13.18

135

130

3

2131

136

Female

Male120.1

10

151

153

6.2 Mounting

6.2.1 Before positioning the discharge portspos. 140 and 141 in the rotor housing,check that they are free of burrs andmarks in particular on the surfaceswhich are going to rest against therotor housing.

Check the rotor housing for similar de-fects on the corresponding contactsurfaces.

6.2.2 Push the discharge ports into place inthe rotor housing and tighten thescrews pos. 142 and the steel gasketspos. 143.

S Tighten the screws pos. 142 to halfthe torque (see table of torque mo-ments in Section 21, Appendices) tomake sure that the discharge portsare in close contact with the rotorhousing end surface.Loosen the screws and retightenthem slightly to facilitate the subse-quent adjustment.

Mount the slide pos. 200 and tightenthe adjusting screw pos. 148 looselyin the two discharge ports.

S While pushing the slide pos. 200back and forth, tighten the screwspos. 148 one after the other untilthe slide is moving smoothly backand forth.

S Now fit the locking screw pos. 147and tighten it to 32 Nm.

S Mount and tighten the blank-offscrew pos. 146 as well as thegasket pos. 149.

S Finally, tighten the screws pos. 142to the prescribed torque.

Remember that the steel gasketspos. 143 are not to be reused, butreplaced with new ones in order toobtain tightness.

6.2.2 Before inserting the rotors pos. 110in the rotor housing, it isrecommended that the Vi slide pos.200 is positioned in the rotorhousing to support the rotors.


13--23 0173--529--EN

Fig. 13.19

8

T0177141_0/V20

8

8

The rotors are marked with a number on theend surface that faces the compressor suc-tion end.

The marking must have the same number onboth rotors. When mounting the rotors, thecatching between the rotors must be asshown in Fig. 13.19.

(The number ”8” is an example).

It is also extremely important that the maleand female rotors are positioned in the rotorhousing as indicated in the spare parts draw-ing and cast on the end cover pos. 20.

6.2.4 The bearing systems at thecompressor discharge end consist ofthe following parts for each rotor:

balance piston

roller bearing

special ball bearing

set of adjustment ring

Femalerotor

Malerotor

130 135

131 136

132 137

133 138

Pos. Pos.

The adjustment sets consist of the fol-lowing rings:

Dia.70/90 Dia.80/100FemaleMale

Thickness

0.49

0.52

0.55

0.58

0.61

1

1

1

1

1

1

1

1

1

1

+0--0.01

0.64 1 10.67 1 1

Number of rings

mm mm

In case of replacement, all bearingsmust be replaced.

6.2.5 Grease the shaft ends with Molykotegrease and position the balancepistons pos. 130 and 135 manually.The balance pistons must turn asindicated in the spare parts drawing.

6.2.6 With the tool arrangement shown inFig. 13.20, press the roller bearinginner rings into position.

Mount the roller bearings with thebearing manufacturer’s marking fac-ing outwards.

On the female rotor, turn tool no. 7 asshown in Fig. 13.20. On the male ro-tor, the conical end of the tool mustbe facing the bearing.

Before mounting the bearings, lockthe rotors at the opposite end asshown in Fig. 13.16.

Tighten the nut no. 23.3 with torquewrench no. 40.2 to 70 Nm.


13--240173--529--EN

Fig. 13.20

136

131

T0177135_0 V19

24.1

20.2

23.3

1

7

Female

Male

Fig. 13.21

135

130

3

2131

136

Female

Male

10 21

120.1 23.2151

153

6.2.7 Press the roller bearing outer ringspos. 131/136 in position with toolsshown in Fig. 13.21.The factory marking must faceoutwards.

6.2.8 Press the innermost ball bearing innerring pos. 132/137 into position by

means of the same tool arrangementas shown in Fig. 13.20.

Tighten the nut no. 23.3 to 70 Nm.The factory marking must face in-wards.

Note that the O-ring pos. 152/154 isnot mounted when the thrust coverspos. 151/153 are used as mountingtools.


13--25 0173--529--EN

Fig. 13.22

Female 132133

137Male 138

153 43151 40

44

115

8.2

8.1

6.2.9. After removing the above toolarrangement, mount the following asshown in Fig. 13.22.

a: Insert the ball bearing outer ringspos. 132/137 manually. Place themin the same position as the mountedinner rings.

b: Tools no. 8.1 on the male rotorand 8.2 on the female rotor andtighten with the screws pos. 115:

S 100 Nm for SAB 128 Mk2 and 3.

S 225 Nm for SAB 163 Mk2 and 3.

c: Mount the thrust covers pos. 151and 153.

d: Secure the cover pos. 40 with thescrews pos. 43.

e: Mount the adjusting screws pos. 44,but do not tighten them.

f: Dismantle the locking tools.

6.3 Adjustment of Axial Clearanceof Rotors

After the bearings have been mounted asdescribed in the previous section, the axialclearance of the rotors can be adjusted witha tool arrangement Fig. 13.23, which ismounted on the rotor shaft ends.

Start by adjusting the female rotor.

Fig. 13.23

52

53

31

22.6

30

22.2

24.2

Female rotor

Male rotor

110


13--260173--529--EN

Adjustment

6.3.1 Screw in the screw no. 22.6 manuallyuntil tool no. 30 has the same dis-tance to both shaft ends as shown inFig. 13.23. Tighten the screw no. 22.2to 14 Nm, whereby the female rotor ispressed against the discharge portpos. 141. The adjusting screw pos. 44must be loose.Set dial meter on ”0”.

6.3.2 Now screw in the adjusting screw pos.44 at the female rotor and tighten to32 Nm. Read the dial meter and notethe difference. The difference indi-cates how much the rotor can bemoved axially.

a: By way of example this movementcould be 0.630 mm.

b: As the correct movement must bebetween 0.05 and 0.10 mm,the average figure is 0.075 mm.This figure is deducted from themeasured value:

0.630-0.075 = 0.555 mm

6.3.3 From the adjusting set pos. 133,select the adjusting ring whose thick-ness comes closest to the calculatedvalue. In the example above thecalculated value is 0.55 mm. Thethickness is stamped on the rings.

6.3.4 By inserting the selected adjustingring as shown in Fig. 13.22 (pos. 133)and repeating the adjustment men-tioned in section 6.3.2, it is certainthat the movement remains within thementioned tolerances (0.05 and 0.10mm). The exact measure is noteddown for later application(see point 6.3.10).

The exact measure for a female rotorcan eg be 0.061 mm after the adjust-ments in sections 6.3.3 and 6.3.4.

To be able to insert the adjustingrings, the following must be done:

-- Loosen the adjusting screw pos. 44

-- Dismantle the cover pos. 40

-- Take out the thrust cover pos. 153

-- Take out the ball bearing outer ringmanually together with the balls.

The remaining parts of the tool arrangementare not dismantled.

6.3.5 After the adjustment, loosen the ad-justing screw pos. 44 and dismantlethe cover pos. 40, the thrust coverpos. 153 and the tool no. 8.2(see Fig. 13.22).

6.3.6 By means of the tools shown inFig. 13.20, mount the outmost ballbearing inner ring and tighten thethrust plate pos. 114 with the screwpos. 115.

Tighten the screw to :

• 70 Nm for SAB 128 Mk2 and 3

• 225 Nm for SAB 163 Mk2 and 3

6.3.7 Insert the locking pin pos. 119 in thegroove of the ball bearing outer ring,turning it so that the groove facesdownwards.

6.3.8 Position the O-ring pos. 154 on thethrust cover pos. 153 and fit the screwno. 22.3 on the thrust cover and lockwith the nut no. 23.1.

Place the thrust cover in position andturn the screw no. 22.3 until thegroove in the thrust cover catches thelocking pin pos. 119. This can be reg-istered by the cover being carefully


13--27 0173--529--EN

pressed inwards during the turning.Thus it can be pressed in a littlefurther when the locking pin catchesthe groove in the thrust cover.

6.3.9 Mount the cover pos. 40 and secure itwith the screws pos. 43. Rememberthat the adjusting screws pos. 44must be loose.

Adjust the male rotor in the same way asdescribed in sections 6.3.1 to 6.3.9 bymounting the adjusting tools shown inFig. 13.24.

Fig. 13.24

53

52 22.6

31

22.2

24.2

Female rotor

Male rotor

30

110

T0177135_0 V16

Final Adjustment

After both rotors have been adjusted and theexact measures have been noted down, therotors are ready for the final adjustment.

6.3.10 Compare the exact measure foreach of the rotors with the measuresin column 1 of the following table.Column 2 indicates the final adjustment measure.

For instance, the exact measure of0.062 mm for the female rotor willbe between 0.061 and 0.065, which

leaves a final adjustment measureof 0.05 mm.

Exact measuresbetween

mm mm1 2

0.050-0.055 0.0400.056-0.060 0.0450.061-0.065 0.0500.066-0.070 0.0550.071-0.074 0.0600.075-0.079 0.0650.080-0.084 0.0700.085-0.089 0.0750.090-0.094 0.0800.095-0.100 0.085

measuresFinal adjustment

With the adjusting tools mounted asshown in Fig. 13.24 and the dial meterset at ”0”, tighten the adjusting screwpos. 44 while reading the dial meter.The dial meter indicator must movethe final adjustment measure.

6.3.11 After this final adjustment, lock theadjusting screws pos. 44 with thepointed screws pos. 45.The adjustment of the male rotor isnow completed.

6.3.12 Then mount the adjusting tools asshown in Fig. 13.23 and describedin section 6.3.1. Repeat the adjustment described in sections 6.3.10and 6.3.11 for the female rotor.

6.3.13 Check manually that the rotors areeasily turned.


13--280173--529--EN

7. Compressor Protection SystemTo protect the compressor against too highlevels of pressure, it has a built-in protectionvalve, type POV, pos. 704 which is controlled

by the pilot valve, type BSV8, pos. 700. Theprotection system is shown in Fig. 13.25 anddescribed in the following.

Fig. 13.25

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. 13.25 is actu-ated by the high pressure P1. The valve isfitted with a stainless metal bellow ➀. Thereference pressure in the bellow is the at-mospheric pressure P0. The effective area ofthe bellow is exactly equivalent to the area ofthe valve seating, meaning that the backpressure P2” does not affect the openingpressure of the valve.

The main valve is a normally closed valve.The high pressure P1 affects the lower sideof the valve cone ➁ propagating up throughthe piston rod ➂ to the upper chamber ➃ ofthe valve, producing a pressure on the piston➄. The area of the piston is larger than the

area of the valve seating. Together with theforce of the spring this will keep the valveclosed.

When the pressure P1 reaches the set pres-sure of the pilot valve, the valve will open.The pressure P2” of the pilot line and lowerchamber ➅ of the main valve will increase.The pressure of the lower chamber is limitedby flow through the nozzle ➆. When the flowthrough the pilot valve exceeds the capacityof the nozzle, the pressure of the chamber ➅

will increase, provided that the main valve isopen. When the pressure P1 is reduced, thepilot valve will close, and the pressure P2” isequalized through the nozzle ➆. The springwill then close the main valve. The closingtime is < 30 seconds, depending on the size


13--29 0173--529--EN

of the nozzle. The spring is dimensioned sothat a differential pressure level (P1-P2) of 7bar will open the valve completely.

7.2 Dismantling of Protection System

By dismantling the screws pos. 702 and 716as shown in Fig. 13.26, the complete safety

system can be lifted off the compressor.Take care not to damage the O-rings pos.703 and 717.

Any further dismantling of the system isusually not necessary. Sabroe Refrigerationrecommends not to disassemble the variouscomponent parts.

Fig. 13.26

720

701

720

726

727

700732730731733

4161--t13_4

716

702

A

703

702

717

716

7.3 Control of Opening Pressure

Control of the operation and opening pres-sure of the protection system should be car-ried out according to local regulations. Notethe following:

7.3.1 Isolate the compressor unit at the stopvalves and evacuate the refrigerant.Make sure that the unit cannot bestarted unintentionally and that thereis no excess pressure in the system.

7.3.2 Dismantle the complete protectionsystem by means of the screws pos.702 and pos. 716.Take care not to damage theO-rings pos. 703 and 717.

7.3.3 Dismantle the pilot valve pos. 700 byloosening the nuts pos. 720. Then dis-mantle the nuts pos. 726 and pos.730.


13--300173--529--EN

Fig. 13.27

G 3/8”

727

726

..

7.4 Testing of Pilot Valve pos. 700

7.4.1 The pilot valve is usually tested in atest bench. However, it can be con-nected to a pressure source bymeans of a high-pressure hose. Theconnection nut shown as pos. 726 inFig. 13.27 has a 3/8” thread. A pres-sure gauge should be used.

7.4.2 By slowly increasing the pressure,check that:a: the pilot valve remains tight untilthe opening pressure is reached.b: the valve opens at the pressure in-dicated on the name plate.By opening entirely for the air supply,check that the pilot valve is able toopen to full lifting height.

7.5 Testing of Complete Protection

System

7.5.1 When testing the complete system,mount the pilot valve as shown inFig. 13.26. Keep the pressure hose inplace as described in section 10.4.1.

7.5.2 When opening for the pressuresource, the pilot valve will open at thepressure checked in section 10.4.2.This will activate the main valve pos.704, which can be checked by glanc-ing through the flange A -- Fig. 13.26.

7.6 Remounting of Protection System

7.6.1 When remounting the pilot valve, usenew pipe sections pos. 701.It is also recommend to use new fit-tings pos. 720, 727 and 732.

7.6.2 When remounting the complete sys-tem on the compressor, position theO-rings pos. 703 and 717 and tightenthe screws pos. 702 and 716 as pre-scribed.

7.6.3 After charging refrigerant to the sys-tem, check that the system is notleaking.

0178-277-EN

98.05


13--31 0173--529--EN

Oil temperature regulating systemSAB 110, 128, 163, 202 and VMY 536

In the above screw compressor units wherethe oil system is cooled by either a refrige-rant-cooled oil cooler, type OOSI, or a water-cooled oil cooler, type OWSG, the oil tempe-rature is usually regulated by a thermostaticthree-way valve as illustrated in fig. 1.

Fig.1

A

This thermostatic three-way valve is used inthe following dimensions:

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 thename plate on the valve cover.

Function

The valve pos. 46 is fitted in a bypass pipingsystem as shown in fig. 2.

Fig. 2To the compressor

Oil cooler

From oil receiver

Three-wayvalve

As shown in fig. 3 and 4, the valve works byletting a built-in thermo element, pos. 1, reg-ulate a cone, pos. 2, so that cold and warmoil is mixed to the set temperature.

In fig. 3 the thermo element is shown in itscold position, ie 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, thus shutting off theflow of warm oil.


13--320173--529--EN

During operation the thermo element will ad-just the regulating cone so that the two oilflows are mixed to the set oil temperature

and leave the valve through connectingbranch 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. It cannot be read-justed.

Service

Generally, 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

Apply the following procedure:

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 to keep the thermo elementin a fixed position, is best dismantlled byturning it slightly and then lift it up by

means of a big screwdriver.Watch out ! There may still be oil in thesystem.

S Remove the thermo element from thevalve housing manually.

Assembly

Assembly of the valve is done in the reverseorder. Attention should be paid to the follow-ing:

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.


13--33 0173--529--EN

Oil pump pos. 63

The gerotor is a positive displacement pump-ing unit consisting of just two elements. Theinner rotor has one less tooth than the outer

and has its centerline positioned at a fixedeccentricity from the centerline of the outerelement.

Fig. 13.28

Inlet

Outlet

Outlet

Inlet

Pumping Sector

Start-upThe pump must only run without oil flow forbrief periods.

Checking Rotating Directionof MotorBefore initial start-up of the oil pump, re-member to check the rotating direction of themotor. The rotating direction is indicated onthe electric motor with an arrow. Seenthrough the motor shield of the motor, themotor must rotate anti-clockwise.


13--340173--529--EN

Service

Service of the oil pump must be carried outas described in the following.

Warning!

Failure to follow these instructions couldresult in serious bodily injury or death.

Do not attempt to work on any Tuthillpump installation before completing thesteps below.

Disconnect the drive so that it cannot bestarted while work is being performed.

Review the Material Safety Data Sheet(MSDS) applicable to the liquid beingpumped to determine its characteristicsand the precautions necessary to en-sure safe handling.

Vent all pressure within the pumpthrough the suction or discharge lines.

All Tuthill pumps contain residual ISO32 lube oil from the factory productiontest. Determine if this is compatible withthe fluid you are pumping. If the fluid isincompatible, consult the factory.

Disassembly of Seal

1. Deburr shaft especially around the key-way area.

2. Hold the pump in a vice, cover down andunscrew seal plug and remove fromshaft (this may be tight due to the bear-ing).

3. Gently remove carbon carrier and springfrom the shaft. Then the drive ball andspring plate can be removed.

4. Remove static seal plate from bearinghousing (this may be tight due to the Oring)

5. Inspect rotor, if badly scored in seal orbearing area, rotor should be replaced.Also check seal faces for the same scor-ing. Remove 0--rings and check for de-formation, again replace if there is anydoubt.

6. Clean all parts thoroughly and replacestatic seal plate.

7. Refit spring plate and drive ball ensuringthat the ball seats correctly into the holein the shaft.

8. Replace the spring and carbon carrier onthe shaft and push down gently untilspring is down to the spring plate.

9. Ensuring that the groove on the carboncarrier is in line with the drive ball, thenrefit seal plug and screw down.

Disassembly of Pump1. Deburr shaft especially around the key-

way area.

2. Hold the pump in a vice, cover down andunscrew seal plug and remove fromshaft (this may be tight due to the bear-ing).

3. Gently remove carbon carrier and springfrom the shaft. Then the drive ball andspring plate can be removed.

4. Remove static seal plate from bearinghousing (this may be tight due to the Oring)


13--35 0173--529--EN

5. Hold body in the vice with the shaft point-ing downwards. Remove the 4 off 6mmcap head screws and remove the coverby pulling upwards, place to one side.

7. The inner rotor is attached to the shaft soboth can be removed together by pullingon the end of the shaft. Once they areout then remove the outer rotor.

8. The individual parts must now be in-spected for damage. The keyway in theend of the rotor must be in good condi-tion and there must not be any deepscratches or grooves on the followingsurfaces:

a. The ID surface of the housing.

b. The OD of the outer rotor.

c. Both faces of outer rotor.

d. The OD of the inner rotor.

e. Both faces of the inner rotor.

f. The surfaces of the cover.

g. Areas on the shaft of the rotor where theseal and the bearing seats.

InspectionCheck cover, housing, inner and outer rotorfor wear, chipped or broken teeth. Drop off incapacity is generally caused by the abrasiveaction of foreign materials in the oil, resultingin endplay of both the rotors.

Check for side movement in the shaft assem-bly, as this indicates potential bearing failure.

Reassembly of Pump

1. Clean all parts thoroughly using greatcare to eliminate dirt.

2. Take the body with the seal area facingdownwards and push the shaft and innerrotor into the bores ensuring that it ispushed down onto the bottom face.Once these are in place the outer rotorover the inner rotor ensuring that theteeth mesh with no problems.

3. Place the cover onto the shaft (the coverwill only fit one way due to the offset onthe cover and the bore in the body).

4. Hold the body in a vice with the shaftfacing upwards and make sure that theshaft turns freely.

5. Refit spring plate and drive ball ensuringthat the ball seats correctly into the holein the shaft.

6. Replace the spring and carbon carrier onthe shaft and push down gently untilspring is down to the spring plate.

7. Ensuring that the groove on the carboncarrier is in line with the drive ball, thenrefit seal plug and screw down.


13--360173--529--EN

Fig. 13.29

1. Cover2. O--ring3. Outer gear4. Inner gear5. Body6. Bearing7. Housing plug8. O--ring

9. Seal assy.10. Shaft11. Bush12. Bush13. Flange14. O--ring15. O--ring16. Flange

14 131516

1 2 3 4 5 6

789101112

NOTE : Sabroe Refrigeration only carries pos. 2 and pos. 9 as spare parts for the pump.See spare parts survey for SAB 128 and SAB 163 Mk4.


13--37 0173--529--EN

Mounting and Dismounting of Coupling

Mounting

Assemble the coupling as shown inFig. 13.30 and mount it on the compressorand motor shafts as described in the follow-ing:

S When mounting the coupling, pay atten-tion to the measurements C and E in thetable below, Fig. 13.31.

Fig. 13.30

CT0177120_0/V1

E

G F

Fig. 13.31

CompressorType

CouplingType

Bolt DimensionSpanner

Cmm

Emm

SAB 128 225 1/2”

SAB 163 262 9/16”

127¦0.514¦0.5

10+1.00

S Before mounting the coupling on thecompressor shaft, clean the couplingflange, the individual parts in the bushingand the rotor shaft.

S Lubricate all parts with a little refrigerantmachine oil. Do not lubricate with Molyb-denum, high-pressure oil or grease.

S It is recommended to press on the coupl-ing flange on the motor by means of athreaded rod with nut and tightening bar.

S Do not strike the coupling flange asthis may damage the bearings.


13--380173--529--EN

S Fasten coupling flange to the motor andcompressor shafts with pointed screwand tongue connection.

S If the coupling is supplied without bor-ing because the motor is unknown at thetime of delivery, the coupling flange mustbe balanced according to ISO 1940G 2.5 to a max. of 6000 rpm withouttongue, but with the pointed screw.

S Assemble bushing as shown inFig. 13.32 and loosen screws pos. 1 1turn.

Fig. 13.321

S Mount some of the screws pos. 1 in thedismantling holes with thread as shownin Fig. 13.33. Adjust manually so that thesurfaces are even as indicated by the

mark .

Fig. 13.33

1

S Mount the bushing in the coupling flangeand push it right to the bottom marked

as shown in Fig. 13.34.

Fig. 13.34

S Remove the screws from the dismantlingholes and remount them in the bushingas shown in Fig. 13.33. Tighten thescrews manually.

S By means of the torque key, cross-tighten all screws pos.1 by first tighten-ing them to half of the torque Ms andthen to Ms as indicated in the followingtable.

Torque Ms

Compressortype

Screws pos.1Quantity x Dim.

TorqueMs [Nm]

SAB 128 8 x M6 15

SAB 163 8 x M8 35

Keep tightening the screws to the torqueMs until none of the screws can be turnedanymore.


13--39 0173--529--EN

Dismounting of Coupling Flange

Dismounting of the coupling flange from thecompressor shaft is carried out in the follow-ing way:

S Loosen screws pos. 1 a few turns.

S Mount screws pos. 1 in the dismantlingholes as shown in Fig. 13.33 and cross-tighten them evenly until the two taperrings have been pressed apart and haveloosened the coupling flange from theshaft.

S Remove coupling flange with bushing.

Dismantling of Coupling

When dismantling the coupling, it is import-ant to note the positions of bolts, washersand nuts as they must be refitted in the sameorder. Tie a string or a piece of threadthrough one of the bolt holes in the coupling

discs to avoid that the plates are turned inrelation to each other and to the flange.

Mounting

S Mount the two coupling parts, motorflange F and compressor flange G as de-scribed earlier, see Fig. 13.34.Pay attention to the measurement E asshown in Fig. 13.30, and table Fig. 13.31.

S Mount motor and compressor and secureto the base frame as described.Check distance C as shown in tableFig. 13.31.

S Mount the coupling intermediate sectionsand the two flexible discs and secure withthe bolts as shown in Fig. 13.30. Thetorque moment is shown in the tablebelow, Fig. 13.36.

However, do not mount the bolts that se-cure the flexible discs to the motor flangeuntil the alignment has been completed.


13--400173--529--EN

Alignment Procedure

The series 52 coupling is aligned as de-scribed in the following. The accuracy where-by the coupling must be aligned is indicatedin the table below, Fig. 13.35.

In principle, the alignment is a question ofmoving the motor so that its shaft is placed incontinuation of the compressor shaft.

Fig. 13.35

T0177120_0/V1

2Z

a

1

X

A

CGH

F

•

Fig. 13.36

Max variation at 180° rotation

Pos. 1 Pos. 2CouplingNo

Dia. Distance TorquemomentA

mmCmm

Horizontalmm

Verticalmm mm

225

262

145

168

34

41 0 -- 0.05 0 -- 0.10 0 -- 0.10

Nm

127¦ 0.5


13--41 0173--529--EN

Parallel Shafts on a HorizontalLevel1. Turn the coupling so that the alignment

tool is in top position.

2. Guide measuring pin pos. 2, Fig. 13.35,towards the coupling flange with a 1 mmfeeler gauge in between and secure thepin. Remove the feeler gauge.

3. Turn the coupling 180°. Motor and com-pressor are turned at the same time.Measure with feeler gauge how much thedistance from the measuring pin to coupl-ing part has changed. The change iscalled X.

4. Measure the distance b between the feetof the motor as shown in Fig. 13.37.Measure the distance a from the middle ofpin 2 to the centre line of the motor asshown in Fig. 13.35.

5. Insert liners with thickness Y either underboth front feet or both rear feet, tilting themotor at the desired end. Use the follow-ing formula for calculation of the linerthickness:

Y = X •2ab

Fig. 13.37

T0177056_0b

y

6. After having tightened the motor bolts, re-peat the measuring and compare the re-sult with the table values.

Parallel Displacement to CorrectCentre Height

1. Turn the coupling so that the alignmentgauge faces downwards.

2. Guide the measuring pin pos. 1,Fig. 13.35, towards the coupling part witha 1 mm feeler gauge in between. Securethe pin and remove the feeler gauge.

3. Turn the coupling 180° and measure withfeeler gauge how much the distance hasincreased. The increase is called Z.

4. Then lift the motor by placing liners withhalf the thickness, i.e. Z/2, under all fourfeet.

5. After securing the motor, repeat themeasuring and compare the result withthe table values.

Parallel Shafts on a Vertical Level

1. Turn the coupling so that the alignmentgauge faces horizontally to one side.

2. Move both measuring pins towards thecoupling with a 1 mm feeler gauge in be-tween. Lock the pins and remove thefeeler gauges.

3. Turn the coupling as close to 180° as al-lowed by the cap cover and measure withfeeler gauge the deviations from the orig-inal one millimetre on both pins.

4. Moving and turning the motor sidewayswith the adjustment screws and repeatingthe measuring, align the motor in accord-ance with the table.Remember that the motor must be se-cured during each measuring.


13--420173--529--EN

Final Installation1. Tighten the fixing bolts on the motor.

2. Dismantle the alignment tool.

3. Mount bolts between the flexible discs andthe coupling flange of the motor. Tightenall bolts to the torque moment indicated intable below Fig. 13.35.

4. Check distance C.

5. Once the coupling alignment has beencarried out correctly, fit the outer shell ofthe coupling guard on the adaptor platewhich is secured on the compressor shaftseal cover.

Push the outer shell, which is placed in-side the inner shell, so far towards thedriving motor that access to the rotatingparts is made impossible. SeeFig. 13.38.

6. Recheck the coupling with a compressorstill warm from operation and with pres-sure on piping connections.

Fig. 13.38

T0177045_0

0171-464-EN

94.05


13--43 0173--529--EN

Refrigeration Plant Maintenance

Operational Reliability

The main reasons for operating malfunctionsof 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.

In the following some information is givenabout how to keep contaminants out of therefrigeration system and at the same timefacilitate day-to-day supervision of the plant.

Pumping down the RefrigerationPlant

Before dismantling any parts of the refriger-ation plant for inspection or repair, the plantmust be pumped down.

1. Open suction and discharge stop valveson the compressor.

2. Close the liquid stop valve after the con-denser or receiver so that liquid refriger-ant can be collected in the receiver. Anysolenoid valves in the liquid line must beopened by force so that the liquid line isemptied of refrigerant. Adjust any con-

stant-pressure valves to bring evaporatorpressure down to atmospheric pressure.

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 pressureis equal to atmospheric pressure, stopthe compressor and shut off the dis-charge stop valve. Shut off any stopvalves in the oil return line.

If the receiver has an extra stop valve inthe feed line, it can be closed. Practicallythe entire refrigerant charge will then beshut up in the receiver.

Note:The receiver must not be overfilled! Thereshould be a minimum gas volume of 5%.

5. A slight overpressure should normallyremain in the piping system - this safe-guards the system against the penetra-tion of air and moisture.

6. Before dismantling any parts, the oper-ator should put on a gas mask.

Dismantling Plant

To prevent moisture from penetrating into therefrigeration plant during repairs, it is advis-able to follow the rules below:

1. No component should be opened unnec-essarily.

2. When dismantling the system, the pres-sure in the system should be a littlehigher than atmospheric pressure.


13--440173--529--EN

3. Note:If the piping system is colder than thesurroundings, there is a considerable riskof damp precipitation (condensation) onthe cold plant parts. Plant components tobe dismantled must be warmer than theambient temperature.

4. No two points in the system should beopened at the same time.

5. Plug, close or at least cover the openingwith oiled paper or the like.

6. Note that filters may be very moist.

Tightness Testing and Pumpingdown the Refrigeration PlantBefore refrigerant is recharged to the part ofthe refrigeration plant which has beenopened, the section must be pressure testedas described in the section entitled PressureTesting.

Pump down in order to eliminate air andmoisture. See the section on Evacuation.Otherwise, follow the instructions given in theseparate instruction manual on plant compo-nents.

Note:If the oil in oil separator of the screw com-pressor has been in contact with the at-mospheric air for a long period of time, itmust be replaced with fresh oil of thesame grade and make.

0171-466-EN

94.05


13--45 0173--529--EN

Ordering Spare Parts

When placing an order for spare parts,please state the following:

1. Compressor No

All compressors are fitted with an identifica-tion plate, which states the type and com-pressor no of the compressor and indicatesthe type of refrigerant be used.

2. Part No

Spare parts drawings and parts lists in theService Manual contain the following sparepart indentification:

a) Spare part no -- a reference number,which makes it easier to find a part in thedrawing and the parts list.

b) Designation of the part.

c) Part no -- a 7-digit number.

When ordering spare parts, please state thedesignation and part number. If in any doubt,state the spare part no too.

3. Forwarding instructions

When ordering spare parts, please state theforwarding address, and the address towhich the invoice is to be sent. If appropriate,please state the name of your local bank,method of transport and required deliverydate.

4. Classification certificate

If requiring a certificate from a classificationauthority, please state this on the order asthe inspection and issuing procedures takeextra time and incur extra expenses.

5. Quotation No

If a quotation no has been stated during ear-lier correspondence, please refer to thiswhen placing your order -- it will help us toidentify and execute your order quickly.


13--460173--529--EN

Spare Part Sets for Screw Compressor and Unit.

It is always an advantage to have a stock of spare parts for both compressor and unit. In thisway the customer or a Sabroe Refrigeration service engineer is able to carry out the necessaryreplacements without wasting time waiting for new spare parts to arrive.

On contacting Sabroe Refrigeration’s local representative, you may receive specificationsfor the following spare part sets for compressor and unit.

Compressor Block:

S Standard set of sparesThis set contains a representative selec-tion of O-rings and gaskets.

S Certificate set of sparesBesides the parts contained in the stan-dard set of spares, this set also includesbearings and shaft seal.

Basic Unit:

S Standard set of spares:This set includes the following spare partsfor the components mentioned below:

-- 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, sealing 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:Besides the parts contained in the stan-dard set of spares, this set also includesspare parts for the components mentionedbelow:

-- 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


13--47 0173--529--EN

0173--078--EN

02.04

20. Final DisposalService Manual SAB 128R and SAB 163R Mk4

20--00173--529--EN

20. Final Disposal

Table of Contents

Final Disposal 20--1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .General 20--1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Safety Precautions 20--1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Disposal of Machine Parts 20--1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Disposal of Oil and Refrigerant 20--1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Disposal of Electrical Components 20--2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Disposal of Batteries 20--2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .


20--1 0173--529--EN

Final Disposal

The purpose of this document is to describehow to safely dispose of this equipment orpart of it.

This document is primarily intended for thede-commissioning engineers and authorities.





General

Safety Precautions

Danger !

Before dismantling the plant, read Section 3,Safety Precautions carefully. Failure to do somay result in personal injury or even death.

Dismantling of a cooling unit which is to bescrapped must be carried out in a safe way.

Authorized refrigeration personnel must par-ticipate in the first part of the dismantling pro-cess as fundamental knowledge of refrigerat-ing systems and the risks involved isrequired.

Before dismantling the plant, refrigerant andoil must be drained into containers intendedfor the purpose. Disconnect all electrical con-nections to the unit. Remove fuses in themain switchboard.

During the dismantling process, the indi-vidual machine parts and components mustbe sorted so that disposal can take place inan efficient way.

Danger !

Take great care if using cutting tools, egangle grinder or flame cutter, during the dis-mantling process as pipes or the like will con-tain oil residue which may ignite. Refrigerantresidue does also involve a great risk asHFC and HCFC refrigerants will developtoxic gasses when heated. Make sure thatthere are no air traps as heating will result ina pressure rise.

Disposal of Machine Parts

When dismantling the plant, it is important tosort the parts to be disposed of. Compressor,frame, containers, etc belonging to the cat-egory of iron and metal scrap must be deliv-ered to an approved scrap dealer complyingwith the prevailing rules and regulations ofthe individual country.

Disposal of Oil and Refrigerant

Oil and refrigerant must be delivered for de-struction or regeneration at a receiving sta-tion for hazardous waste, including used oilfilters. The receiving station must complywith the prevailing rules and regulations ofthe individual country.


20--20173--529--EN

Disposal of Electrical Components

Electrical and electronic products, eg wiring,panels, hardware, etc must be delivered to areceiving station approved to handle elec-tronic waste. The receiving station must com-ply with the prevailing rules and regulationsof the individual country.

Disposal of BatteriesUsed batteries from eg the backup of thecomputer control must be delivered for de-struction at a receiving station. The receivingstation must comply with the prevailing rulesand regulations of the individual country.

21. AppendicesService Manual SAB 128R and SAB 163R Mk4

21--00173--529--EN

21. Appendices

Table of Contents

Appendices 21--1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .References to Instructions 21--1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Appendix 21--2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Torque moments for screws and bolts 21--3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Torque moments for coupling 21--4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .


21--1 0173--529--EN

AppendicesThe purpose of this document is to collect allrelevant instructions for products deliveredfrom sub-supplier and which are used in theSabroe product in question.





References to InstructionsThe instructions from the sub-suppliers mustas far as possible be copied from the originalinstructions, firstly, to avoid any errors andsecondly, to avoid losing the right to claimdamages.


21--20173--529--EN

AppendixThis section includes data sheets, instructions of components and tables of torque moments.

1. List of torque moments

2. Controlling equipmentPressure transducer, AKS32R, AKS2050, AKS3000, AKS3050Temperature sensor P2208Pressure cut-outs, type KP1, KP5, MP55Thermostats, type KP61--81Thermostatic injection valve, type TEATTransmitter(s)

3. ValvesValves type SCV 40-200 /SCV / STV 250--300Non return valve, type NRVAMain expansion valve, type PMFLPilot controlled regulator, type PM1

4. FilterFilter, type FIA

5. Piping diagram order specific. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Wiring diagram order specific. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Dimension sketch order specific. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Placing of vibration dampers order specific. . . . . . . . . . . . . . . . . . . . . . . . .Other instructions order specific. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Note:This instruction material may include descriptions of components which are not part of theproduct in question.

0171-595--EN

00.12


21--3 0173--529--EN

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

SAB 128R and SAB 163R Mk4 Screw compressor units · Service Manual SAB 128R and SAB 163R Mk4 EN M...

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Transcript of SAB 128R and SAB 163R Mk4 Screw compressor units · Service Manual SAB 128R and SAB 163R Mk4 EN M...