Instruction Manual

SAB 163 HM/HF

Screw Compressor Unit

0178-202- EN Rev. 00.03 Christian Xs Vej 201, P.O. Box 1810, DK-8270 Hjbjerg, Denmark
Phone +45 86 27 12 66 . Fax +45 86 27 44 08
99.06

Instruction Manual
for
SAB 163 Mk3

The screw compressor and unit can be fitted
with different equipment, depending on their
functions and requirements.
Some of these variants are described in this
instruction manual, even though they are not
fitted on your particular unit.
A cross (x) in the following table indicates
which variants that are fitted on your unit
with the shop no. stated below.

Type of drive Male drive Female drive

Refrigerant R717 R22 Other

Shop no.

UNISAB II and manual regulation of the Vi slide

Instrumentation
UNISAB II and automatic regulation of the Vi slide

Water-cooled oil cooler OWSG/OWRG

Water-cooled oil cooler Type B

Refrigerant-cooled oil cooler OOSI

Oil cooling
Refrigerant injection in compressor HLI

Vessel type HESS

Economizer
system Closed system and vessel type EOSE
(ECO-system)
Open system and vessel type SVER

Ex-execution Both compressor and unit are safeguarded

0178-050-EN 1
Preface
The aim of this instruction manual is to
provide the operators with a thorough
knowledge of the compressor and the unit, at
the same time providing information about:
S the function and maintenance of the
individual components;
S service schedules;
S procedure for dismantling and
reassembling of the compressor.
The instruction manual also draws attention
to typical sources of errors which may occur
during operations. It states their cause and
explains what should be done to rectify them.
It is imperative that the operators familiarize
themselves thoroughly with the contents of
In the space below you can enter the name and address of your local SABROE
REPRESENTATIVE :
SABROE REFRIGERATION A/S
P.O. Box 1810, DK8270 Hjbjerg
Chr. Xs Vej 201, rhus, Denmark
2 0171-702-EN
this instruction manual to ensure reliable and
efficient operation of the plant as SABROE is
unable to provide a guarantee against
damage occurring during the warranty period
where this is attributable to incorrect
operation.
To prevent accidents during dismantling and
assembly of compressors and components,
these should only be carried out by
authorized personnel.
96.06
The contents of this instruction manual must
not be copied or passed on to any
0171-500-EN
unauthorized person without Sabroes
permission.
Phone: +45 86 27 12 66
Telefax: +45 86 27 44 74
Table of Contents

Instruction Manual for SAB 163 Mk3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

Preface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Table of Contents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Description of compressor SAB 163 Mk3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Screw compressors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
General safety instructions and considerations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Handling of the compressor, areas of application,
safety equipment and symbols, safety at servicing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Safety equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Safety symbols . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
First Aid for accidents with Ammonia . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
First aid for accidents with HFC/HCFC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Protecting the operator as well as the environment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Sound data for reciprocating and screw compressor units all types of compressors . . 21
Vibration data for compressors - all types . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Compressor Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Operating limits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Compressor Unit Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Type of compressor unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
Compressor and unit operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
1. Preparations before starting up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
2. Initial start-up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
3. Current control at normal operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
4. Normal stop . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
5. Preparations before a lenghty standstill period . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
6. Pressure testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
7. Evacuation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
8. Operating log . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
Service Schedules for screw compressors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
Preparations before compressor inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
Cleansing of oil in the unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
Checking the oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
Assessing the oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
Visual assessment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
Analytical evaluation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
The analysis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
Major Service Intervals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
Oil charging, weight and shipping volume . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
Servicing the refrigeration plant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47

0178-050-EN 3
Maintenance of Compressor SAB 128/163 Mk3 - Dismantling and Assembly . . . . . . . . . 49
1. Oil filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
2. Suction filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
3. Shaft seal type 680 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
4. Regulating cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
5. Regulating slide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
6. Slide stop for Vi-regulation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
Magnetic coupling for Vi-indication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
7. Suction cover and bearing in compressor shaft end . . . . . . . . . . . . . . . . . . . . . . . . . . 63
8. Rotors and bearings in compressor discharge end . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
9. Capacity indicator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
Magnetic coupling for capacity indication type A and B . . . . . . . . . . . . . . . . . . . . . . . . . 73
Transmitter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
Limiting the minimum capacity of the screw compressor . . . . . . . . . . . . . . . . . . . . . . . . 76
10. Compressor Protection System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
Systems for regulation of compressor capacity and Vi ratios SAB 128/163 Mk3 . . . . . . . 81
1. Regulation of compressor capacity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
2. Automatic regulation of the Vi-slide - For SAB 163 Mk3 only . . . . . . . . . . . . . . . . . . 82
3. Manual regulation of the Vi slide - For SAB 128/163 Mk3 . . . . . . . . . . . . . . . . . . . . . 83
Adjusting the position of the Vi-slide
SAB 128 Mk3 R22, R134a, R404A/R507, R407C . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
Adjusting the position of the Vi-slide
SAB 163 Mk3R22, R134a, R404A/R507, R407C . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
Adjusting the position of the Vi-slide R717 - SAB 128 Mk3 . . . . . . . . . . . . . . . . . . . . . . 86
Adjusting the position of the Vi-slide R717 - SAB 163 Mk3 . . . . . . . . . . . . . . . . . . . . . . 86
Torque moments for screws and bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
Component description SAB 128/163 Mk3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
Fine separator element . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90
Oil level glass, pos. 31 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91
Stop valve, pos. 34 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91
Discharge stop valve and non-return valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91
Heating rods for heating the oil in reciprocating and screw compressors . . . . . . . . . . . . . 92
Water-cooled oil cooler type OWSG/OWRG . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93
Water-cooled oil cooler, type B . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96
Refrigerant-cooled oil cooler type OOSI . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98
Oil temperature regulating system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99
Refrigerant injection in compressor HLI (High-stage Liquid Injection R717) . . . . . . . . . . . 102
Throttle Valve pos. 52 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104
Oil pump pos. 63 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105
Spare Parts Drawings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107
Flow security . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108
Safety and monitoring devices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109

4 0178-050-EN
Refrigeration Plant Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111
Operational reliability . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111
Pumping down the refrigeration plant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111
Dismantling plant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111
Tightness testing and pump-down of refrigeration plant . . . . . . . . . . . . . . . . . . . . . . . . . 112
Troubleshooting on the Screw Compressor Plant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113
Selecting lubricating oil for SABROE compressors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122
Alignment of compressor unit and coupling - Coupling series 52 . . . . . . . . . . . . . . . . . . . . 151
Mounting of Series 52 coupling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 154
Key to Piping diagrams for screw compressors type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 161
Ordering Spare Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 165
Spare Part Sets for screw compressor and unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 166
Tools for compressor SAB 163 Mk3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0661-816
List of parts for SAB 163 Mk3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0661-885
Spare parts survey for SAB 163 Mk3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0661-883
Spare Parts drawing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0661-884
Piping diagramm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . order specific
Wiring diagramm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . order specific
Dimension sketch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . order specific
Placing of vibration dampers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . order specific
Other instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . order specific

0178-050-EN 5
Description of compressor SAB 163 Mk3
Compressor SAB 163 Mk3 is a capacity
adjustable screw compressor equipped with
oil injection.
The two rotors are provided with 4 and 6
grooves (male and female rotors,
respectively) in an asymmetric profile under
SRM licence. At the suction end, the rotors
are provided with roller bearings, while the
bearings at the discharge end consist of a
combined set of roller bearings, assimilating
the radial load, and ball-bearings,
assimilating the axial load. The axial forces
are partly equalized by rotating balance
pistons mounted on the rotors.
The rotors are available in either hardened
or non-hardened design. If the compressor
is fitted with hardened rotors, the motor can
be connected to either male or female rotor.
The idle shaft end is blanked off with a cover.
For non-hardened rotors, the motor can only
be connected to the male rotor.
On the shaft to which the motor is connected,
a shaft seal of the slide ring type which
effectively seals between the interior volume
of the compressor and the atmosphere, has
been fitted.
The compressor is provided with a large
built-in oil filter, which effectively prevents dirt
particles in the refrigerating plant from pene-
trating into the compressor together with the
suction gas.
The compressor is also equipped with a non-
return valve, preventing the rotors from
rotating in reverse whenever the electricity to
the motor is cut off. The non-return valve is
controlled by the internal suction pressure of
6 0178-050-EN
the compressor. In this way it is kept open
during operation without causing
unnecessary loss of pressure in the suction
gas.
The SAB 163 Mk3 compressor block is very
compact in its construction. It has both oil fil-
ter and electrical flow switch built in, hereby
reducing the number of connecting pipes.
The compressor can be capacity regulated
continuously from approx.10% to 100% by
means of a slide system fitted under the
rotors.
A piston moves the slide system. This piston
is influenced by the gas pressure on the
96.12
compressor discharge side and the
lubricating oil pressure controlled by solenoid
valves. As a rule, Sabroes microelectronic
0178-056-EN
control system is used to control the solenoid
valves.
The SAB 163 Mk3 screw compressor has
one more control system, by which the built-
in Vi volume ratio of the compressor can be
controlled. This means that the compressor
always works at its highest efficiency, even at
variable operating pressures in the
refrigeration plant.
The Vi control is particularly effective with the
compressor working at 100% capacity and
acts as a mechanical stop to the capacity
slide already mentioned. In this way the
capacity slide adapts the size of the
discharge gas outlet opening, maintaining the
same compression ratio in the compressor
as the pressure ratio from discharge to
suction side in the refrigeration plant.
At a reduced compressor capacity the Vi
control system is of little effect.
The built-in Vi volume ratio can be adjusted As shown in fig. 1 this name plate contains
in the following two ways: (Please check your the compressor shop number, which
type of compressor on page 1). should be used whenever you contact
Sabroe concerning the compressor.
S Manual adjustment of the Vi slide
This is done by turning the spindle under
the rotor shaft in accordance with the
curves in the instruction manual. SABROE
S Automatic adjustment of Vi slide
AARHUS DENMARK
This is done by means of the oil pressure Type Refrigerant
Shop no Year
and two solenoid valves, controlled by
Max. speed r.p.m.
UNISAB II. Swept volume m3/h
Working pressure bar
The type of screw compressor can be
Test pressure bar
determined by reading the name plate placed
on the end surface of the compressor, just
T0177093_2
above the capacity cylinder.

0178-050-EN 7
Safety precautions
Screw compressors
WARNING
Read related safety precautions
before operating this machine. Failure
to follow safety instructions may result
in serious personal injury or death.
Important
The safety precautions for this Sabroe
Refrigeration machine have been set down to
assist the operator, programmer and
maintenance personnel in practicing good
shop safety procedures.
The operator and maintenance personnel
must read and understand these precautions
completely before operating, setting up,
running, or performing maintenance on the
machine.
These precautions are to be used as a guide
to supplement the safety precautions and
warnings in the following:
a. All other manuals pertaining to the
machine.
b. Local, plant, and shop safety rules and
codes.
c. National safety laws and regulations.
General safety instructions and
considerations
Personal safety
Machine owners, operators, set-up workers,
maintenance, and service personnel must be
aware of the fact that constant day-to-day
8 0178-015-EN
safety procedures are a vital part of their job.
Accident prevention must be one of the
principal objectives of the job regardless of
the activity involved.
Know and respect your machinery. Read and
practice the prescribed safety and checking
procedures. Make sure that everyone who
works for, with, or near you fully understands
and - more importantly - complies with the
following safety precautions and procedures
when operating this machine.
Observe and follow safety warnings on the
compressor/unit.
98.03
Use safety protective equipment. Wear
approved eye or face protection when
operating parts containing refrigerant. Protec-
0170-124-EN
tive shoes with slip-proof soles can also help
avoid injuries. Always keep the protective
equipment in good condition.
Never operate or service this equipment if
affected by alcohol, drugs or other
substances or conditions which decrease
alertness or judgement.
Work area safety
Always keep your work area clean. Dirty
work areas with hazards such as oil, debris,
or water on the floor may cause someone to
fall onto the floor, into the machine, or onto
other objects resulting in serious personal
injury.
Make sure your work area is free of
hazardous obstructions and be aware of
protruding machine members.
Report unsafe working conditions to your
supervisor or safety department.
Tool safety
Always make sure that the hand tools are in
proper working condition.
Remove hand tools such as wrenches,
measuring equipment, hammers, and other
miscellaneous parts from the machine
immediately after use.
Lifting and carrying safety
Contact Sabroe Refrigeration if you have any
questions or are not sure about the proper
procedures for lifting and carrying.
Before lifting or carrying a compressor/unit or
other parts, determine the weight and size by
referring to things such as tags, shipping
data, labels, marked information, or manuals.
Use power hoists or other mechanical lifting
and carrying equipment for heavy, bulky, or
hard to handle objects. Use hook-up
methods recommended by your safety
department and know the signals for safely
directing a crane operator.
Never place any parts of your body under a
suspended load or move a suspended load
over any other person. Before lifting, be
certain that you have a safe spot for
depositing the load. Never work on a
component while it is hanging from a crane
or other lifting mechanism.
If in doubt as to the size or type of lifting
equipment, method, and procedures for
lifting, please contact Sabroe Refrigeration
before proceeding to lift the compressor,
motor, unit or its components.
Always inspect slings, chains, hoists, and
other lifting devices prior to use. Do not use
lifting devices found to be defective or in a
questionable condition.
0178-015-EN
Never exceed the safety rated capacity of
cranes, slings, eyebolts, and other lifting
equipment. Follow standards and instructions
applicable to any lifting equipment.
Before inserting an eyebolt, be certain that
both the eyebolt and the hole have the same
size and type threads. To attain safe working
loads, at least 90% of the threaded portion of
a standard forged eyebolt must be engaged.
WARNING
Failure to follow the safety
instructions outlined on this page
may result in serious personal injury
or death.
Installation and relocation safety
Before lifting the compressor, unit or other
parts of the plant, please consult the machine
manual or Sabroe Refrigeration for further
information on proper methods and
procedures.
An electrician must read and understand the
electrical schematics prior to connecting the
machine to the power source. After
connecting the machine, test all aspects of
the electrical system for proper functioning.
Always make sure the machine is grounded
properly. Place all selector switches in their
OFF or neutral (disengaged) position. The
doors of the main electrical cabinet must be
closed and the main disconnect switch must
be in the OFF position after the power
source connection is complete.
When the compressor is installed, be sure
that the motors rotate in the right indicated
direction.
9

WARNING
Failure to follow the safety
instructions outlined on this page
may result in serious personal injury
or death.
Setup and operation safety
Read and understand all the safety
instructions before setting up, operating or
servicing this compressor. Assign only
qualified personnel, instructed in safety and
all machine functions, to operate or service
this compressor.
Operators and maintenance personnel must
carefully read, understand, and fully comply
with all machine mounted warning and
instruction plates. Do not paint over, alter, or
deface these plates or remove them from the
compressor/unit. Replace all plates which
become illegible. Replacement plates can be
purchased from Sabroe Refrigeration.
Safety guards, shields, barriers, covers, and
protective devices must not be removed
while the compressor/unit is operating.
All safety features, disengagements, and
interlocks must be in place and functioning
10
correctly prior to operation of this equipment.
Never bypass or wire around any safety
device.
Keep all parts of your body off the
compressor/motor/unit during operation.
Never lean on or reach over the compressor.
During operation, be attentive to the
compressor unit process. Excessive
vibration, unusual sounds, etc., can indicate
problems requiring your immediate attention.
Maintenance safety
Do not attempt to perform maintenance on
the compressor unit until you read and
understand all the safety instructions.
Assign only qualified service or maintenance
personnel trained by Sabroe Refrigeration
to perform maintenance and repair work on
the unit. They should consult the service
manual before attempting any service or
repair work and when in doubt contact
Sabroe Refrigeration. Use only Sabroe
Refrigeration replacement parts; others may
impair the safety of the machine.
Before removing or opening any electrical
enclosure, cover, plate, or door, be sure that
the Main Disconnect Switch is in the OFF
position and the main fuses are dismantled.
0178-015-EN
If any tool is required to remove a guard,
cover, bracket, or any basic part of this
compressor, place the Main Disconnect
Switch in the OFF position, lock it in the
OFF position. If possible, post a sign at the
disconnect switch indicating that
maintenance is being performed.
Dismantle main fuses to the unit.
DANGER:
HIGH VOLTAGE
Before working on any electrical
circuits, turn the machine Main
Disconnect Device OFF and lock
it.
Dismantle the main fuses to the
compressor unit.
Unless expressly stated in
applicable Sabroe Refrigeration
documentation or by appropriate
Sabroe Refrigeration Field Service
Representative, do NOT work with
electrical power ON. If such ex-
press statement or advice exists,
working with electrical power ON
should be performed by a Sabroe
Refrigeration Field Service Repre-
sentative. The customer and subse-
quent transferees must determine
that any other person performing
work with electrical power ON is
trained and technically qualified.
FAILURE TO FOLLOW THIS
INSTRUCTION MAY RESULT IN
DEATH OR SERIOUS PERSONAL
SHOCK INJURY.
Whenever maintenance is to be performed in
an area away from the disconnect and the
0178-015-EN
disconnect is not locked, tag all start button
stations with a DO NOT START tag.
Adequate precautions, such as warning
notices, or other equally effective means
must be taken to prevent electrical
equipment from being electrically activated
when maintenance work is being performed.
When removing electrical equipment, place
number or labeled tags on those wires not
marked. If wiring is replaced, be sure it is of
the same type, length, size, and has the
same current carrying capacity.
Close and securely fasten all guards, shields,
covers, plates, or doors before power is
reconnected.
An electrial technician must analyse the elec-
trical system to determine the possible use of
power retaining devices such as capacitors.
Such power retaining devices must be dis-
connected, discharged, or made safe before
maintenance is performed.
Working space around electrical equipment
must be clear of obstructions. Provide ade-
quate illumination to allow for proper opera-
tion and maintenance.
Materials used with this product
Always use Sabroe Refrigeration original
spare parts.
Please, note the type of refrigerant on which
the compressor is operating and the precau-
tions that you need to pay attention to as de-
scribed in the following sections:
S First aid for accidents with Ammonia.
S First aid for accidents with HFC/HCFC.
S Protecting the operator as well as the en-
vironment.
11
Handling of the compressor, areas of application,
safety equipment and symbols, safety at servicing
Direction of rotation
In order to reduce the noise level from the
electric motors these are often made with
specially shaped fan wings, thus determining
a particular direction of rotation.
Consequently, it is essential that the motor is
ordered with the correct direction of rotation
made for the compressor.
The direction of rotation of the compressor is
indicated by an arrow cast into the compres-
sor cover as shown on the following sketch.
Please, notice that male and female drive
have different directions of rotation.
Female Male
Seen towards shaft ends
Handling of compressor and unit
For lifting of the compressor it has been
equipped with a threaded hole for mounting
of the lifting eye. As to the weight of the com-
pressor, see table on compressor data.
WARNING
The compressor block alone may
be lifted in the lifting eye.
The same applies to the motor.
12
The unit is lifted by catching the lifting eyes
welded onto the unit frame. These have been
clearly marked with red paint. The weight of
the unit is stated on the package as well as in
the shipping documents.
During transportation and handling care
should be taken not to damage any of the
components, pipe or wiring connections.
Areas of application of the screw
compressors
Compressor types:
SAB 110 SM/SF, SAB 110 LM/LF,
SAB 128 HM/HF,
SAB 163 HM/HF,
SAB 202 SM/SF, SAB 202 LM/LF,
VMY 536 M/B
Application
In view of preventing an unintended applica-
tion of the compressor, which could cause
injuries to the operating staff or lead to tech-
nical damage, the compressors may only be
applied for the following purposes:
S As a refrigeration compressor with a num-
ber or revolutions and with operating limits
as indicated in this manual or according to
a written agreement with SABROE.
S With the following refrigerants:
R717 R22 R134a R404A R507
R600 R600A R290 LPG
Other HFC refrigerants in accordance with
SABROEs instructions.
All other types of gas may only be used
following a written approval from
SABROE.
0178-015-EN
S In an explosion-prone environment, pro-
vided the compressor is fitted with ap-
proved explosion-proof equipment.
WARNING
The compressor must NOT be
used:
S For evacuating the refrigera-
tion plant of air and moisture,
S For putting the refrigeration
plant under air pressure in
view of a pressure testing,
S As an air compressor.
Safety equipment
Emergency device
The compressor control system must be
equipped with an emergency device.
In case the compressor is delivered with a
SABROE-control system this emergency de-
vice is found as an integrated part of the con-
trol.
The emergency device must be executed in
a way to make it stay in its stopped position,
following a stop instruction, until it is deliber-
ately set back again.
0178-015-EN
It must not be possible to block the emergen-
cy stop without a stop instruction being re-
leased.
It should only be possible to set back the
emergency device by a deliberate act, and
this set back must not cause the compressor
to start operating. It should only make it pos-
sible to restart it.
Other demands to the emergency device:
S It must be possible to operate it by means
of an easily recognizable and visible
manual handle, to which there is free ac-
cess.
S It must be able to stop any dangerous si-
tuation, which may occur, as quickly as
possible without this leading to any further
danger.
Combustion motors
If combustion motors are installed in rooms
containing refrigeration machinery or rooms
where there are pipes and components con-
taining refrigerant, you must make sure that
the combustion air for the motor is derived
from an area in which there is no refrigerant
gas, in case of leakage.
Failure to do so will involve a risk of the lubri-
cating oil from the combustion motor mixing
with the refrigerant; at worst, this may give
rise to corrosion and damage the motor.
13
Safety symbols DANGER: The high voltage sign

Before putting a compressor/unit into opera-

tion they must be provided with warning
signs corresponding to the actual design of DANGER:
compressor/unit and in accordance with the HIGH VOLTAGE
rules and regulations in force.

The CAUTION sign

Before working on any electrical circuits, turn
A CAUTION tag is fixed on the compressor the machine Main Disconnect Device OFF
like the one illustrated below. This sign im- and lock it. Dismantle the main fuses to the
poses upon the users to read the Safety Pre- compressor unit.
cautions section in the manual before han-
Unless expressly stated in applicable Sabroe
dling, operating or servicing the compressor
Refrigeration documentation or by appropri-
and unit.
ate Sabroe Refrigeration Field Service Rep-
resentative, do NOT work with electrical po-
wer ON. If such express statement or ad-
vice exists, working with electrical power
ON should be performed by a Sabroe Re-
CAUTION frigeration Field Service Representative. The
customer and subsequent transferees must
determine that any other person performing
work with electrical power ON is trained and
technically qualified.
Before handling, installing, operating or
servicing the compressor and unit, read
the Safety Precautions section in the
Instruction Manual.
It is the responsibility of the operator or
his employer that the instruction manual
WARNING
is always available.
This sign must not be removed nor be
Failure to follow this instruction
damaged in any way.
may result in death or serious
Antes de manejer, instalar, poner en mar- personal shock injury.
cha o dar servicio al compresor y la uni-
dad, leer la seccin Precauciones de
seguridad en el Libro de Instrucciones.
Es respondabilidad del operaro o de su
patrn, que el libro de instrucciones Explosion-proof electrical execution
permanezca siempre al alcance de la
mano. If the compressor is delivered in an explo-
Esta seal no debe de ninguna manera sion-proof electrical execution it will, further
suprimirse o daarse.
to the SABROE name plate, be equipped
2516-297
with an Ex-name plate like the one illus-
trated below.

14 0178-015-EN

T2516273_0
The temperature of tangible surfaces
When a compressor is working, the surfaces
that are in contact with the warm discharge
gas also get warm. The temperature de-
pends on which refrigerants and under which
operating conditions the compressor
is working, however,. Often, it exceeds 70C
which for metal surfaces may cause your
skin to be burnt even at a light touch.
Consequently, the compressors will be
equipped with yellow warning signs
informing you that pipes, vessels and
machine parts close to the warning signs
during operation are so hot that your skin
may be burnt from 1 seconds touch or
longer.
Internal protection
Compressor blocks and units are usually
delivered without any refrigerant or oil con-
tent in the crankcase.
In order to protect the compressors against
internal corrosion, they are delivered eva-
cuated of all athmospheric air and charged
with Nitrogen (N2) to an overpressure of
0.2 bar.
0178-015-EN
In such cases a yellow label like the one
shown below are stuck on the compressor
surface.
Pfyldt beskyttelsesgas N2
Charged with inert gas
Enthlt Schutzgas 0,2 bar
Charg du gaz protecteur 3 PSI
Contiene gas protector 1534-169
Safety at servicing
WARNING
Read related safety precautions be-
fore operating this machine. Failure to
follow safety instructions may result in
serious personal injury or death.
Before dismantling a compressor or unit
attention should be paid to the following
points:
S Read related Safety Precautions section
in this manual before opening the com-
pressor and other parts of the refrigeration
plant.
S Make sure that the motor cannot start up
inadvertently. It is recommended to re-
move all main fuses.
S Switch off all electric components on the
compressor/unit before the dismantling.
S Make sure that there is neither
overpressure nor any refrigerant in the
part to be dismantled. Close all necessary
stop valves.
S Use gloves and protective glasses and
make sure to have a gas mask ready to
be used in connection with the current re-
frigerant.
S Use the prescribed tools and check that
they are properly maintained and in good
working condition. In explosion-proof
areas use tools specially suited for this
specific purpose.
15
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 a
distinctive, pungent odour that even at very
low, harmless concentrations is detectable by
most persons. Since ammonia is self-alarm-
ing, it serves at its own warning agent, so
that no person will voluntarily remain in con-
centrations which are hazardous. Since am-
monia is lighter than air, adequate ventilation
is the best means of preventing an accu-
mulation.
Experience has shown that ammonia is ex-
tremely hard to ignite and under normal
conditions is a very stable compound. Under
extremely high, though limited concentra-
tions, ammonia can form ignitable mixtures
with air and oxygen, and should be treated
with respect.
Basic rules for first aid
1. Call a doctor immediately.
2. Be prepared: Keep an irrigation bottle
available, containing a sterile isotonic
(0.9%) NaCl-solution (salt water).
3. A shower bath or water tank should be
available near all bulk installations with
ammonia.
4. When applying first aid, the persons as-
sisting should be duly protected to avoid
further injury.
16
Inhalation
1. Move affected personnel into fresh air im-
mediately, and loosen clothing restricting
breathing.
2. Call a doctor/ambulance with oxygen
equipment immediately
3. Keep the patient still and warmly wrapped
in blankets.
4. If mouth and throat are burnt (freeze or
acid burn), let the conscious patient drink
water, taking small mouthfuls.
5. If conscious and the mouth is not burnt,
give hot, sweet tea or coffee (never feed
an unconscious person).
6. Oxygen may be administered, but only
when authorized by a doctor.
7. If breathing fails, apply artificial respira-
tion.
Eye injuries from liquid splashes or con-
centrated vapour
1. Force the eyelids open and rinse eyes im-
mediately for at least 30 minutes with the
salt water solution just mentioned
2. Call a doctor immediately.
Skin burns from liquid splashes or con-
centrated vapour
1. Wash immediately with large quantities of
water and continue for at least 15 minutes,
removing contaminated clothing carefully
while washing.
2. Call a doctor immediately.
3. After washing, apply wet compresses
(wetted with a sterile isotonic (0.9%)
NaCl-solution (salt water)) to affected
areas until medical advice is available.
0178-015-EN
First aid for accidents with HFC/HCFC
Refrigerant no.: R134a - R505A R507 R22, etc
WARNING
No plant can ever be said to be
too safe.
Safety is a way of life.
General
HFC/HCFC form colourless and invisible
gasses which are heavier than air and smell
faintly of chloroform at high concentrations
only. They are non-toxic, non-inflammable,
non-explosive and non-corrosive under nor-
mal operating conditions. When heated to
above approx. 300C they break down into
toxic, acid gas components, which are
strongly irritating and aggessive to nose,
eyes and skin and generally corrosive.
Besides the obvious risk of unnoticeable,
heavy gases displacing the atmospheric
oxygen, inhalation of larger concentrations
may have an accumulating, anaesthetic
effect which may not be immediately
apparent. 24 hours medical observation is,
therefore, recommended.
Basic rules for first aid
1. When moving affected persons from low-
lying or poorly ventilated rooms where
high gas concentrations are suspected,
the rescuer must be wearing a lifeline, and
be under continuous observation from an
assistant outside the room.
0178-015-EN
2. Adrenalin or similar heart stimuli must not
be used.
Inhalation
1. Move affected person into fresh air im-
mediately. Keep the patient still and warm
and loosen clothing restricting breathing.
2. If unconscious, call a doctor/ambulance
with oxygen equipment immediately.
3. Give artificial respiration until a doctor au-
thorizes other treatment.
Eye injuries
1. Force eyelids open and rinse with a sterile
isotonic (0.9%) NaCl-solution (salt water)
or pure running water continuously for 30
minutes.
2. Contact a doctor, or get the patient to a
hospital immediately for medical advice.
Skin injuries - freeze burns
1. Wash immediately with large quantities of
luke warm water to reheat the skin.
Continue for at least 15 minutes, removing
contaminated clothing carefully while
washing.
2. Treat exactly like heat burns and seek
medical advice.
3. Avoid direct contact with contaminated oil/
refrigerant mixtures from electrically burnt-
out hermetic compressors.
17
Protecting the operator as well as the environment

High concentrations of refrigerant vapours

WARNING are suffocating when they displace air; if high
concentrations of refrigerant vapours are in-
No plant can ever be said to be haled they attack the human nerve system.
too safe.
Safety is a way of life. When halogenated gasses come into contact
with open flame or hot surfaces (over approx.
Increasing industrialisation threatens our
300C) they decompose to produce poiso-
environment. It is therefore absolutely im-
nous chemicals, which have a very pungent
perative that we protect nature against pollu-
odour, warning you of their presence.
tion.
In high concentrations, R717 causes respira-
To this end, many countries have passed le-
tory problems, and when ammonia vapour
gislation in an effort to reduce pollution and
and air mix 15 to 28 vol. %, the combination
preserve the environment. These laws apply
is explosive and can be ignited by an electric
to all fields of industry, including refrigeration,
spark or open flame.
and must be complied with.

Be especially careful with the following sub-
stances:
S refrigerants
S cooling media (brines etc)
S lubricating oils.
Refrigerants usually have a natural boiling
point which lies a good deal below 0C. This
means that liquid refrigerants can be extre-
mely harmful if they come into contact with
skin or eyes.
Oil vapour in the ammonia vapour increases
this risk significantly as the point of ignition
falls below that of the mixture ratio stated.
Usually the strong smell of ammonia will
give ample warning of its presence before
concentrations become dangerous.
The following table shows the values for refri-
gerant content in air, measured in volume %.
Certain countries may, however, have an offi-
cial limit which differs from those stated.

Halogenated refrigerants Ammonia

R134a R404A R507 R22 R717

Unit

TWA
Time weighted ave- vol.% 0.1 0.1 0.1 0.1 0.005
rage during a week

Warning smell vol.% 0.2 0.002

18 0178-015-EN
Furthermore, it can be said about
refrigerants:
S If halogenated refrigerants are released
directly to the atmosphere they will break
down the ozone stratum in the strato-
sphere. The ozone stratum protects the
earth from the ultraviolet rays of the sun.
Halogenated refrigerants must, therefore,
never be released to the atmosphere. Use
a separate compressor to draw the refrig-
erant into the plants condenser/receiver
or into separate refrigerant cylinders.
S Most halogenated refrigerants are mis-
cible with oil. Oil drained from a refrigera-
tion plant will often contain significant
amounts of refrigerant. Therefore, reduce
the pressure in the vessel or compressor
as much as possible before draining the
oil.
S Ammonia is easily absorbed by water:
At 15C, 1 litre of water can
absorb approx. 0,5 kg liquid
ammonia (or approx. 700 litres
ammonia vapour).
S Even small amounts of ammonia in water
(2-5 mg per litre) are enough to wreak
havoc with marine life if allowed to pollute
waterways and lakes.
S As ammonia is alkaline it will damage
plant life if released to the atmosphere in
large quantities.
Refrigerant evacuated from a refrigerant
plant shall be charged into refrigerant cylin-
ders intended for this specific refrigerant.
If the refrigerant is not to be reused, return it
to the supplier or to an authorized incinerat-
ing plant.
0178-015-EN
Halogenated refrigerants must never be
mixed. Nor must R717 ever be mixed with
halogenated refrigerants.
Purging a refrigeration plant
If it is necessary to purge air from a refrige-
ration plant, make sure you observe the follo-
wing:
S Refrigerants must not be released to the
atmosphere.
S When purging an R717 plant, use an ap-
proved air purger. The purged air must
pass through an open container of water
so that any R717 refrigerant remaining
can be absorbed. The water mixture must
be sent to an authorized incinerating plant.
S Halogenated refrigerants can not be ab-
sorbed by water. An approved air purger
must be fitted to the plant. This must be
checked regularly using a leak detector.
Cooling media
Salt solutions (brines) of calcium chloride
(CaCl2) or sodium chloride (NaCl) are often
used.
In recent years alcohol, glycol and halogena-
ted compounds have been used in the brine
production.
In general, all brines must be considered as
harmful to nature and must be used with
caution. Be very careful when charging or
purging a refrigeration plant.
Never empty brines down a sewer or into
the environment.
The brine must be collected in suitable con-
tainers, clearly marked with the contents, and
sent to an approved incinerating plant.
19
Lubricating oils alkyl benzene-based synthetic oil
Refrigeration compressors are lubricated with polyalphaolefine-based synthetic oil
one of the following oil types, depending on
the refrigerant, plant type and operating glycol-based synthetic oil.
conditions. When you change the oil in the compressor
or drain oil from the refrigeration plants ves-
mineral oil sels, always collect the used oil in containers
marked waste oil and send them to an ap-
semi-synthetic oil proved incinerating plant.

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

20 0178-015-EN
 Sound data for reciprocating and screw
compressor units - all types of compressors

In the following tables the noise data of the
compressors is stated in:
A-weighted sound power level LW
(Sound Power Level)
A-weighted sound pressure level LP
(Sound Pressure level)
The values for LW constitute an average of a
large number of measurings on various units.
The measurings have been carried out in ac-
cordance with ISO 9614-2.
The values are further stated as average
99.06
S SAB 81-83-85-87-89, SAB 128, Mk3,
SAB 163 Mk3, SAB 202, SAB 330, SV
and FV:
Compressor block + IP23 special motor +
oil separator.
S SAB 128 HR and SAB 163 HR:
Compressor block at max. number of
revolutions + IP23 special motor + oil
separator
S SAB 110:
Compressor block + IP23 standard motor
+ oil separator

sound pressure in a free field above a re-

Dimensional tolerances are:
flecting plane at a distance of 1 meter from
a fictional frame around the unit. See fig. 1. 3 dB for SAB, SV and FV screw com-
0170-114--EN

Normally, the immediate sound pressure
lies between the LW and LP values and can
be calculated provided that the acoustic data
of the machine room is known.
For screw compressors the average values
are indicated in the tables for the following
components.
pressors
5 dB for VMY screw compressors
As to the reciprocating compressors the
values are stated for the compressor block
only.
The dimensional values are stated for 100%
capacity.

Fig. 1

Fictional frame

Dimensional plane

1 meter Reflecting plane

1 meter

0170-114-EN 21
Note the following, however:
S at part load or if the compressor works
with a wrongly set Vi the sound level can
sometimes be a little higher than the one
indicated in the tables.
S additional equipment such as heat ex-
changers, pipes, valves etc. as well as the
choice of a different motor type can in-
crease the noise level in the machine
room.
S as already mentioned, the stated sound
pressures are only average values above
a fictional frame around the noise source.
Thus, it is sometimes possible to measure
higher values in local areas than the ones
stated for inst. near the compressor and
motor.
22
S the acoustics is another factor that can
change the sound level in a room. Please
note that the sound conditions of the site
have not been included in the stated
dimensional values.
S by contacting SABROE you can have
sound data calculated for other operating
conditions.
The tables have been divided into reciprocat-
ing and screw compressors, respectively.
The reciprocating compressors are further
divided into one- and two-stage compressors
as well as in a heat pump. In each table the
operating conditions of the compressor dur-
ing noise measuring have been stated, just
as the refrigerant used has been mentioned.
0170-114-EN
RECIPROCATING COMPRESSORS Two-stage
One-stage Evaporating temperature = 35C
Evaporating temperature = 15C Condensing temperature = +35C
Condensing temperature =+35C Refrigerant = R22/R717
Refrigerant = R22/R717 Number of revolutions =1450 rpm.
Number of revolutions =1450 rpm.
Compressor block LW LP

Compressor block LW LP TCMO 28 81 66

TSMC 108 S 95 79
CMO 24 84 69
TSMC 116 S 97 81
CMO 26 86 71
TSMC 108 L 96 80
CMO 28 87 72
TSMC 116 L 98 82
SMC 104 S 95 79
TSMC 108 E 96 80
SMC 106 S 96 80
SMC 108 S 97 81 TSMC 116 E 98 82

SMC 112 S 99 82
SMC 116 S 100 83
Evaporating temperature = 35C
Condensing temperature = +35C
SMC 104 L 96 80
Refrigerant = R22/R717
SMC 106 L 97 81
Number of revolutions = 900 rpm.
SMC 108 L 98 82
SMC 112 L 100 83 Compressor block LW LP
SMC 116 L 101 84
TSMC 188 100 82
SMC 104 E 96 80
SMC 106 E 97 81
SMC 108 E 98 82 Heat pump
SMC 112 E 100 83 Evaporating temperature = +20C
SMC 116 E 101 84 Condensing temperature = +70C
Refrigerant = R22/R717
Number of revolutions =1450 rpm.
Evaporating temperature = 15C
Condensing temperature = +35C
Compressor block LW LP
Refrigerant = R22/R717
Number of revolutions = 900 rpm. HPO 24 91 76
HPO 26 93 78

Compressor block LW LP HPO 28 94 79

HPC 104 97 81
SMC 186 101 83 HPC 106 98 82
SMC 188 102 84 HPC 108 99 84

0170-114-EN 23
SCREW COMPRESSORS
Evaporating temperature = 15C Evaporating temperature = 35C
Condensing temperature = +35C Condensing temperature = 5C
Refrigerant = R22/R717 Refrigerant = R22/R717
Number of revolutions = 2950 rpm.
Number of revolutions = 2950 rpm.
*Number of revolutions = 6000 rpm.

Compressor block LW LP

SAB 110 SM 98 81 Compressor unit LW LP

SAB 110 SF 98 81
SAB 110 LM 98 81 SAB 163 BM 106 88
SAB 110 LF 98 81 SAB 163 BF 110 92
SAB 128 HM Mk2 102 84
SAB 128 HF Mk2 106 88
SAB 128 HM Mk3 101 84
SAB 128 HF Mk3 104 86 Evaporating temperature = 15C
SAB 128 HR* 102 84 Condensing temperature =+35C
SAB 163 HM Mk2 105 86 Refrigerant = R22/R717
SAB 163 HF Mk2 109 90 Number of revolutions = 2950 rpm.
SAB 163 HM Mk3 103 86
SAB 163 HF Mk3 106 87
SAB 163 HR* 103 85
SAB 202 SM 104 85
SAB 202 SF 105 86 Compressor block LW LP
SAB 202 LM 104 85
SAB 202 LF 105 86 VMY 347 H 97 82
VMY 447 H 100 85
SAB 330 S 106 87
SAB 330 L 106 87 VMY 536 H 104 88
SAB 330 E 106 87
SV 17 100 83
SV 19 101 84
Evaporating temperature = 0C
FV 19* 101 86
Condensing temperature =+35C
SV 24 103 85
FV 24* 104 86
Refrigerant = R22/R717
SV 26 103 85 Number of revolutions = 2950 rpm.
FV 26* 107 85
SAB 81 101 86
SAB 83 102 85 Compressor block LW LP
SAB 85 103 86
SAB 87 105 86 VMY 347 M 99 84
SAB 89 108 85 VMY 447 M 101 86
VMY 536 M 105 89
Min liquid pressure for liquid injection, suction
pressure bar (a) x 2+2 bar

24 0170-114-EN
 Vibration data for compressors all types

Vibration data for SABROE screw compres-
sors comply with the following norm:
ISO 2372 group C
Depending on the laying of the foundation
and the size of the motor a screw compres-
sor unit can - under normal circumstances -
be classified in Class III or IV according to
the following table from ISO 2372. Recip.
compressor units can be classified in class
IV, likewise under normal conditions.

Vibration severity ranges and examples of their application to small machines (Class I) medium size ma-
chines (Class II), large machines (Class III) and turbo machines (Class IV)

Examples of quality judgement

Ranges of vibration severity for separate classes of machines

ms-velocity V (in mm/s)

Range Class I Class II Class III Class IV
at the range limits
95.06

0.28
0.28
0.45
0.45 A
0170-115-EN

0.71
0.71 A
1.12
1.8
1.12 B A
1.8 B A
2.8
2.8 C B
4.5
4.5 C B
7.1
7.1 D C
11.2
11.2 D C
18 18
28
D
28 D
45
45
71

SABROE screw compressor unit:
Group C, class III or IV
SABROE recip. compressor unit:
Group C, class IV.
Pay attention to the following, however:
S On placing the unit on the vibration
dampers delivered by SABROE
(additional) the vibrations against the
foundation are reduced by:
85-95% for screw compressor units
80 % for recip. compressor units
S However, a higher vibration level may oc-
cur if:
Motor and compressor have not been
aligned as described in the Instruction
Manual.
For screw compressors, if the compres-
sor runs at a wrong Vi ratio.
The pipe connections have been
executed in a way that makes them force
pull or push powers on the compressor
unit or they may transfer vibrations to the
unit, caused by natural vibrations or con-
nected machinery.
The vibrations dampers have not been
fitted or loaded correctly as indicated on
the foundation drawing delivered
together with the order.

0178-250-EN 25
Compressor Data
SAB 128/163 Mk3

Compressor Rotor Intern. Rotor L/D P Motor at 2950 Motor at 3550

type drive volume dia. max. male rotor swept vol. male rotor swept vol.
ratio bar
1 Vi mm 2 3 rpm m3/h rpm m3/h

SAB 128 H-M male 127.5 2950 303 3550 364

SAB 128 H-F female 2.0-4.5 127.5 1.7 20 4425 454 5325 547
SAB 163 H-M male 163.2 2950 635 3550 764
SAB 163 H-F female 163.2 4425 952 5325 1145

1) The female drive design can be changed to male drive 2) Rotor length divided by rotor diametre
3) Discharge pressure minus suction pressure

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

98.04
Block weight Centre height
Kg mm

0178-053-EN
SAB 128 H-M 290 200
SAB 163 H-M 460 245

Operating limits S Further, note the additional operating

limits provided the compressors have the
The enclosed diagrams for R717, R22,
R134a, R404A/R507 and R407C indicate the following extra equipment:
limits within which the compressor is per-
HLI (High Stage Liquid Injection)
mitted to work.

Please, observe the following: HLI + Economizer, simultaneously

S The upper operating limits are for Male S The use of an economizer is allowed with-
Drive and Female Drive, respectively in the entire permissible operating area of
(see compressor type on p.1). the compressor.

26 0178-050-EN
 Operating SAB128H SAB163H MK3
C
limits 60
MALE DRIVE

R717
50
FEMALE DRIVE

40

Condensing temperature HLI + ECO HLI

30

20

10

-10
R717
-20

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

(T250835_0) Evaporating temperature

Operating
C SAB 128 H, SAB 163 H Mk3
limits
MALE DRIVE
R22 60

50
FEMALE DRIVE

40
Condensing temperature

HLI + ECO HLI

30

20

10

10
R22
20

30
60 50 40 30 20 10 0 10 20 C
Evaporating temperature
(T250834_0)

0178-050-EN 27
 Operating
C
SAB 128 H, SAB 163 H Mk3
limits
MALE DRIVE
R134a
70
FEMALE DRIVE
60
HLI+
ECO
50
Condensing temperature
HLI

40

30

20

10

0
R134a
10

20
50 40 30 20 10 0 10 20 30 C

Evaporating temperature
(T250836_0)

Operating
limits SAB 110S/L, SAB 128H, SAB 163H Mk3
C
R404A - R507 MALE DRIVE
50

HLI
40

SAB163H:
30 HLI+
FEMALE DRIVE
ECO
Condensing temperature

20 HIGH STAGE
SAB110-SAB128
NO FEMALE
10 DRIVE LIMIT

0
NOTE:
LOW STAGE SAB110 STANDARD UNITS

-10 ARE NOT DESIGNED FOR

LOW STAGE OPERATION.

-20
R404A-R507
-30
-70 -60 -50 -40 -30 -20 -10 0 10 C

(T250829_2)
Evaporating temperature

28 0178-050-EN
 Operating SAB 110S/L, SAB 128H, SAB 163H Mk3
limits
LIMIT FOR MODEL S/H, SAB110L
R407C TC C LIMIT FOR MODEL M, SAB202L
60
MALE DRIVE
50
HLI
Condensing temperature 40
FEMALE DRIVE

30 HLI +
econ

20 SAB 202:
No HLI
operation
10 Limit model MB/B

SAB 110
0 standard units not
for Booster opr.

10 VMY 447:
Below curve full flow
oil pump required
20
R407C
30
-70 60 50 40 30 20 10 0 10 20 TE C

Evaporating temperature
(T250133_1)

0178-050-EN 29
Compressor Unit Data
SAB 128/163 Mk3

SAB 128 Mk3 Height

Vibration damper

Width

96.02
EXTRACTION OF FINE SEPARATOR ELEMENT

600

0178-054-EN

Length 1500

CLEANING OF OIL COOLER OWSG

Table SAB 128

MAX. DIMENSIONS MAX. NET
COMPRESSOR REFRIGERANT OIL COOLING WIDTH LENGTH Z WEIGHT
HEIGHT
TYPE SYSTEM 1) MM MM MM MM KG 2)

SAB128H R717 1364 2200 1378 68

OWSG,OOSI
MK3 1150
R22 HLI,BLI
R134a 1419 2200 1403 68
R404A/
R507

1) OWSG = HEAT EXCHANGER WITH SHELL (WATER) 2) EXCL. MOTOR, OIL AND WATER
OOSI = HEAT EXCHANGER WITH SHELL (REFRIGERANT)
HLI = REFRIGERANT INJECTION INTO THE COMPRESSOR
BLI = REFRIGERANT INJECTION INTO DISCHARGE PIPE

30 0178-050-EN
 SAB 163 Mk3

Height
Vibration damper

Width

EXTRACTION OF FINE SEPARATOR ELEMENT

800

IEC 315 L

Length 1900

CLEANING OF OIL COOLER OWSG

Table SAB 163

MAX. DIMENSIONS MAX. NET
COMPRESSOR REFRIGERANT OIL COOLING WIDTH LENGTH HEIGHT Z WEIGHT
TYPE SYSTEM 1) MM MM MM MM KG 2)

SAB163H R717 OWSG,OOSI 1576 2628 1670 68

MK3 HLI,BLI 1800
R22
R134a 1739 2628 1725 68
R404A/
R507

1) OWSG = HEAT EXCHANGER WITH SHELL (WATER) 2) EXCL. MOTOR, OIL AND WATER
OOSI = HEAT EXCHANGER WITH SHELL (REFRIGERANT)
HLI = REFRIGERANT INJECTION INTO THE COMPRESSOR
BLI = REFRIGERANT INJECTION INTO DISCHARGE PIPE

0178-050-EN 31
Type of compressor unit
On the base frame of the compressor unit a
name plate has been fitted as shown in fig 1.
This name plate provides you with all rele-
vant information in accordance with CE label-
ling.

AARHUS
DENMARK

Type

Approval
no.

Serial no.

Max. operating bar

pressure

Test pressure bar

Compressor and vessel data:

See their nameplates

T290927 0

32 0178-050-EN
 Compressor and unit operation
SAB 128 Mk3, SAB 163 Mk3 and SAB 202
During operation of the compressor, the be-
low points should be observed. These are
described in detail in the following sections.
1. Preparations before starting up.
2. Initial start.
3. Current control requirements at normal
operation.
4. Normal stop.
5. Preparations before a lengthy standstill
97.02
period.
6. Pressure testing.
0178-255-EN
7. Evacuation.
8. Operating log.
1. Preparations before starting up
After the compressor unit has been installed
in its final place and all connections for refrig-
erant, water and electricity, instruments and
safety switches have been established, carry
out the following:
a) Check that the rotating direction is correct
with the coupling dismounted. The rotating
direction is marked by an arrow on the
suction cover of the compressor.
b) Check the rotating direction of the oil
pump.
c) Mount coupling and check that tolerances
and alignment are in accordance with the
coupling instruction.
d) Connect the vacuum pump to valve pos.
24 and empty unit to a vacuum of approx.
0178-250-EN
4-5 mm Hg. If necessary, use a thermo-
static vacuum gauge for measuring of
pressure and fill up with dry air or
nitrogen until the pressure reaches 1 bar.
Then empty again to 4-5 mm Hg.
e) Top up with new oil of a quality recom-
mended in the oil instruction. Fill the oil
hose with oil, insert it into the vessel with
new oil and connect to valve pos. 62 (do
not use a hose with an inner diameter
smaller than valve pos. 62). Close valve
pos. 60, valve pos. 65 must also be
closed.
Start the pump by hand. In case the pump
refuses to suck, carefully open valve pos.
64 until gas pockets, if any, have been re-
moved. Charge as much oil that the oil
level is visible in the upper sight glass.
The amount of oil appears from the table
on Oil Charging.
Important
Please, observe that the inner diameter
of the oil hose must be min. 28 mm and
the hose itself max. 3 metres long in or-
der to avoid cavitation in the oil pump.
f) Open all internal valves.
g) Slowly open the suction and discharge
stop valves and fill up the plant with refrig-
erant according to the instruction manual
for this plant.
2. Initial start-up
a) Check that the compressor is easy to turn
by hand.
b) Check oil level in the oil separator.
33
c) Open suction and discharge stop valves
completely. Open the remaining internal
valves.
Check that all external valves on the re-
frigeration plant are open or closed in ac-
cordance with the piping diagram.
d) Check the free access of the cooling water
to the oil cooler, if any.
e) Check the supply of power to the com-
pressor.
f) Check the position of the Vi-slide and
make sure that the capacity slide is in its
minimum position.
g) Start compressor as described in the UNI-
SAB II manual.
h) Watch out for abnormal sounds and check
that the compressor works up a differential
pressure.
If nothing abnormal has been observed,
allow the compressor to work at normal
operating pressure, and adjust the capac-
ity regulation to its immediate requirement
or to automatic operation. Currently check
pressure, temperatures and power con-
sumption.
Important
Pay attention to the procedures for run-
ning down of the evaporating pressure as
indicated in the instruction on refrigeration
plants.
i) Do not leave the compressor for the first
60 mins.
34
3. Current control at normal
operation
The following should be noted daily:
Suction pressure (bar).
Suction temperature (C).
Discharge pressure (bar).
Discharge pipe temperature (C)
Oil temperature (C).
Power consumption (amp.).
Number of hours
The position of the Vi slide
4. Normal stop
Regulate the compressor down to min. ca-
pacity.
Set the change-over switch on stop.
5. Preparations before a lenghty
standstill period
Once the compressor has been pressure
equalized, close the stop valves of the com-
pressor unit as well as all other valves con-
necting the unit to the plant, e.g. those of oil
coolers or economizers.
Switch off and safeguard the compressor
main switch.
6. Pressure testing
Before charging the plant with refrigerant, it
must be pressure tested and emptied.
Pressure test the plant using:
S Dry air - Pressurized cylinders containing
dry atmospheric air may be used - never
use oxygen cylinders.
S Air compressor for high pressure.
S Nitrogen.
0178-250-EN
 Important
Do not use the plant compressors for
pressurizing the plant. Water or any other
liquid must not be used in connection with
pressure testing.
In case nitrogen is used it is important to
place a reduction valve with pressure
gauge between the nitrogen cylinder and the
plant.
During pressure testing it is important that
pressure transducers and other control
equipment are not exposed to the test pres-
sure. Similarly, the compressor stop valves
must be closed during testing.
Normally, the plant safety valves should be
blanked off during the pressure testing as
their opening pressure is lower than the test
pressure.
Important
During this pressure testing no persons
are allowed in the rooms with plant com-
ponents or in the vicinity of the plant out-
side the rooms.
S The entire plant is strength tested accord-
ing to the local rules for pressure testing.
S Usually, the test pressure must not be
allowed to exceed the design pressure.
However, also in this case the local rules
and regulation apply.
S In case there is a request for the compres-
sor to be pressure tested together with the
unit, the test pressure on the compressor
must not exceed 24 bar.
S Hereafter, lower the pressure to 10 bar for
24 hours as a first leak testing as a
tight plant will maintain this pressure dur-
ing the entire period.
0178-250-EN
During leak testing, it is permitted to enter the
rooms and approach the plant.
S As a second leak testing search all weld-
ings, flange joints etc. for leaks by apply-
ing soapy water, while at the same time
maintaining the 10 bar pressure.
During the pressure testing set up a pressure
test report containing the following:
Date of pressure testing.
Who carried out the testing.
Test pressure
Comments.
7. Evacuation
After pressure testing the refrigeration plant
must be evacuated in order to remove atmo-
spheric air and moisture. Evacuation must be
carried out on all types of refrigeration plants
regardless of the type of refrigerant to be
filled into the plant.
Note that HCFC, HFC and CFC refrigerants
hardly mix with water. Consequently, it is im-
portant to make a particularly thorough evac-
uation of these plants.
The boiling point of a liquid is defined as the
temperature by which the steam pressure is
equal to atmospheric pressure.
The boiling point of water is 100C. If the
pressure is lowered, so is the boiling point of
water.
The following table indicates the boiling point
of water at very low pressures:
Boiling point At pressure
of water C mm HG
5 6,63
10 9,14
15 12,73
20 17,80
35
For evacuation, use a vacuum pump which S Carry out an evacuation to a pressure be-
empties the plant of both air and water va- low 5 mm Hg.
pour.
S Next blow in dry air or nitrogen in the sy-
stem to a pressure equal to atmospheric.
The vacuum pump must be able to lower the
pressure to approx. 0.1 mm Hg (mercury S Evacuate again to a pressure below 5 mm
column), and it must be equipped with a gas Hg.
ballast valve. Use this valve to the greatest
extent possible in order to prevent condensa- S Shut off the vacuum pump from the refrig-
tion of water vapour in the vacuum pump. eration plant and check that the pressure
does not rise within the next few hours. If
Important there is still water in the system, it will
Never use the refrigeration compressor for evaporate and cause a pressure increase.
emptying of the plant. This means that the evacuation has not
been satisfactorily carried out and has to
In order for an evacuation to be satisfactorily be repeated.
carried out the final pressure must be below
5 mm Hg. Attention should be paid to the fact 8. Operating log
that there is a risk that the water still present
To be in control of the operating conditions of
in the refrigeration plant may freeze in case
the plant it is recommended to keep an oper-
the ambient temperatures are below 10C.
ating log in order to be able to keep an eye
In that case it is necessary to heat up the
on any changes that may occur in the operat-
surroundings of the components as ice only
ing conditions.
evaporates slowly.
Below table is an example of such an operat-
Evacuation is recommended carried out as ing log. The information in this log is needed
follows: in order to make a satisfactory diagnosis.

Power consump. Compressor Condenser Temperature

Electric motor
Suction pipe
temperature
Disch. man.

revolutions

Fact.: 1 2
Suct. man.

Number of

pipe temp.
Discharge

Machine

Time No.: Cooling water Temp. of

CV/kW: ambient
room

COS : Air Suction pipe Air Suction pipe

air
n: rpm
Inlet Outlet Inlet Outlet Pres. Temp. Inlet Outlet Pres. Temp.
A V kW C C rpm C C C C lh C C C C C C C C C C

36 0178-250-EN
 Service Schedules for screw compressors
SAB 110, 128/163Mk3, 202 & VMY
Good and careful servicing of the compres-
sor and the unit is of great importance for
their proper functioning and service life.
It is therefore recommended that these ser-
vice instructions be followed; based on the
number of operating hours, they indicate the
service tasks to be carried out.
Preparations before compressor
inspection
99.05
Before dismantling any part of the compres-
sor or unit for inspection or repair, the pres-
sure must be reduced to atmospheric
0178-028-EN
pressure. This is done as follows:
S Regulate the compressor down to its low-
est capacity stage and stop it.
S Now close all stop valves in the pipe con-
nections to the unit except for the suction
stop valve pos. 20, which remains open
until the pressure in the unit has been
equalized to the suction pressure. This is
described in the passage called The non-
return valve.
S Close suction stop valve pos. 20.
S Any excess pressure in the unit is equal-
ized to atmospheric through stop valve
pos. 24. See the Key to Piping Diagrams
and the chapter on: Protecting the Envi-
ronment.
The heating element in the oil separator
must remain connected until the pressure
is completely equalized, thus boiling the
refrigerant out of the oil.
0178-028-EN
S Remove main fuses for the compressor
motor in order to prevent it from starting
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 below procedure depending on the the
type of your compressor:
SAB 110, SAB/163 and SAB 202
Above-mentioned compressors all have built-
in oil filters.
Follow the procedure described in the pre-
vious passage: Preparations before com-
pressor inspection.
Remove oil filter as described in section:
Maintenance of the compressor.
VMY with external oil filter
As the units may be fitted with one or two oil
filters (mounted in parallel) apply procedures
A or B.
A: Units with one oil filter only
Bring compressor to minimum ca-
pacity, and stop it.
When pressure in unit is equalized
to suction pressure, close stop val-
ves before and after oil filter.
Any over pressure in filter housing
is equalized to atmospheric pres-
sure through the evacuation valve
on filter housing.
Cover on filter housing can now be
dismantled, as described in section
Oil filter.
37
 B: Units with two parallel oil filters
While the compressor is operating,
the stop valves before and after
one of the oil filters must be closed.
Over pressure in filter housing is
equalized to atmospheric pressure
through evacuation valve on filter
housing.
Cover on filter housing can now be
dismantled, as described in section
Oil filter.
Cleaning of oil in the unit
The most critical time for an oil filter is, how-
ever, right after initial start-up of compressor.
Although an effort should be made to keep
the plant free of any impurities when as-
sembled, experience shows that it may be
difficult to avoid impurities in tubes and ves-
sels.
These impurities will be conveyed by the suc-
tion gas to the suction filter, where large-
sized impurities are intercepted. Smaller im-
purities will pass through the filter and be
conveyed to the oil separator, where they are
suspended in the oil. From here they are tak-
38
en to the lubricating system of the unit and
absorbed by the oil filter.
These impurities may result in a need to
change the oil filter cartridge shortly after
initial start-up.
It is equally important to check the oil at
regular intervals as specified in the sections
Checking the oil and Assessing the oil.
Purification of the oil may be done by means
of a 3 micron filter in a closed system.
During this process, the oil must not come
into contact with the oxygen and moisture in
the air.
In addition, it is important that all pressures
and temperatures be kept within the specified
values and that filters be kept clean; provided
inspection is carried out to the schedules
prescribed below, compressor and unit will
work efficiently and achieve a long service
life.
The following charts indicate the schedules
for checking the oil in the compressor unit
and a more detailed description of the opera-
tions to be performed during scheduled ser-
vice inspections.
0178-028-EN
Checking the oil

Operating hours between main inspections Service schedules

See chart for main inspections Number of operating
20000h 30000h 40000h hours from initial start-
up and after each main

inspection (see foot-
HCFC R717 HCFC R717 HCFC R717 note)

50
200


1000

2500

5000


10000














15000
20000


25000

30000



35000
40000

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

It is advisable to assess the oil as described in the following chart.
If this assessment is not made, the oil charge must be replaced with fresh oil.




The oil charge must be replaced with fresh oil.

Service schedules
Serviceterminer after
efter initialigangstning
frste start-up of compressor.
af kompressoren.
Serviceterminer efter hvert hovedeftersyn.
Service schedules after each main inspection.

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

0178-028-EN 39
Activities during a service inspection

Periodic service Activity

1 Daily 1.1 External inspection and leak check.
1.2 Check the oil level in the oil separator.
1.3 Check pressures and temperatures.
1.4 Check for unusual vibrations or noise.
1.5 Record operating data in the log book.
2 After 50 hours operation 2.1 Clean the suction filter.

3 After 200 hours 3.1 Clean the compressor suction filter.

operation 3.2 Take an oil sample from the oil separator and apprai-
se it visually, or send the sample to a laboratory for
anlysis.
Both methods are described in the section entitled
Assessing the oil.
3.3 Replace the filter cartridge in the oil filter, unless it
has been replaced earlier.
3.4 Clean all other oil filters and connections to and from
the compressor.
3.5 Check the coupling and its alignment (SAB 110*)
3.6 Check that all screws and nuts have the correct tor-
que.
4 After 1000 hours 4.1 Clean the compressor suction filter.
operation 4.2 Take an oil sample from the oil separator and apprai-
se it visually, or send the sample to a laboratory for
analysis.
Both methods are described in the section entitled
Assessing the oil.

5 After 2500 hours 5.1 Clean the compressor suction filter.

operation 5.2 Take an oil sample from the oil separator and send it to
a laboratory for analysis, as described in Assessing
the oil.
5.3 Fit a new oil filter cartridge.
5.4 Clean all other oil filters and connections to and from
the compressor.
5.5 Check the coupling and its alignment (SAB 110*)
5.6 Check that the pressure switches and thermostats
function correctly (refer to the set values in the instruc-
tion book).
If UNISAB II computerized control is fitted, check the
transducers
(see the instruction manual for UNISAB II )

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

40 0178-028-EN
 Periodic service
6 After 5000 hours.
operation
This service should be
repeated after every
5000 hours of operation
7 Major service
Carried out as specified
for the individual screw
compressor type.
(See the diagram for major
service)
* Check the elastic intermediate part to see whether there are any visible oblique cracks in the rubber part.
If such cracks are observed, replace the intermediate part.
0178-028-EN
Activity
6.1 Clean the compressor suction filter.
6.2 Fit a new oil filter cartridge.
6.3 Clean all other oil filters and connections to and from
the compressor.
6.4 Check the coupling and its alignment (SAB 110*)
6.5 Check that the pressure switches and thermostats
function correctly (refer to the set values in the in-
struction manual).
If UNISAB II computerized control is fitted, check the
transducers (see the instruction
manual for UNISAB II)
6.6 Take an oil sample from the oil separator and send
the sample to a laboratory for analysis, as descri
bed in the section entitled Assessing the oil. Please
also refer to the table entitled Checking the oil.
7.1 Total overhaul of the compressor, including fitting
new gaskets. As the compressor is already open,
inspect the bearings and, if necessary, fit new ones.
Check the regulating system.
7.2 Overhaul and clean the compressor motor.
N.B.
Follow the service schedule specified by
the motor manufacturer.
7.3 Fit a new oil filter cartridge.
7.4 Drain off the compressor oil and charge with new,
fresh oil.
7.5 Check the coupling and its alignment (SAB 110*)
7.6 Check that the pressure switches and thermostats
function correctly (refer to the set values in the in-
struction book).
If UNISAB II computerized control is fitted, check the
transducers
(see the instruction manual for UNISAB II)
41
Assessing the oil
Refrigeration machine oil is a vital part of the
compressor, as it not only lubricates and
cools the movable parts of the compressor, it
also prevents abrasive particles from en-
tering the rotor 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 the
compressor is in operation, which gives a
representative sample. Before taking the
sample, clean the drain valve and drain off a
little oil to prevent any impurities which may
have accumulated in the valve or the piping
from 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 up
to a clear light source, it will be easy to as-
sess the quality. You can also compare the
sample with the fresh oil of the same make
and grade.
An oil which you approve on the grounds of a
visual assessment must:
be clear and shiny
not contain any visible particles
feel viscous, smooth and greasy when a
drop is rubbed between two fingers and
without any signs of solid particles.
If you dont feel that you can approve the oil
by visual assessment, charge with new oil or
send a sample to a laboratory for analysis.
Note:
If the oil sample is poured into a glass
bottle, this must not be hermetically
sealed until all the refrigerant in the oil
sample has evaporated. Refrigerant in the
oil may produce excess pressure in the
42
bottle with subsequent risks of explosion.
Never fill a bottle up completely. Do not
send glass bottles through the postal ser-
vice use purpose-made plastic bottles.
Please, see below.
Analytical evaluation
Naturally, the oil sample can be analysed by
the oil company which supplies the oil. As
a special offer to our customers SABROE
has developed an analytical concept, in
cooperation with Mobil Oil, which is able to
analyse all oil makes. This will mean a uni-
form reporting of the results. The analysis
allows the following to be determined:
S Whether or not the oil is still usable - after
filtering, if necessary - or whether it should
be replaced.
S Whether solid particles that may be pres-
ent in the oil originate from the bearings or
other components exposed to wear and
tear in which case the compressor must
be inspected.
S Each report will include the corresponding
measuring results from the previous 3 oil
analyses. In this way you will be able to
follow up on the state of both the oil and
the compressor from one analysis to the
next.
Procedure
S A form set with a plastic sampling bottle
and a dispatching envelope can be re-
quested from the local Sabroe Refrigera-
tion representation.
S The oil sample must be drained from the
cleaned oil drain valve into the sample
bottle. Screw the lid loosely on and let the
bottle stand for a few hours to enable re-
0178-028-EN
 frigerant contained in the oil sample to
evaporate before sending it to the labora-
tory.
S Please follow the Sampling and Shipping
Instructions enclosed in the form set in
which the address of the laboratory in Hol-
land is also mentioned.
The analysis
The following table states some average val-
ues that can be applied in practice. However,
you should be on the alert whenever the re-
sults of the analyses approach these values.
In some cases the water content of 100 ppm
in HCFC plants may be too much and thus
lead to Cuplating in the shaft seal.

Limiting values
Sabroe Oil PAO 68 Sabroe Oil AP 68 Sabroe Oil A 100
Parameter Unit Method Target Target Target
Spec. Max. Min. Spec. Max. Min. Spec. Max. Min.
Viscosity @ 40C cSt ASTM D 445 66 76 53 64 74 51 100 115 80
TAN *1) mg KOH/g ASTM D 664 0.03 0.2 0.01 0.2 0.05 0.2
SAN * 2) mg KOH/g ASTM D 665 0 0 0
Water ppm Karl Fisher 100 100 100
Appearance report report report
Colour ASTM D report report report
1500
Pentane Insolubles W% MM 490 0.05 0.05 0.05
(5mm)
Oxidation abs/cm IR,1700-1720 5 5 5
/cm
Nitration abs/cm IR,1627-1637 5 5 5
/cm
Nitro Compounds abs/cm IR,1547-1557 0.5 0.5 0.5
/cm

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

0178-028-EN 43
A report is drawn up for every sample re-
ceived. This report concludes:
S Whether the oil can still be used without
taking any further action.
S Whether the oil can be used after it has
been filtered through a very fine filter. If
this is necessary, the oil must be pumped
directly from the compressor unit through
a 3 micron filter and back to the unit. The
44
system must be completely closed, to pre-
vent the oil being affected by moisture in
the air.
Whether the oil is no longer fit for use.
The report will always be sent to the address
stated on the sample label included in the
form set. A copy will be sent to SABROE
REFRIGERATION so that we are in a
position to advise you, if required.
0178-028-EN
 Major Service Intervals
SAB 110, SAB 128/163 Mk3, SAB 202

Condensing temp.
TC (C) Extreme operating conditions Normal operat. cond.
20000 hour interval 30000 hour interval
55

55

50
50

45
45

40 40

35 35

30 30
95.10

25
25
20
20
0178-030-EN

15
15
10
10 5
5 0 Booster conditions
0 5 40000 hour interval
5 10
10 15
20
20 30
30
50 50

R22
R717 50 30 20 10 5 0 5 10 15 20 25

Evaporating temp.
50 30 20 10 5 0 5 10 15 20 25 TE (C)

T0177068_0

0178-250-EN 45
Oil charging, weight and shipping volume
SAB 128/163 Mk3 and SAB 202
Oil charging (oil level at the middle of upper sight glass during operation)
Oil cooler Oil separator Compressor + pipes Total, unit
Type Litres Litres Litres Litres
SAB SAB SAB SAB SAB SAB SAB SAB SAB SAB SAB SAB
128 163 202 128 163 202 128 163 202 128 163 202

OOSI 1614 11 11 11 80 103 216

OOSI 2114 20 20 20 89 112 225
OOSI 2714 31 31 123 236
OOSI 3214 48 48 140 253
OOSI 4114 86 291
OWSG 1615 25 87
OWSG 1619 25 25 117 230
OWSG 2115 39 60 80 180 9 12 25 97
OWSG 2119 39 39 131 244
OWSG 2719 63 63 155 278
OWSG 3219 78 283
OWSG 4119 119 324
HLI 0 0 0 69 92 205

96.02
Weight (excl. motor, refrigerant, oil and water)
Oil cooler Basic Unit Compressor block Total, unit
Type Kg Kg Kg Kg

0178-256-EN
SAB SAB SAB SAB SAB SAB SAB SAB SAB SAB SAB SAB
128 163 202 128 163 202 128 163 202 128 163 202

OOSI 1614 78 78 78 1008 1528 3218

OOSI 2114 130 130 130 1060 1580 3270
OOSI 2714 180 98 1630 3320
OOSI 3214 215 180 1665 3355
OOSI 4114 215 3520
OWSG 1615 120 1050
OWSG 1619 130 380 1580 3270
OWSG 2115 185 700 950 2100 230 500 1040 1115
OWSG 2119 210 210 1660 3350
OWSG 2719 310 310 1760 3450
OWSG 3219 440 3580
OWSG 4119 740 3880
HLI 20 20 20 950 1470 3160

Shipping volume (excl. motor)

Oil cooler Compressor type
Type m3
SAB SAB SAB
128 163 202

OOSI 2114 5
OOSI 3214 8
OOSI 4114 11
OWSG 2115 6
OWSG 2719 9
OWSG 4119 12
HLI 4 7 10

46 0178-250-EN
 Servicing the refrigeration plant

During both start-up and operation it must be S the condenser pressure is not excessively
made sure that the plant is working correctly. high, and

Compressor and condenser must be able to

work satisfactorily, safety devices must be
intact and the evaporator must function under
load - that is to say:
S the desired temperatures are observed,
S the oil pressure and discharge pipe
temperature on the compressor are
correct,
97.07
S the plant otherwise works as it is sup-
posed to.
The service instructions outline some general
guidelines for servicing the refrigeration
plant, with some references to the instruction
manual. The service instructions should
therefore be read and followed carefully.

Check Interval Activity

0171-470-EN

Condensing pressure Excessively high pressure may be

due to:
reduced cooling effect
Pressure air in the condenser.
and temp. Too low condenser pressure im-
Daily
plies a risk of restricting the refri-
gerant supply to the evaporator.

Discharge pipe temperature Normal discharge pipe tempera-

ture acc. to instructions.

Filter in Accumulated dirt causes reduced

liquid line refrigerant supply to the evapora-
thermostatic valve Clean when tor.
Filters suction line needed If a filter has a hot inflow and cold
oil return
discharge, this may be due to
clogging of the component.

Moisture in the sight-glass Some installations are provided

(on HFC/HCFC installations) with a sight-glass featuring mois-
ture indicator; if the indicator col-
Dehumidi- our switches from green to yellow,
fier When
there is moisture in the refrige-
needed
rant.
Change the drying filter regularly.

0178-250-EN 47
 Check Interval Activity

Refrigerant charge Inadequate charge results in re-

duced plant capacity and often
leads to an excessively high dis-
charge pipe temperature.
Refrige-
rant Periodically The plant must be searched regu-
Leak detection
larly for leaks. Flanges and joints
settle during the plants initial op-
eration period. They must therefo-
re be tightened and checked.

Safety pressure controls Adjust operating point and check

Automatic
Automatic operating Periodically the function. Replace switch sys-
controls
controls tem if sticking.
Alarms
Lubrication of electric mo- Clean and lubricate according to
tors suppliers instructions. At temper-
atures lower than -25C, use spe-
cial lubricant.
Electric
motor Periodically
Check in accordance with the
Alignment of coupling
instructions of the instruction
V-belt drive
manual.
Tighten loose V-belts, if any,
or replace by new ones.
Con- Corrosion Periodically Marine condensers are normally
denser normally protected against galvanic corro-
min. 4 sion by the mounting of corrosion
times a plugs in the condenser covers.
year
Metallic contact between corro-
sion plug and cover is essential to
proper functioning.

Frosting-up Problem-free operation is condi-

When tional on the evaporator being
Evapora- needed kept free of ice. Defrost as and
tor when required.

Oil draining (ammonia plant) Periodically Check evaporator, intermediate

cooler, receiver, etc. for oil accu-
mulation. Exercise caution; use a
gas mask.

48 0178-250-EN
 Maintenance of Compressor SAB 128/163 Mk3
Dismantling and Assembly
Servicing work on the SAB 128/163 com-
pressor must be carried out by professional,
well-trained staff acquainted with the com-
pressor.
These instructions describe the complete dis-
mantling and assembly of the compressor,
although this will not always be required.
When dismantling, parts should be marked to
ensure that they can be remounted in the
same position as before.
Torque moments for screws and bolts as
98.06
stated in the Torque moments table must be
strictly observed.
0178-061-EN
Preparations before dismantling
A description is given below of complete dis-
mantling, inspection and reassembly of the
compressor.
Partial dismantling and inspection can be
undertaken while the compressor is secured
to the base frame. To allow a complete dis-
mantling, however, the compressor must be
lifted off the baseframe. For further details,
see the section below entitled Sequence for
dismantling the compressor.
It is important that dismantling and handling
of the various parts be done as described in
these instructions in order to avoid damage
when restarting the compressor.
Therefore, read the instructions carefully,
before commencing the work.
0178-050-EN
As O-ring gaskets have a tendency to ex-
pand beyond their size when exposed to oil
and refrigerant, it is useful to have an extra
set of gaskets ready before starting work.
See the list of spare part sets in this instruc-
tion manual.
Tools
Apart from having the necessary tools at
hand (see the tool list in the instruction man-
ual), it is an advantage to place the compres-
sor on an iron plate when dismantling comp-
letely. This will allow for easy removal of oil
leaking from the compressor during disas-
sembly.
It is also recommended to position the com-
pressor in a spot with plenty of space around
and to ensure that the room is clean and
dust-free.
Elimination of refrigerant gas
Shut off the suction and discharge stop
valves and eliminate the refrigerant gas as
described in the section Environmental pro-
tection.
Removal of various accessories
When working on the compressor, the power
to the compressor motor must be cut off and
it must be ensured that the compressor can-
not be inadvertently started (if necessary, re-
move the master switches).
49
Dismantle the following parts from the Note:
compressor: For cleaning and drying compressor parts,
do not use twist or any other fluffy cloth.
1. Coupling between compressor and motor.

2. Flanges connecting the suction and dis- Dismantling the compressor

charge sides of the compressor to plant Sequence for dismantling
and oil separator (in the case of total dis-
mantling). Sequence
Parts to be dismantled and
Descrip. no.
3. Oil piping connected to the compressor. Oil filter 1
Suction filter and non-return valve 2
There may be oil in these pipes. They Shaft seal, balance piston and 3
should therefore be loosened carefully to shaft cover
Regulating cylinder 4
allow for collection of this oil. Regulating slide 5
Slide stop for Vi regulation 6
When the oil pipes have been removed,
Suction cover and bearings 7
they must be stored without being neither in compressor shaft end
bent nor damaged. Rotors and bearings in 8
compressor discharge end
Capacity indicator 9
4. Electrical connections to the compressor
block.
The individual points are described below.
The position numbers in the following sec-
tions refer to the spare parts drawing. Reassembling the compressor
Clean all parts carefully before reassembling.
Draining oil from the compressor
Examine the parts for damage and wear and
Following dismantling of the oil pipes, quite replace with new parts, if necessary.
some oil may still remain in the compressor. Examine all gasket rings to see if they can be
Most of it can be removed by unscrewing the reused. If in doubt, replace with new parts.
threaded plug pos. 24 on the underside of
the compressor while this is suspended, for Before remounting, lubricate all parts, includ-
example, in the crane. ing screws, with clean fresh refrigeration oil.

50 0178-050-EN
1. Oil filter
The oil filter pos. 470 is a replaceable filter
cartridge, fitted in the compressor block as
shown on the spare parts drawing.
Along with the consumption of the filtering
capacity of the filter cartridge, the pressure
loss across the filter increases, which is reg-
istered by the two pressure transducers pos.
752 and pos. 753.
Make sure that a new filter cartridge is at
hand as the replaced oil filter cannot be
cleaned.
Before removing the filter cartridge from the
compressor block, stop the compressor and
the pressure will be equalized to atmospheric
pressure. Further, empty the oil filter hous-
ing of oil, which is done by using drainage
valve pos. 48 see piping diagram as well as
fig. 1.1. This drainage is most easily car-
ried out while there is still some excess
pressure left in the compressor.
Fig. 1.1
48 Cutting ring connection
Pipe dia.OD = 10 mm
ID = 8 mm
1.1. Removal and cleaning
After the pressure in the compres
sor has been equalized to atmo-
spheric, dismantle oil pipe pos. A at
flanges B and C as illustrated in fig. 1.
0178-050-EN
Fig. 1
B
A
C
T4840165_0
1.1.1. Next, dismantle electrical coupling
pos. 753 and temperature transmitter
pos. 761.
1.1.2. By removing screws pos. 456, cover
pos. 450 with oil cartridge pos. 470
and O-ring pos. 452 can be extracted
from the oil filter housing.
1.1.3. By dismantling nut pos. 455 filter car-
tridge pos. 470 can be pulled out
across spindle pos. 458.
1.1.4. Do not dismantle magnetic filter pos.
460, but wipe it with a clean piece of
cloth.
1.2. Mounting of oil filter cartridge
1.2.1. After cleaning cover pos. 450 on the
inside, mount filter cartridge pos. 470
and O-ring pos. 453.
Fasten the parts with nut pos. 455.
1.2.2. Position the complete cover pos. 450
with O-ring pos. 452 in the compres-
sor and tighten with screws pos. 456.
1.2.3. Mount oil pipe pos. A and fasten it
onto flanges B and C as illustrated in
fig. 1. If considered necessary, replace
O-ring in flange B and gasket in flange
C. See part numbers in in Spare Parts
Survey in the section on Oil system
Flange connection.
51
1.2.4. Next, fit the electrical coupling onto
pressure transducer pos. 753 and
temperature transmitter pos. 761.
2. Suction filter
The suction filter is built into the compressor
housing above the rotors.
The purpose of the filter is to collect the im-
purities conveyed from the evaporator sys-
tem with the suction gas.
Experience shows that a good deal of impuri-
ties are collected in the filter during the initial
period following start-up of a new refrigera-
tion plant.
Consequently, it is important to clean suction
filter after 200 hours of operation from the
initial start-up of the compressor.
In case this is not done, there is a certain risk
that the suction filter may burst due to an ex-
cessive differential pressure across the filter.
2.1. Extraction of suction filter
2.1.1. Begin by removing the oil filter as de-
scribed in section 1.1.
2.1.2. Next, dismantle the float switch as fol-
lows:
S Dismantle circlip pos. 511 by hand,
hereby loosening washer pos. 508
and spring pos. 510.
Normally, float ball pos. 507 cannot
be removed before nipple pos. 505
has been unscrewed.
S Dismantle electrical coupling pos.
500 and unscrew nipple pos. 505.
52
Hereby, float ball pos. 507 is loos-
ened; remember to support it by
hand.
2.1.3. By removing screws pos. 280 it is pos-
sible to pull out flange pos. 279 to-
gether with oil filter housing pos. 480
and non-return valve pos. 260.
But watch out, there may be a fair
amount of oil behind the flange as
mentioned in pt. 1.1.2.
During the dismantling, apply the
two supports no. 25 from the tools
kit. These are mounted diagonally in
the holes, in which screws pos. 280
were fitted. Pull out the flange pos.
279 by means of two of the screws
pos. 280, which are fitted in the two
threaded holes in the flange.
Once the flange is loose, pull the
whole unit straight out of the compres-
sor block, guided by the two supports.
2.1.4. Now take out suction filter pos. 170 by
hand, at the same time taking great
care that no dirt falls out of the fil-
ter.
As an extra safety measure it is re-
commended to check that in particu-
lar the oil chamber in the block be-
tween O-rings pos. 281 and 481 is
completely clean before reassemb-
ly.
2.1.5. Clean the suction filter in an oil deter-
gent and blow dry and clean it with
compressed air.
0178-050-EN
2.2. Mounting of suction filter
After cleaning suction filter pos. 170,
check that the filter mesh is undam-
aged.
Mount suction filter as follows:
2.2.1. Place suction filter in the suction
chamber by hand and press it firmly
into flange pos. 253. In order to make
the suction filter fit firmly onto the
flange, you may press it into an oval
shape before the mounting. Center
the other end of the suction filter in the
suction chamber.
2.2.2. Check that non-return valve pos. 260
is easy to move back and forth and
check that the oil chamber in the com-
pressor block is clean as described in
pt. 2.1.4.
2.2.3. Using the supports no. 25 as guides,
position the complete unit with flange
pos. 279, oil filter housing pos. 480
and non-return valve pos. 260 in the
compressor. Remember the two O-
rings pos. 281 and 481.
Using these two supports guide the
whole unit straight into the compres-
sor, avoiding to push the suction filter
out of its central position as indicated
in pt. 2.2.1. Press the whole unit into
place with your hands until flange pos.
279 touches the housing.
2.2.4. Mount and tighten screws pos. 280
with the prescribed torque.
0178-050-EN
2.2.5. Next, mount float switch as follows:
S Lead float ball pos. 507 through the
oil filter housing and up into the float
housing.
Note:
The float ball must be positioned
as shown in fig. 2 with the NO mark
facing upwards.
131
Fig. 2
NO
NC
S Position nipple pos. 505 with guide
tube in the threaded hole of the
housing and guide the float ball into
place on the guide tube in which the
electrical switch is situated.
S Screw nipple pos. 505 together with
gasket pos. 506 firmly into place, at
the same time making sure not to
squeeze the float ball.
S Now mount spring pos. 510, washer
pos. 508 and circlip pos. 511.
S Finally, mount the electrical coupling
pos. 500.
2.2.6. Next, mount oil filter as described in
section 1.2.
53
2.3. Non-return valve
Once oil filter housing pos. 480 has
been dismantled as described in sec-
tion 2.1, check that non-return valve
pos. 260 is easy to move back and
forth. It is usually not necessary to dis-
mantle the nonreturn valve. It can be
dismantled in the following way, how-
ever:
2.3.1 Dismantling
By removing screw pos. 262 the
whole non-return valve comes
loose.
Before dismantling the non-return
valve, loosen locking screw pos.
266 by means of an Allen key.
Using two wrenches that engage in
the holes of the valve cone pos. 260
and the locking device pos. 265
as illustrated by fig. 3 the two
parts can be taken apart.
Pay attention to the tense spring
pos. 261.
Fig. 3
58 - 62 5
5 240
68 - 75 6
54
If necessary, it is possible to replace
tape bearings pos. 264 by new
ones as they are easy to place in
the grooves of the valve cone.
2.3.2 Assembly
Assemble the non-return valve in the
reverse order to the one described in
pt. 2.3.1.
Note the following, however:
Assemble valve cone pos. 260 and
locking device pos. 265 with the
wrenches just mentioned and fix lo-
cking screw pos. 266. Remember
to fit spring pos. 261.
Assemble the non-return valve
completely before fixing it in oil filter
housing pos. 480 with screw pos.
262.
0178-050-EN
3. Shaft seal type 680 O-ring pos. C seals against the shaft seal
cover (80).
81
Fig. 1 120 Oil out D
B The rotating part of the shaft seal, in which
E C
w

A
80 the carbon face pos. F is fitted, is fastened
w
on the rotor shaft by means of the 3 pointed
w w w w
w w
screws pos. E and tighten by means of the
static O-ring pos. D.

w w

83
Please be extremely careful with the
F lapped surfaces of the cast-iron seat
and the carbon face. The slightest
Oil in
scratch will impair the sealing effect.
3 to 4 mm
T264106, rev. 0

Removing the shaft seal

S Take the pressure off the compressor - as
Designation Pos.
described in the instruction manual - and
No.
Cast iron seat A dismantle the coupling.
Rotating part with carbon face B S Remove all screws pos. 82. The shaft seal
Outer O-ring C cover pos. 80 can then be pulled out over
Inner O-ring D the shaft. If the cover sticks, so that it is
O-ring for cover 81 not possible to remove it manually, use
two cover screws fitted in the threaded
The shaft seal must ensure complete tight-
holes of the flange to ease it off.
ness between the compressor shaft and the
compressor housing, so that the inside of the Note that the holes are not threaded all
compressor is completely sealed off from the the way, so it is advisable to insert a steel
atmosphere. pin dia. 8 x 40 before putting the screw
into the hole.
The shaft seal type 680 has a built-in metal
bellow in its rotating part which, apart from The oil splash ring pos. 113 and the cast-
ensuring tightness, also assimilates axial dis- iron seat pos. A will come out together
placement and provides the necessary com- with the cover.
pressive force between the two slide faces
S The part, with carbon ring, can then be
mentioned below.
drawn out over the shaft. Normally tools
The seal is a slide ring type, consisting of a are not required.
stationary cast-iron seat pos. A which is posi-
Fitting the shaft seal
tioned in the shaft seal cover (80). Rotation is
prevented by a pin pos. 83. S Clean the shaft seal cover pos. 80 and the
rotor shaft thoroughly. Check the shaft for
The end face of the cast-iron seat is lapped scratches and marks that might cause
to ensure that the slide face seals tightly. The leaks.

0178-050-EN 55
 Oil the shaft and shaft seal parts with the
same type of refrigeration oil as the one
used in the compressor.
S Press the rotating part carefully in over the
rotor shaft until it touches the recess on
the rotor shaft as shown on the drawing.
Do not press the carbon ring but use two
screw drivers as illustrated by fig. 2.
In this way you avoid twisting the bellows
in the shaft seal.
Fig. 2
S Then tighten the 3 pointed screws alter-
nately with the supplied 3 mm Allen key.
S Mount the cast-iron seat pos. A and the
O-ring pos. 6 in the shaft seal cover and
make sure that the pin pos. 83 catches the
slot in the seat pos. A.
56
S Carefully ease the shaft seal cover in over
the shaft until it meets resistance from the
rotating part. Before screw pos. 82 has
been tightened, there will be a gap of 3 to
4 mm between the two flanges, as shown
in fig. 1.
Check to ensure that O-ring pos. 81 is cor-
rectly placed.
S Insert screws pos. 82 and tighten them
alternately - take care not to damage the
shaft seal by tightening unevenly. Tighten
the screws with the torque inidcated in the
instruction manual.
S Fit the oil splash ring pos. 113.
Fit the coupling as described in the
Instruction Manual and turn the shaft (by
hand) to check that it rotates freely.
Balance piston at suction end
Attach balance piston pos. 120 to the rotor to
be coupled to the motor so that the tubular
pin pos. 118 slots into the milled recess.
Cap cover
After dismantling of screws pos. 92, disman-
tle cap cover pos. 90 by mounting two of the
screws in the free threaded holes in the
flange of cap cover. Hereby, the cap cover
can be pushed out. Remounting of the cap
cover is done in the same way as the shaft
seal cover.
0178-050-EN
4. Regulating cylinder
The purpose of the regulating cylinder pos.
50, the built-in piston system and the capac-
ity slide pos. 200 is to adapt the capacity of
the compressor to the actual cooling require-
ments of the plant.
The system works by letting the piston pos.
201, 202, 203 and 204 move the capacity
slide pos. 200 back and forth hydraulically.
This opens modulatingly for an internal by-
pass channel which - when the position of
the piston is to the extreme right on the draw-
ing - is most open. Hereby, the compressor
runs at its lowest capacity.
Dismantling
S Dismantle capacity indicator as described
in section 9.
S After dismantling of screws pos. 62, the
cover pos. 60 can be pushed free of the
cylinder by mounting two of the screws no.
21.2 in the threaded holes of the flange.
Watch out, there may be oil in the cylin-
der!
S Remove cover together with capacity indi-
cator as an entire unit. Pull the whole thing
straight out in order not to damage the
0178-050-EN
spindle pos. 210 and its catching in the
piston.
Dismantle cover and capacity indicator
following the description in the section on
Capacity indicator.
S At the piston first dismantle screws pos.
206, and next the whole unit pos. 202 and
201 can be pushed free of the piston rod
and pulled out af the cylinder.
For this purpose use screws No. 22.2
which are fitted diagonally in the piston
and screwed completely through until they
press against the piston rod pos. 207.
Watch out for oil behind the piston.
S Before dismantling regulating cylinder pos.
50, it is recommended to move Vi-slide
pos. 190 to minimum position by turning
the spindle pos. 180 clockwise.
Hereby, the spring pos. 191 is slackened
as much as possible, but pay attention to
the fact that a weaker spring force still re-
mains which will press the regulating cylin-
der pos. 200 out against regulating cylin-
der pos. 50.
S Dismantle regulating cylinder pos. 50 after
removing screws pos. 52.
57
5. Regulating slide
The regulating slide pos. 200 can now care-
fully be pulled out of the compressor by
hand.
Two PTFE tape bearings are fitted in the reg-
ulating slide the purpose of which is to guide
the slide on the guide tube pos. 192. Usually,
the PTFE tape bearings are only replaced
during an overhaul of the compressor.
Any dismantling of piston rod pos. 207 and
slide pos. 200 can be done by removing
screw pos. 311 and locking plate pos. 310.
Mounting
The assembly is done in reverse order from
the one described above, and attention must
be paid to the following:
S When assembling piston rod pos. 207 and
slide pos. 200, pay attention to O-ring pos.
209. Tighten the screw pos. 311 to the
torque prescribed in the table. Also check
that pin pos. 205 is in position and in good
working order. The flat end of the pin must
point down towards the spindle.
S When mounting the slide, spring pos. 191
must be in position as shown on the draw-
ing.
58
S Carefully guide the regulating slide onto
the guide tube without damaging the two
PTFE bearing tapes, pos. 208.
S When mounting the cylinder pos. 50, this
must be pressed against spring pos. 191
while fitting the screws pos. 52. Pay atten-
tion to O-ring pos. 51.
Tighten the screws pos. 52 with 75 Nm
on SAB 128, and with 130 Nm on SAB
163.
S Assemble the piston, consisting of pos.
201, 202, 203 and 204, and insert it in the
cylinder pos. 50 as one whole unit. Make
sure that the sealing ring pos. 204 is posi-
tioned as shown on spare parts drawing
with the open side facing inwards.
Pull the entire unit onto the piston rod pos.
207 by means of screws No. 22.2 until the
screws pos. 206 can be fitted and tight-
ened.
S When mounting cover pos. 60 the spindle
pos. 210 must catch the piston rod pos.
207 and pin pos. 205. Pay attention to O-
ring pos. 61.
S Fasten the cover with screws pos. 62.
S Mount the capacity indicator as described
in section 9.
0178-050-EN
6. Slide stop for Vi-regulation
The purpose of the Vi-regulating system is to
regulate the built-in volume ratio of the com-
pressor so that the compression ratio of the
compressor is equal to the pressure ratio be-
tween the condensing pressure and the
evaporating pressure in the refrigeration
plant. The system works by dislocating slide
stop pos. 190, hereby - via the regulating
slide pos. 200 - changing the size of the dis-
charge port of the compressor. This changing
of the size of the discharge port increases -
or diminishes - the compression chamber
and consequently the compression ratio.
The Vi-regulation may be carried out either:
A: manually on SAB 128 and 163 Mk3
or
B: automatically on SAB 163 Mk3 only
A: Manual Vi adjustment
Manual adjustment of the Vi slide stop posi-
tion is described in a separate section in this
instruction manual. Please refer to table of
contents and fig 6.1.
Adjustment of the system is described in a
separate section of this instruction manual.
Fig. 6.1
190
104
184
182
183
180
186
192
103
102
100
T0177135/V2
193
0178-050-EN
Dismantling
After dismantling of screws pos. 102, screw
out the whole unit with the slide stop cover
pos. 100 and the bearing housing pos. 103
by turning the spindle pos. 180 anti-clock-
wise.
When the spindle has been completely
unscrewed from the thread in the slide
guide pos. 192, the unit can be removed
by hand.
S By dismantling screws pos. 104, the cover
pos. 100 is dismantled from the bearing
housing pos. 103, and the sealing rings
pos. 182, 183 and 184 can be removed by
hand.
S Spindle pos. 180 and ball bearings pos.
186 can now be pushed out of bearing
housing, pos. 103.
S Slide stop pos. 190 and slide guide pos.
192 are squeezed together and should
usually not be separated. Do not remove
the unit from the compressor until suction
cover pos. 20 has been dismantled.
Please refer to section 7.
S Screw pos. 193 acts as a slide stop and
should usually not be dismantled.
Mounting
When mounting - which is done in reverse
order from the dismantling - attention must
be paid to the following:
S Insert the ball bearings, which must be
well greased with ball-bearing grease in
the bearing housing pos. 103 with the col-
lar of the spindle pos. 180 in between.
Avoid knocking on the bearings.
59
S Before assembling of slide stop cover pos.
100 and bearing housing pos. 103, posi-
tion the sealing rings pos. 182, 183 and
184 as shown on drawing. The open side
of the sealing ring pos. 183 must face the
ball bearing. Assembling is done by
means of screws pos. 104.
Check that the spindle is easy to turn.
S Mount the whole unit in position by screw-
ing the spindle into the slide guide pos.
192 until the slide stop cover pos. 100
bears against the suction cover pos. 20.
Pay attention to O-ring pos. 101.
Secure with screws pos. 102

B: Automatic Vi-regulation - only for SAB 163 Mk3

Fig. 6.2 Magnetic coupling pos. 405

400 405 407 406 372 374 390 190 370 191

401

403

402



395

396


410

415

5 4 3 2 1 373 371 382 380 381 20

from T4161T01_2_4_JAN

By automatic Vi regulation, see fig. 6.2, the
slide stop is moved by oil pressure controlled
by solenoid valves and a position transmitter
pos. 410.
Dismantling
S First dismount the electrical connection to
position transmitter pos. 410.
S Dismount the pipe connection to the cover
pos. 380.
S Having removed the screws pos. 382, the
cylinder pos. 380 and appurtenant parts
can be pulled out with care as one unit.
Be careful not to damage the spindle pos.
390 and the sealing ring pos. 371.

60 0178-050-EN
S The entire unit including the magnetic cou-
pling pos. 405 can be dismantled and as-
sembled as described in the following sec-
tion Magnetic coupling for Vi-indication.
S Dismantle piston pos. 372 by removing
screws pos. 374, whereby the sealing ring
pos. 371 can be taken out. Pay attention
to the loose pin pos. 373.
S Slide guide pos. 190 and slide stop pos.
370 cannot be removed until suction cover
pos. 20 has been removed. See section 7
in this respect.
Mounting
When mounting which is done in reverse
order from dismantling attention must be
paid to the following:
S When mounting the piston, pos. 372,
make sure:
S that the open side of the sealing ring
pos. 371 faces the piston as shown on
the drawing,
S that pin, pos. 373, is positioned in the
groove of the piston, pos. 372, and fas-
tened with screws, pos. 374.
S Now mount the entire unit with cover pos.
380, ensuring that spindle, pos. 390,
catches the hole in piston, pos. 372, and
pin, pos. 373.
Take care not to damage
sealing ring pos. 371
O-ring pos. 381
and remember that
the unit must be pressed against spring
pos. 191.
Secure with screws, pos. 382.
S Mount pipe connection to cover, pos. 380.
0178-050-EN
Magnetic coupling for Vi-indication
The rotating movement from spindle, pos.
390 - see fig. 6.2 - is transferred to the trans-
mitter, pos. 410, through a magnetic cou-
pling, pos. 405, which is completely tight to
both oil and refrigerant.
Dismantling
S Start by removing the four screws, pos.
403, whereby cover, pos. 402, and trans-
mitter, pos. 410, can be removed as one
complete unit. Cover, pos. 402, and trans-
mitter, pos. 410, are dismantled by the re-
moval of screws, pos. 415.
S Remove screw, pos. 396, while at the
same time holding back driving disk, pos.
395, using a big screwdriver in the slot of
the washer.
S On removing screws, pos. 401, parts pos.
380 and pos. 400 are dismantled, and the
complete magnetic coupling, pos. 405,
can be pulled out of pos. 400 by hand.
S On dismantling the inner circlip no. 1 it is
possible to pull out the inner magnet re-
tainer no. 2 and spindle, pos. 390, can be
pulled out against the magnetic force.
S Dismantle spindle, pos. 390, by loosening
screw, pos. 407.
Assembling
Assembling of the complete unit is done in
the reverse order to the dismantling. Pay at-
tention to the following, however:
S On assembling parts, pos. 400 and pos.
380, fit O-ring, pos. 406.
S On reassembling the magnetic coupling,
we advise you not to position magnet re-
tainer no. 2 in the coupling until spindle,
pos. 390, has been mounted as the mag-
netic force will make it very difficult to dis-
mantle the parts again.
61
S On mounting driving disk, pos. 395, the 5
slot in the disk must be in a complete ver-
tical position as illustrated on the following 4
sketch.
3
395

S On mounting the transmitter pin no. 3

must engage in the slot of the disk,
pos. 395.
S If arm no. 4 has been dismounted from the
transmitter, it must be mounted correctly
as follows:
S Find the 4mA point of the transmitter by
turning the shaft as described in In-
struction manual for UNISAB II.
S Mount arm no. 4 so that pin no. 3 is
positioned as illustrated on the sketch.
S Tighten pointed screw no. 5.
S Mount transmitter, pos. 410, as shown in
fig. 6.2 with the connection facing down-
wards.

62 0178-050-EN
7. Suction cover and bearing in compressor shaft end
Before suction cover pos. 20 can be dis- Shaft seal cover pos. 80 and shaft seal
mantled, the following parts must be re-
Cap cover pos. 90
moved as described earlier:
Slide stop cover pos. 100

Fig. 7.1 9 5 2

21.2 22.4 T0177135_0 V12

Dismantling can be knocked out of the cover with a

S With tools Nos. 55 and 56, knock out
guide pins pos. 22
S Dismantle screws pos. 23
S Carefully pull out suction cover above the
shaft ends, the outer rings of the roller
bearings pos. 111 emerging with it.
S Hereafter, the outer rings with the rollers
Fig. 7.2
1
punch. They cannot be reused.
S After dismantling of the retention pin pos.
118 pull the inner ring of the roller bearing
out of the rotors as shown in fig 7.1. The
numbers on the drawing refer to the tools
list.
S Lock the rotors as shown in fig 8.1.

24

20.2

23.3 7

T0177135_0 V11

0178-050-EN 63
Mounting
When mounting, pay attention to whether the
motor is to be connected to the male or fe-
male rotor.
S First, mount locking tool No. 11 on the end
of the rotor on which the inner ring of the
roller bearing is to be squeezed on as
shown in fig 7.3.
Fig. 7.3
S Press on the inner rings of the roller bear-
ings with the tools as shown in fig 7.2.
Remember to grease the shafts with
Molykote grease. Tighten to 70 Nm.
Always mount new roller bearings.
S Mount driving pin pos. 118 on the rotor
shaft in which the shaft seal is to be
mounted.

11 S Mount suction cover pos. 20 with the

guide pins pos. 22 and tighten the screws
pos. 23. Pay attention to O-ring pos. 21.

S Press the outer rings with rollers into posi-

tion as shown in fig 7.4. Remember to use
tool No. 4 as shown on the drawing.
22.7
S Dismantle locking tool No. 11.

S Now mount the remaining parts as men-

T0177135_0 V21
tioned at the beginning of this section.

Fig. 7.4
1 4

24.1

20.2

23.3 7

T0177135_0 V20

64 0178-050-EN
8. Rotors and bearings in compres-
sor discharge end
Before the rotors can be removed from the
compressor, the parts mentioned in section 7
must be disassembled. Next, proceed as fol-
lows:
By dismantling the screws pos. 115 it
is a good idea to lock the rotors in or-
der to prevent them from rotating. For
this purpose use arrangement fig 8.1
in the rotor shaft end.
Fig. 8.1
30

8.1. Dismantling

8.1.1. Loosen the four locking screws pos.

31 110
45 and slacken the two adjusting
screws pos. 44 by 3 to 4 turns. 22.6

8.1.2. Dismantle cover pos. 40 by removing

screws pos. 43.

8.1.3. Pull out the two inner covers pos. 151

and 153 by means of screws No 22.3,
which must be mounted in the
threaded holes in the middle of the
covers.
Be careful not to lose the two lock-
ing pins pos. 119.
8.1.4. Now dismantle screws pos. 115,
whereby clamps pos. 114 can be re-
moved.
Remember to dismantle the tools
again before pressing out the ro-
tors.
8.1.5. It is now possible to push out the ro-
tors - one at a time - by means of the
tools shown in fig 8.2.
Screw the four long threaded journals
No. 20.1 from the tools set into the
threaded holes used for securing cov-
er pos. 40.

Fig. 8.2
10 20.1 23.2

6 1

21.1

T0177135_0 V14

0178-050-EN 65
 By pressing the rotors - one at a time - Fig. 8.2.1
so far with screw No. 21.1 that they
become loose and can be removed by
hand, the inner rings of the bearings
are loosened from the rotors at the
same time as they cannot pass the
discharge ports pos. 140 and 141. 144

145
8.1.6. Loosen discharge ports pos. 140 and
141 as follows:

Remove screws pos. 142.

The first production series of SAB
163 Mk3 compressors are fitted
with an adjusting screw pos. 144
and locking screw pos. 145 as
shown in fig. 8.2.1.
Using key no. 51.2 begin by dis-
mantling locking screw pos. 145,
next loosen adjusting screw pos.
144 with the same key.
There is only one set of screws pos.
144/145 per discharge port.
Note:
It is essential to loosen screws pos.
144 before pressing out the dis-
charge ports as described in the fol-
lowing.
On the more recent production se-
ries of SAB 163 Mk3 and all SAB
128 Mk3 the discharge ports are
adjusted by means of adjusting
screw pos. 148 and locking screw
pos. 147 as shown on the spare
parts drawing.
T4161T01_0_3
With this kind of construction start
by dismantling the blank-off screw
pos. 146 together with gasket pos.
149. Next, dismantle pos. 147 and
loosen pos. 148 with key no. 51.2.
There is only one set of screws pos.
146/147/148 per discharge port.
Note:
It is essential to loosen screws pos.
148 before pressing out the dis-
charge ports as described in the fol-
lowing.
8.1.7. Press out the outer rings of the main
bearings and the discharge ports pos.
140 and 141 by means of the tools
shown in fig 8.3. Normally, the bear-
ings should not be reused.
Notice, that O-rings pos. 152 and 154
are not mounted.
8.1.8. Remove balance pistons pos. 130 and
135 from the discharge port by hand.

66 0178-050-EN
 Fig. 8.3
2
Female 141 130 131
Male 140 135 136 3 151
8.2. Mounting
8.2.1. Before positioning the discharge ports
pos. 140 and 141 in the rotor housing,
check that they are free of burrs and
marks, in particular on the surfaces
which are going to abut on the rotor
housing.
Likewise, check the rotor housing for
similar defects on the corresponding
contact surfaces.
8.2.2. Push the discharge ports into place in
the rotor housing and tighten screws
pos. 142 and steel gaskets pos. 143.
S Begin by tightening screws pos. 142
with half the torque (see table on
torque moments) in order to make
sure that the discharge ports are in
close contact with the end surface in
the rotor housing.
Next, loosen the screws and tighten
them again slightly in order to facili-
tate the subsequent adjustment.
0178-050-EN
153
20.1 1 23.2
10 21.1
T0177135_0 V17
Next mount capacity slide pos. 200
and tighten adjusting screw pos. 148
(144) loosely in the two discharge
ports.
S While pushing capacity slide pos.
200 back and forth, tighten screws
pos. 148 (144) alternately until
the capacity slide is just moving
smoothly back and forth.
S Now fit locking screw pos. 147 (145)
and tighten with 32 Nm.
S Mount and tighten blank-off screw
pos. 146 as well as gasket pos. 149.
S Finally, tighten screws pos. 142 with
the prescribed torque.
Remember that steel gaskets pos.
143 are not to be reused but must
be replaced by new ones in order to
obtain tightness.
8.2.3. Before inserting the rotors pos. 110
into the rotor housing, it is recom-
mended that the Vi-slide pos. 190/192
is brought into position in the rotor
housing to support the rotors.
67
Fig. 8.4
Thickness Number of rings
+0 Male Female
0.01 Dia.70/90 Dia.80/100
mm mm
8
0.49 1 1
0.52 1 1
8
0.55 1 1
0.58 1 1
8 0.61 1 1
0.64 1 1
T0177141_0/V20
0.67 1 1
The rotors are marked with a number on the
end surface that faces the suction end of the In case of replacement, all bearings
compressor. must be replaced.

The marking must have the same number on
both rotors and the catching between the ro-
tors must, on mounting, be as shown in fig
8.4.
(The number 8 is given as an example).
It is also extremely important that the male
and female rotors are positioned in the rotor
housing as indicated on the spare parts
drawing and cast on the end cover pos. 20.
8.2.4. The bearing systems at the discharge
end of the compressor consist of the
following parts for each rotor:
Female
rotor
Pos.
a balance piston 130
a roller bearing 131
a special ball bearing 132
a set of adjustment ring 133
The adjustment sets consist of the fol-
lowing rings:
8.2.5. Start mounting of the bearings by
greasing the shaft ends with Molykote
grease. Then position balance pistons
pos. 130 and 135 by hand.
The balance pistons must turn in the
direction indicated on the spare parts
drawing.
8.2.6. With the tool arrangement as shown in
fig 8.5, press the inner rings of the
roller bearings into position.
Mount the roller bearings with the
bearing manufacturers marking facing
outwards.
Male On the female rotor, turn tool No. 7 as
rotor shown in fig 8.5. On the male rotor,
Pos.
135 the conical end of the tool must be
136
facing the bearing.
137 Before mounting the bearings it is a
138 good idea to lock the rotors at the op-
posite end, as shown in fig 8.1.
Tighten nut No. 23.3 with torque
wrench No. 40.2 to 70 Nm.

68 0178-050-EN
 Fig. 8.5
Female 131
1
Male 136 24.1

20.2

7 23.3

T0177135_0 V19

Fig. 8.6

Female 130 131 2 153

20.1 1 23.2
Male 135 136 3 151

10 21.1



T0177135_0 V17

8.2.7. Press the outer rings pos. 131/136 of
the roller bearing in position with tools
as shown in fig 8.6.
The factory marking must face out-
wards.
8.2.8. Press the inmost inner ring of the ball
bearing pos. 132/137 into position by
means of the same tool arrangement
as shown in fig 8.5 incl. the descrip-
tion.
Tighten nut No. 23.3 with 70 Nm. The
factory marking must face inwards.
Notice that the O-ring pos. 152/154 is
not mounted when thrust covers pos.
151/153 are used as mounting tools.

0178-050-EN 69
 Fig. 8.7
Female 133 132 8.2 153
43
Male 138 137 8.1 151
40

115

44

T0177135_0 V18

8.2.9. After removing above tool arrange-
ment, mount the following, as shown
in fig 8.7.
a: The outer rings of the ball bearings
pos. 132/137, which are inserted by
hand, and placed in the same posi-
tion in relation to the mounted inner
ring as in the original packing.
b: Tools No. 8.1 on the male rotor
and 8.2 on the female rotor and
tighten with screws pos. 115:
S 100 Nm for SAB 128 Mk2 and 3.
S 225 Nm for SAB 163 Mk2 and 3.
c: Mount thrust covers pos. 151 and
153.
d: Secure cover pos. 40 with screws
pos. 43.
e: Mount adjusting screws pos. 44 but
do not tighten.
f: Dismantle locking tools.
8.3. Adjustment of the axial clearance
of the rotors
After mounting of the bearings as described
in the previous section, the axial clearance of
the rotors can be adjusted with tool arrange-
ment fig 8.8, which is mounted on the rotor
shaft ends.
Start by adjusting the female rotor.

Fig. 8.8 30

Female rotor

31
110
24.2
52
22.6
53

22.2 Male rotor

T0177135_0 V15

70 0178-050-EN
Adjustment
8.3.1 Screw screw No. 22.6 in by hand until
tool No. 30 has the same distance to
both shaft ends as shown in fig 8.8.
Tighten screw No. 22.2 with 14 Nm,
whereby the female rotor is pressed
against the discharge port pos. 141.
The adjusting screw pos. 44 must be
loose.
Set dial meter on 0.
8.3.2 Now screw in adjusting screw pos. 44
at the female rotor and tighten with 32
Nm. Read the dial meter and note the
difference that indicates how much the
rotor can be moved axially.
a: This movement can be 0.630 mm,
for instance.
b: As the correct movement must be
between 0.05 and 0.10 mm, the av-
erage figure is 0.075 mm, which is
deducted as from the measured val-
ue, which in example a: is:
0.630-0.075 = 0.555 mm
8.3.3 From adjusting set pos. 133 select the
adjusting ring, whose thickness comes
closest to the calculated value. In this
example it is 0.55 mm. The thickness
is stamped on the rings.
8.3.4 By inserting the selected adjusting
ring as shown in fig 8.7 (pos. 133) and
repeating the adjustment mentioned in
section 8.3.2 it is made sure that the
movement remains within the men-
tioned tolerances (0.05 and 0.10 mm)
mentioned in pt. 8.3.2, and the Exact
measure is noted down for later ap-
plication (see section 8.3.10).
The exact measure for a female rotor
can, for instance, be 0.061 mm after
the adjustments in sections 8.3.3 and
8.3.4.
0178-050-EN
In order to be able to insert the adjust-
ing rings, the following must be done:
Loosen adjusting screw pos. 44
Dismantle cover pos. 40
Take out thrust cover pos. 153
Take out by hand the outer ring of
the ball bearing together with the
balls.
The remaining parts of the tool arrangement
are not dismantled.
8.3.5 After the adjustment, loosen adjusting
screw pos. 44 and dismantle cover
pos. 40, thrust cover pos. 153 and tool
No. 8.2 (see fig 8.7).
8.3.6 By means of the tools shown in fig
8.5, mount the outmost inner ring of
the ball bearing and tighten thrust
plate pos. 114 with screw pos. 115.
Tighten the screw to :
70 Nm for SAB 128 Mk2 and 3
225 Nm for SAB 163 Mk2 and 3
8.3.7 Insert the locking pin pos. 119 in the
groove in the outer ring of the ball
bearing, turning it so that the groove
faces downwards.
8.3.8 Position O-ring pos. 154 on the thrust
cover pos. 153 and fit the screw No.
22.3 on the thrust cover and lock with
nut No. 23.1.
Place thrust cover in position and turn
the screw No. 22.3 until the groove in
the thrust cover catches locking pin
pos. 119. This can be registered by
the cover being carefully pressed in-
wards during the turning, and hereby
it can be pressed in a little further
when the locking pin catches the
groove in the thrust cover.
71
8.3.9 Mount cover pos. 40 and secure with leaves a final adjustment measure
screws pos. 43. Remember that the of 0.05 mm.
adjusting screws pos. 44 must be
loose.
Exact measures Final adjustment
Adjust the male rotor in the same way as between measures
described in sections 8.3.1 to 8.3.9 by mm 1 mm 2
mounting the adjusting tools as shown in fig. 0,050-0,055 0,040
8.9. 0,056-0,060 0,045
Fig. 8.9 0,061-0,065 0,050
0,066-0,070 0,055
0,071-0,074 0,060
22.2 Female rotor 0,075-0,079 0,065
53
0,080-0,084 0,070
52 22.6
0,085-0,089 0,075
24.2 110
31 0,090-0,094 0,080
0,095-0,100 0,085
Male rotor

30 With the adjusting tools mounted as

T0177135_0 V16
Final adjustment
After both rotors have been adjusted and the
exact measures have been noted down, we
are now ready for the final adjustment of
the rotors.
8.3.10 Compare the exact measure for each
of the rotors with the measures in col-
umn 1 of the following table. Column 2
thus indicates the final adjustment
measure.
For instance, the exact measure of
0,062 mm for the female rotor will be
between 0.061 and 0,065, which
shown in fig 8.9 and the dial meter set
at 0, tighten adjusting screw pos. 44
while reading the dial meter. The dial
meter indicator must move the final
adjustment measure.
8.3.11 After this final adjustment, lock adjust-
ing screws pos. 44 with the pointed
screws pos. 45, and the adjustment of
the male rotor is now completed.
8.3.12 Then mount the adjusting tools as
shown in fig 8.8 and described in sec-
tion 8.3.1. Repeat the adjustment de-
scribed in sections 8.3.10 and 8.3.11
on the female rotor.
8.3.13 Check that the rotors are easy to turn
by hand.

72 0178-050-EN
9. Capacity indicator A: Visual capacity indicator
B: Capacity indicator with position trans-
As it appears from the spare parts drawing, mitter.
the following two types of standard systems Look at page 1 to see which system your
for capacity indication can be mounted. compressor is using.

Fig. 9.1 Magnetic coupling pos. 216

50 1 2 3 70 71

216

221
223
350

75

74

210 218 217 61 60 219 224 72 73

Magnetic coupling for capacity Flange pos. 72

indication type A and B
The rotating movement from spindle, pos.
210, see fig. 9.1, is transferred to the trans-
mitter pos. 350 through a magnetic coupling,
pos. 216, which is completely tight to both oil
and refrigerant.
Dismantling
After cover, pos. 60, has been dismantled
from slide, pos. 50, dismantle the following
parts:
S By removing screws, pos. 73, the follow-
ing parts are taken apart:
Sight glass, pos. 75, available in two
different designs, either for visual in-
dication or for mounting of transmitter.
O-ring pos. 74
Supporting ring pos. 224
S Remove screws, pos. 71, and indicator
housing, pos. 70, can be taken down.
S Dismantle indicator dial, pos. 221, by loos-
ening screw, pos. 223.
S By removing screws, pos. 219, the entire
magnetic coupling, pos. 216, can be
pressed out of the flange, pos. 60, by
hand.

0178-050-EN 73
S By dismantling circlip no. 1 the inner mag-
net retainer no. 2 and spindle, pos. 210,
can be pulled out against the magnetic
force.
S Dismantle spindle, pos. 210, by loosening
screw, pos. 218.
Assembling
Assembling of the complete unit is carried
out in reverse order to the dismantling.
Pay attention to the following, however:
S On mounting of the magnetic coupling in
cover, pos. 60, O-ring, pos. 217, must be
fitted.
S Before fastening indicator dial, pos. 221,
with screw, pos. 223, it should be posi-
tioned so that the slot points to the left and
40 below horizontal. See sketch.
Transmitter
Usage:
The position transmitter is used for remote
indication of compressor capacity. By inte-
grating electronic limit switches into the con-
trol, max. and min. compressor capacity can
be signalled, for instance.
74
40
S On mounting of sight glass, pos. 75, it
should be positioned so that the 0 mark
is right above the slot in the indicator dial,
pos. 221.
S A transmitter, if any, pos. 350, must be
fitted on the sight glass, pos. 75, so that
the electric socket faces downwards when
the 0 mark of the sight glass stands right
above the slot in the indicator dial as de-
scribed above.
S The retaining pin no. 3 of the transmitter
must engage in the slot in indicator wash-
er, pos. 221, on mounting sight glass, pos.
75.
Assembling
The following drawing shows a position
transmitter for capacity signalling and indica-
tion. The transmitter is fitted in the sight glass
with the plug facing vertically down. The
transmitter arm is turned by the indicator dial
by means of pin GT8.1, fitted in the slot of
the dial.
0178-050-EN
 Slide position 4.5 4.
Volume ratio 3.5
3. 2
100%
2.5 3
SPAN + ZERO 1

GT8.1
2.
0%

T0177063_0

Connect the position transmitter to the con- S Turn the sight glass until the 0% mark
trol system according to the following dia- aligns with the indicator dial with the ca-
gram: pacity slide in its minimum position.

S With the Zero screw adjust to the desired

Terminal Used for
minimum signal. With controls supplied by
1 Signal 0 - 20 mA SABROE, adjust to 4mA signal. One turn
2 Voltage supply with the ZERO screw changes the signal
24 V DC +/20%
to 2mA.
3 Frame OV
Not used S With the capacity slide in maximum posi-
tion, adjust the output signal to 20mA on
the SPAN screw. One turn changes the
Adjustment:
signal to 1mA.
S Turn the transmitter shaft until the output
signal is approx. 4mA. On UNISAB II the Note:
display shows 0%. Secure the arm oppo- The adjustment of the slide will affect the
site the 0% mark on the sight glass. Fit max. position of the capacity slide. The
sight glass with transmitter on the com- max. signal of the position transmitter
pressor. Make sure that the pin GT8.1 must therefore be adjusted on the SPAN
catches the slot on the indicator dial! screw after adjustment of the Vi slide.

0178-050-EN 75
Limiting the minimum capacity of the screw compressor
SAB 128H Mk3, SAB 163H Mk3

228 210,2 229 75,2

The above mentioned screw compressors, Each individual part in the system is shown
which are used at evaporating temperatures on the above drawing. Reference is made to
below 20C for refrigerant R717 or R22, are the List of Parts at the end of this instruction
fitted with a spacer ring pos. 228 which manual.
changes the minimum capacity of the com-
pressor from normally approx. 10% to: Pos. 228 Spacer ring
Pos. 229 O-ring
Pos. 210.2 Spindle
SAB 128 Pos 75.2 Glass for indicator
approx. 30%
SAB 163
Dismantling and assembly
The limitation eliminates undesirable noise in The system is dismantled and asembled as
the compressor in the start and stop periods. described in section 9 Capacity indicator, and
the spacer ring pos. 228 can be removed by
hand by catching the hole in the middle.
When the spacer ring is mounted it can be
positioned arbitrarily.

76 0178-050-EN
10. Compressor Protection System
In order to protect the compressor against
inadmissibly high pressures, it has a builton
protection valve type POV, pos. 704 which is
Fig. 10.1 Pilot valve, BSV8, pos. 700
Oil separator, condenser Condensing pressure
Functional description
The pilot valve, shown in fig. 10.1, is actu-
ated by the high pressure P1. The valve is
supplied with a stainless metal bellow . The
reference pressure in the bellow is the atmo-
spheric pressure P0. The effective area of the
bellow is exactly equivalent to the area of the
valve seating, which means that the back
pressure P2 does not affect the opening
pressure of the valve.
The main valve is a normal closed valve. The
high pressure P1 is affecting the lower side of
the valve cone propagating up through the
piston rod to the upper chamber of the
valve, producing a pressure on the piston .
The area of the piston is larger than the area
of the valve seating. Together with the power
of the spring this will keep the valve closed.
0178-050-EN
controlled by the pilot valve type BSV8, pos.
700. The protection system is shown in fig.
10.1 and described in the following:
Main valve, POV, pos. 704
Evaporator
Evaporating pressure
Compressor
When the pressure P1 reaches the set pres-
sure of the pilot valve, it will start opening.
The pressure P2 of the pilot line and of the
lower chamber of the main valve will in-
crease. The pressure of the lower chamber is
limited by flow through the nozzle . When
the flow through the pilot valve exceeds the
capacity of the nozzle, the pressure of the
chamber will increase, providing the open-
ing of the main valve. When the pressure P1
is reduced, the pilot valve will close, and the
pressure P2 is equalized through the nozzle
. The spring will then close the main valve.
The closing time is < 30 seconds, depending
on the size of the nozzle. The spring is di-
mensioned to the effect that the difference
pressure (P1-P2) of 7 bar will make the valve
open completely.
77
10.2 Dismantling the Protection System Normally, any further dismantling of the sys-
By dismantling the screws pos. 702 and 721 tem is not necessary, and we recommend not
as shown on fig. 10.2, the complete safety to disassemble the various component parts.
system can be lifted off the compressor.
Take care not to damage the O-rings pos.
703 and 722.

Fig. 10.2 5

702

703 704

3
701 700 Nipple, see fig. 10.3

2
727
730
726
732
721
725
722
4 1

10.3 Controlling the Opening Pressure and thereafter dismantling the nuts
The control of the functioning and the open- pos. 727 and pos. 730.
ing pressure of the protection system should
be carried out in accordance with the local Fig. 10.3 726

regulations and can in practice be done as

follows:

10.3.1 Isolate the compressor unit at the stop

valves and evacuate the refrigerant.
Make sure that the unit cannot be
727
started unintentionally and that there
is no excess pressure in the system. G 3/8

10.3.2 Dismantle the complete protection

system by means of the screws pos.
702 and pos. 721. Take care not to
damage the O-rings pos. 703 and
722.
10.3.3 Dismantle the pilot valve pos. 700 by
first loosening the nuts Nos. 1 and 2
10.4 Testing the Pilot Valve pos. 700
10.4.1 Normally, the pilot valve is tested in a
test bench, however, it can instead be
connected to a pressure source by
means of a high-pressure hose. The
connection nut shown as pos. 727 in

78 0178-050-EN
 fig. 10.3 has a 3/8 thread. In connec-
tion with the pressure source, a pres-
sure gauge should be used.
10.4.2 By slowly increasing the pressure,
control the following:
a: that the pilot valve stays tight until
the opening pressure is reached.
b: that the valve opens at the pressu-
re indicated on the name plate.
By opening now entirely for the air
supply, check that the pilot valve is
able to open to full lifting height.
10.5 Testing the complete Protection
System
10.5.1 For testing of the complete system,
mount the pilot valve as shown on fig.
10.2. keeping, however, still in place
the pressure hose as described in
section 10.4.1.
0178-050-EN
10.5.2 When opening now for the pressure
source, the pilot valve will open at the
pressure controlled in section 10.4.2.
This will activate the main valve pos.
704, which can be checked at a glan-
ce through the flange No. 5 fig. 10.2.
10.6 Remounting the Protection System
10.6.1 When remounting the pilot valve, it will
be a good idea to use new pipe sec-
tions pos. 701 and No. 4 and we sug-
gest also to use new fittings Nos. 1, 2,
3, and pos. 725.
10.6.2 When remounting the complete sys-
tem on the compressor, place the O
rings pos. 703 and 722 and tighten
the screws pos. 702 and 721 as pres-
cribed.
10.6.3 After filling with refrigerant, control that
the system is not leaking to the at-
mosphere.
79
Notes:

80 0178-050-EN
 Systems for regulation of compressor capacity
and Vi ratios SAB 128/163 Mk3
This section comprises the following three
systems:
1. Regulation of compressor capacity.
2. Automatic regulation of the Vi slide.
For SAB 163 Mk3 only.
3. Manual regulation of the Vi slide.
For SAB 128 and 163 Mk3.
Please see on page 1 as to which system
your compressor uses
98.05
1. Regulation of compressor
capacity
0178-057-EN
The regulating system is a complete assem-
bly as shown in fig. 1. It regulates the com-
pressor capacity by supplying or draining oil
from the capacity cylinder pos. 50 (see spare
parts drawing).
0178-085-EN
The system is connected to the oil pressure
at branch B and the oil flows back from the
capacity cylinder through branch A. Branch C
is connected to the capacity cylinder.
Two throttle valves pos. 72 are built into the
system, whereby the oil flow and, conse-
quently, also the motion speed of the capaci-
ty piston can be regulated. The purpose of
the throttle valves is to provide a regular
movement of the capacity piston, adapted to
the operating conditions.
When the spindles are turned clockwise the
oil flow is reduced.
Solenoid valves:
Pos. 70 is a normally closed valve.
Pos. 71 is normally open meaning that with
a non-energized coil it is open for passage.
81
 Fig. 1
C
A B
72
NO NC
71 74 70
Function
1. At constant capacity both solenoid valves
are closed, pos. 71 being energized
whereas pos. 70 is not.
2. When regulating to higher capacity, power
to coil pos. 70 is switched on. Thus both
coils are energized. Pos. 70 now opens
and puts oil pressure on the capacity cyl-
inder. Pos. 71 remains closed.
3. When regulating to lower capacities, the
current is shut off to both coils. Thereby,
pos. 70 closes and cuts the oil pressure to
the capacity cylinder. Pos. 71 opens and
allows the oil to flow away from the capac-
82
72
73
ity cylinder by the power from the spring
pos. 191.
4. When the compressor stops, the current it
cut to both solenoid valves. The capacity
piston is then moved to 0% position as
described under item 3, and the compres-
sor is unloaded at the next start-up.
2. Automatic regulation of the
Vi-slide
For SAB 163 Mk3 only
For regulation of the Vi slide position, the
same type of regulating system is used as for
the regulation of the compressor capacity.
0178-085-EN
This system is described in the preceding
article.
In the following function description, the sole-
noid valve in the Vi regulation system is des-
ignated as shown in the dotted frames in
fig. 1.
Pos. 73 is a normally closed solenoid valve
Pos. 74 is a normally open solenoid valve
The Vi-slide is controlled by either UNISAB II
and works as follows:
2.1 At 100% compressor capacity
S Pos. 73 is open and maintains oil pressure
on the piston of the Vi slide so that the Vi
slide pos. 190 is permanently pressed
against the capacity slide pos. 200. (See
spare parts drawing). Pos. 74 is closed.
S The Vi regulation is managed by the capa-
city regulation system which by small ad-
justments of pos. 200 adapts the Vi ratio
to the suction and discharge pressures on
the compressor. In this adjustment pos. 70
and 71 will receive signals for opening and
closing without this involving any change
of the compressor capacity.
2.2 At reduced compressor capacity
When the compressor capacity is reduced
from 100%, the following happens:
S With the UNISAB II regulating system,
pos. 74 remains closed and pos. 73
closes, which causes the capacity slide to
move away from the Vi slide leaving a gap
between the two slides.
The solenoid valves are regulated by UNI-
SAB II so that both capacity requirement
0178-085-EN
and the Vi slide position are determined
by the pressure ratio over the compressor.
S With the UNISAB II Control regulating sys-
tem, the Vi slide is moved to minimum po-
sition, depending on the pressure ratio
over the compressor. This is an integral
function of the UNISAB II Control, ensur-
ing that operation is as economical as
possible. These settings are non-adjust-
able..
At the same time the position of the ca-
pacity slide will be adjusted to the capa-
city requirement at the actual Vi-ratio.
When the compressor capacity has increa-
sed to 100%, and pos. 200 reaches pos. 190,
the regulating systems return to the function
described in paragraph 2.1.
2.3 When the compressor is
stopped
When the compressor is stopped, the current
to all four solenoid valves is cut off.
This will force pos. 74 and 71 open and allow
the two regulating slides to move to minimum
position, as they are forced away from each
other by the spring power pos. 191.
3. Manual regulation of the Vi slide
For SAB 128/163 Mk3
Instead of automatic regulation of the Vi slide
as described in section 2, regulation can be
done manually.
However, the two systems are not simul-
taneously contained in the compressor.
83

190
180
T0177135_0 V3
On the above drawing, which is a section
taken from the blue spare parts drawing, the
construction of the manual system, which
works as follows, is shown.
Function
The Vi slide pos. 190 functions as a movable
stop for the capacity slide and can thus regu-
late the discharge ports (pos.140/141) size
and hence the compressors built-in volume
ratio Vi.
The Vi slide is moved by giving the spindle
pos. 180 a predetermined number of turns.
S If the spindle is turned clockwise a lower
Vi is obtained
S Turning it counter-clockwise gives a hig-
her Vi.
84
Note:
Adjustment must only be made when the
compressor is either stopped or working at
reduced capacity.
On adjusting the Vi -slide to its max. or
min. position, do not secure it against the
end limits as this may impede the move-
ment of the capacity slide.
Consequently, on adjusting the Vi -slide to
max. or min. position, loosen the spindle
by turning it 1/2 to one turn in the opposite
direction from its extreme position.
For correct adjustment of the Vi slide
position, use the following diagrams as
explained below:
For the actual refrigerant and evaporation
temperature TE, follow the horizontal line to
the intersection with the curve for the actual
condensing temperature TC.
From this point of intersection two readings
can be made by following the line either verti-
cally up or down:
S vertically up, reading the Vi-ratio which
refers to the scale on the compressor ca-
pacity indicator. Notice, whether the com-
pressor is connected to an econo-mizer
or not.
S vertically down, reading the number of
re-volutions the spindle pos. 180 must be
turned counter-clockwise - from its ex-
treme position - in order to achieve opti-
mum efficiency at the given temperatures
TE and TC. Notice, whether or not the
compressor is connected to an economiz-
er.
0178-085-EN
Adjusting the position
of the Vi-slide 2 2.5 3 3.5 4 4.5 Vi
Volume ratio
SAB 128 Mk3 Vi Economizer
2 3 3.5 4 4.5 Vi
R22 SAB 128H
One stage
R134a TE
20
R404A/R507 R22
10
R407C R134a
Evaporating temperature

Condensing temperature
0 R404A/R507
R407C
10
TC
20
C
30 55
50
40 40
30
50 20
10
60
C 25 20 10 0

One stage
0 20 30 33 N turns by the adjusting screw
Adjustment Economizer
0 10 20 30 33 N turns
T250809

Adjusting the position

of the Vi-slide 2 2.5 3 3.5 4 4.5 Vi
Volume ratio
SAB 163 Mk3 VIi Economizer

R22 2 3 3.5 4 4.5 Vi SAB 163H

One stage
R134a TE
R404A/R507 20
R22
R407C 10
R134a
Evaporating temperature

Condensing temperature

0 R404A/R507
R407C
10
TC
20
C
30 55
50
40 40
30
50 20
10
60
C 25 20 10 0

One stage
0 20 30 40 42 N turns by the adjusting screw
Adjustment Economizer
0 10 20 30 40 42 N turns
250811

0178-085-EN 85
Adjusting the position
of the Vi-slide Vi
2 2.5 3 3.5 4 4.5
R717 - SAB 128 Mk3 Volume ratio
Vi
Economizer
2 2.5 3 3.5 4 4.5 Vi
SAB 128H
One stage
TE
20
R717
10
Evaporating temperature

Condensing temperature
0

10 TC
C
20
55
50
30 40
40 30
20
50 10
0
60
25 20 10
C
One stage
0 10 20 30 N turns of the adjusting screw
Adjustment Economizer
0 10 20 30 33 N turns
T250810

Adjusting the position

of the Vi-slide 2 2.5 3 3.5 4 4.5 Vi
Volume ratio
R717 - SAB 163 Mk3 Vi
Economizer
2 2.5 3 3.5 4 4.5 Vi
SAB 163H
One stage
TE
20
R717
10
Evaporating temperature

Condensing temperature

10 TC
C
20
55
50
30 40
40 30
20
50 10
0
60
25 20 10
C
One stage
0 10 20 30 40 42 N turns of the adjusting screw
Adjustment Economizer
250812 0 10 20 30 40 42 N turns

86 0178-085-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

Kpm 0.28 0.53 0.94 2.2 4.1 7.0 11 15 23 30 38 52 68

ft.lbf. 2.1 3.9 6.8 16 30 50 80 110 170 220 270 370 490

Nm 2.7 5.2 9.2 22 40 69 108 147 225 295 375 510 670
94.12

Metric thread (ISO 12.9)

M 4 5 6 8 10 12 14 16 18 20 22 24 27
0171-465-EN

Kpm 0.42 0.78 1.4 3.2 6.1 10 16 23 34 44 55 76 100

ft.lbf. 3.0 5.7 10 23 44 75 120 160 240 320 400 550 720

Nm 4.1 7.6 14 31 60 98 157 225 335 430 540 745 980

Connecting rods with UNF thread

HPO/CMO HPC/SMC 100 SMC 180

UNF 5/16 3/8 5/8

Kpm 2.1 4.4 17
ft.lbf. 15 32 130
Nm 20 43 167

T0177082_0

0172-133-EN 87
 Bolt on discharge valve
HPO/CMO HPC/SMC 100 SMC 180

Kpm 3.2 10.2 35

ft.lbf. 23 75 255
Nm 32 101 344

AMR A Torque (A)

Compressor type Coupling Thread
type Kpm. ft.lbf. Nm

HPO/CMO/TCMO AMR225 5/16 3.5 25 34

104-108 AMR312S 7/16 5.6 40 55

HPC/
SMC/ 112-116 AMR350S 1/2 13 95 128
TSMC
A 186-188 AMR450S 11/16 28 200 275
NORMEX
NORMEX

128 H148 M8 2.2 16 22

163 H168 M8 2.2 16 22

SAB
128 225 5/16 3.5 25 34
Series 52

163 262 3/8 4.2 30 41

Series 52 A
202 312 7/16 5.6 40 55

200 5/16 3.5 25 34

225 5/16 3.5 25 34

262 3/8 4.2 30 41

Series 52

depending
VMY on the 312 7/16 5.6 40 55
motor size
350 1/2 13 95 128

375 9/16 18 130 177

425 5/8 25 175 245

450 11/16 28 200 275

88 0172-133-EN
 Component description SAB 128/163 Mk3

In the component descriptions in this section prises wearing parts or gaskets the spare
the position numbers are the same as on the part numbers can be found in the unit spare
piping diagram. Wherever a component com- parts lists.

Oil separator

Fig. 1
Oil separator SAB 128 Mk3

A
98.05

31 B
30
0178-058-EN

34
T245755_0

Oil separator SAB 163 Mk3

A
B

31

30
34

T245754_0

The oil used in the compressor for lubrica-
tion, sealing and cooling of compressor block
is mixed with the refrigerant gas and together
they are transferred to the oil separator.
In the oil separator oil and gas are separated
and the now almost oil-free gas leaves the
compressor unit through discharge branch
pos. A.
Two filter elements separate the oil from the
gas, of which the major part is separated in
the demisters and drained to the bottom of
the oil separators on SAB 128 and down into
the separate oil vessel on SAB 163 as shown
on the schematic outlines in fig. 2.

0178-085-EN 89
Fig. 2

SAB 128 Mk3 SAB 163 Mk3

Demister Demister A
A

52
Reservoir 52 53
53

Reservoir
Fine separator element pos. 55

Fine separator element pos. 55

T245755_0 T245754_0

The remaining oil in the gas is separated in
fine separator element pos. 55 and led back
to the compressor through throttle valve pos.
52 and sight glass pos. 53. See fig. 2 and the
piping diagram at the end of this manual.
The purpose of the throttle valve pos. 52, de-
scribed in a separate section (see table of
contents), is to regulate the oil flow back to
the compressor.
The throttle valve should only be opened as
much as is required in order for the gas
bubbles to be visible in sight glass pos. 53,
and so that the pipe after the valve feels
slightly warm.
Fine separator element
Normally, it is superfluous to remove or re-
place the fine separator element, but at an
increasing oil consumption it is possible to
inspect the filter or extract it through flange
pos. B.

90 0178-085-EN
Oil level glass, pos. 31
It must always be possible to see an oil level
in one of the two oil level glasses. In case of
recharging with oil the oil level will rise
approx. 10 mm if you keep to the indicated
amounts of oil:
10 mm
SAB 128 Mk3 : 6 litres of oil
SAB 163 Mk3 : 4 litres of oil
In the table on oil charging you may see the
oil quantity for the compressor unit but it
does not include the amount of oil which is
circulating in the refrigerating plant. In R22
systems with large quantities of refrigerant
special allowance must be made for the
amount of oil dissolved in the refrigerant.
Consequently, attention must also during
the operating period after the initial start-up
be paid to the fact that the oil level may sink
rather quickly until the oil contents in the re-
frigeration system has stabilized.
Stop valve, pos. 34
Under the oil reservoir a stop valve pos. 34,
has been fitted, used for draining or charging
of oil.
0178-085-EN
Discharge stop valve and
non-return valve
Discharge stop valve:
Standard units are delivered with a stop
valve welded on the discharge branch of the
oil separator. The discharge branch of the
stop valve is made for welding connection
and has the following dimensions:
Units with the fol- Stop valve dimension
lowing compr.types mm
SAB 128
SAB 163
DN 65
DN 100
Non-return valve:
Next to the discharge stop valve a non-return
valve must be fitted in the discharge pipe
which closes tightly whenever the pressure in
the oil separator is reduced to suction pres-
sure in the unit standstill period.
The non-return valve must be positioned on
the uppermost part of the discharge pipe as
shown in fig. 3. This prevents any condensa-
tion that may have been created in the dis-
charge pipe during the standstill of the unit
from running into the oil separator during re-
start of the unit.
The size of the non-return valve must be
calculated on the basis of the current operat-
ing conditions of the unit.
Fig. 3 Non-return valve
Common discharge valve
Stop valve on unit
91
Heating rods, pos. 30

In order to keep the lubricating oil in the com-
pressor warm during a period of standstill,
the oil reservoir has one or two heating rods
built in. Before start-up, the heating rod (s)
must have been activated for 6-8 hours in
order to ensure that there is only a minimum
of refrigerant in the oil. When containing
much refrigerant, the oil will lose its lubricat-
ing property and the following operational in-
terruptions may occur:
In reciprocating compressors there is a
serious danger of vigorous oil foaming when
the compressor starts as a result of a falling
As illustrated on the drawing the heating rod
consists of an electric heating element, incor-
porated in a dia. 30 mm pipe. The entire hea-
ting cartridge is screwed on tight at the
G 1 1/4 thread.
Note:
The heating rod must not be energized if
the oil level in the reservoir is below the
minimum mark in the sight glass, and it
should generally be switched off during
compressor operation. Remember to turn
off the heating rod whenever the crank-

98.05
case of the reciprocating compressor is
suction pressure.
opened for inspection.
For screw compressors starting with much

0170-017-EN
refrigerant dissolved in the oil, there is a risk The following table indicates which heating
of the compressor being stopped by the Flow rods are used for the various compressor
Switch as the oil will be foaming owing to the types. In the spare parts lists for compressor
fall in pressure through oil pipe and oil filter. or unit you will find the current part numbers.
Marking: Prod. nr.
NV 50 Watt
G 1 1/4 Volt
Manu. date

30
30
50

L1
80 L2

Heating rods
Power Voltage L1 L2 Used for:
Watt V mm mm
270 250
270 230 CMO - TCMO - SMC 100 - TSMC 100
270 115*
158 175
460 250 HPO - HPC, SMC 180 - TSMC 180
460 230 VMY 347 /447 536
460 115* SAB 110 128 163 202 330
* Can be delivered with a UL approval.
All heating rods are executed in Degree of Protection IP54.

92 0178-085-EN
 Watercooled oil cooler type OWSG/OWRG for
screw compressors type
SAB 110, SAB128/163 Mk3, SAB 202

2 5 6
4

3
1
T0177037_0
95.10

No Used for
1 Hot oil inlet
2 Cooled oil outlet
3 Water inlet
0171-561-EN

4 Water outlet
5 Type plate
6 Air purging from water side

For cooling of the oil with water a welded
shell and tube heat exchanger can be deliv-
ered of the OWSG/OWRG type.
Design
The oil cooler consists, in principle, of a cy-
lindrical jacket with a steel tube insert.
The cooler has oil inlet and outlet sockets in
the jacket, whereas the inlet and outlet for
water are placed in one of the end covers.
The covers are made of cast iron. The tube
insert consists of two tube plates, each with a
number of tubes welded in.
Baffle plates are placed between the tubes to
extend the oils passage through the cooler,
thus causing the oil to flow across the tubes,
which significantly improves the heat trans-
mission from the oil to the cooling water.
The end covers on the cooler are formed to
guide the water back and forth a number of
times in order to ensure an adequate water
velocity.
Oil cooler type OWRG is made of stainless
steel in two versions for fresh water and sea
water, respectively. The type is indicated on
the type plate of the cooler.
Futher, the oil cooler can be manufactured
with corrosion plugs on the end covers. To
maintain the corrosion resistance of the two
types of oil cooler, it is a condition that the
pipes never become overheated. Conse-
quently, they must not be uncovered.
To avoid this, it is important that:

0178-268 93
S there are no air pockets on the water side
of the oil cooler. Therefore, the oil cooler
must be supplied with a purge valve on
top of the cover without connections. This
valve may be left out if the water dischar-
ge pipe points upwards, so that air can
escape together with the water.
S the water velocity through the oil cooler
should never be below 1.5 m/sec. Further-
more, this high water velocity prevents
fouling in the oil cooler.
In the fresh water versions, the content of
chloride (Cl-) in the water must not exceed
400 ppm.
In the case of a chlorine treatment, if any, of
water for the sea water version, the amount
of chlorine must not exceed 0.5 mg Cl2 per
litre water for 30 min. once every 24 hrs.
Besides, the oil cooler must be drained of
water for longer standstill periods (more than
1 - 2 weeks).
Application
The OWSG type oil cooler is designed for
connection to a fresh-water system incorpor-
ating anti-corrosion and anti-scaling meas-
ures.
94
When operating with a cooling tower, rust in-
hibitors, algicides and anti-fouling must be
added to the water according to normal prac-
tice in connection with cooling tower sys-
tems.
The OWRG oil cooler type is used where the
quality of the water cannot be guaranteed
satisfactory and constant.
Cleaning
Fouling or soiling of the water side of the
cooler will reduce the heat transfer, and hen-
ce the capacity of the cooler.
The cooler must therefore be checked and
cleaned at regular intervals, depending on
the degree of purity of the cooling water. The
internal pipe diameter is 8 mm.
The OWSG/OWRG oil cooler can be cleaned
by removing the end cover with no connec-
tion branches and scrubbing the piping clean
with a bronze brush.
Give the tubing a final rinse with fresh water.
Alternatively, ready-mixed inhibitive scouring
acids can be used, with subsequent neutrali-
zation. Such agents must be designed for
untreated steel tube heat exchangers. The
chemical manufacturers instructions should
be followed precisely.
0178-268
Regulating the oil temperature
Open system:
If the oil cooler is connected in an open sys-
tem, i.e. it cools by means of cooling tower
water, other fresh water or sea water, the oil
temperature must not be regulated by alter-
ing the water flow through the cooler.
A decreasing water flow will result in fouling
and perhaps in clogged-up tubes which
would lead to corrosion on the tubes.
Instead, the following is prescribed:
S If necessary, use a temperature-regulated
three-way valve to regulate the oil flow
through the cooler.
On SAB 202 the oil temperatur regulation
is based on a two-way valve incl. pilot
valve. See piping diagram.
0178-268
S Or use a temperature-regulated three-way
valve on the water side in connection with
a water pump to maintain the prescribed
water flow through the oil cooler.
Closed system:
OWSG
If this oil cooler is connected in a closed
system, such as a heat recovery system, the
water flow can still be regulated.
OWRG
Only use the mentioned oil coolers for the
prescribed water flow in order to minimize the
risk of corrosion as a result of the combina-
tion of high temperature and ClB content in
the cooling water.
Therefore, we recommend the use of the
same regulating system as prescribed under
Open system.
95
Watercooled oil cooler, type B
SAB 110, SAB 128/163 Mk3, SAB 202
2 3
5 1 4
T0177038_1
Construction
The B-type oil cooler is a stainless steel plate
heat exchanger. A V-pattern is moulded into
each plate together with the inlet and outlet
holes. The plate heat exchanger is assem-
bled by turning the V-pattern upwards and
downwards, alternately. All points of contact
between the V-patterns are copper-welded. A
supporting plate is soldered onto either side.
Between the support plate fitted with connec-
ting branches and the first heat- exchanger
plate, a row of channels is visible. By means
of a welding rod, for instance, check that the
V-pattern faces up-wards, preventing water
from accumulating here. Owing to the princi-
ple of its design, the heat exchanger cannot
be stripped down and must not be used in
R717 plants.
Application
The B-type oil cooler can only be used with
freshwater as cooling agent.
96
No. Used for
1 Hot oil inlet
2 Cooled oil outlet
3 Water inlet
4 Water outlet
95.10
0171-562EN
For water-cooling of oil in units with HFC/
HCFC a B-type soldered plate heat exchang-
er can be used. Refer to page 1 to see the
type of oil cooler used for this unit.
Cleaning
Since the oil cooler cannot be dismantled,
mechanical cleaning is not possible. It is the-
refore recommended that the water filter be
fitted before the oil cooler. Cleaning can only
be done with a cleaning fluid. The cleaning
intervals for the cooling water side of the heat
exchanger should be determined on the ba-
sis of the waters hardness and tendency to
deposit scale.
For cleaning purposes a weak acid can be
used as e.g. a 5% phosphoric acid or, if the
heat exchanger is cleaned often, a 5% oxalic
acid solution. Rinsing with plenty of pure wa-
ter is then required to remove any remaining
acid and dirt.
0178-250-EN
Oil temperature regulation
Open system
If the oil cooler is connected in an open sys-
tem, ie that it is cooled by means of water
from a cooling tower, other fresh water or sea
water, the oil temperature must not be regu-
lated by altering the water flow through the
cooler.
A decreasing water flow could lead to fouling
and perhaps clogged-up cooling pipes which
would lead to corrosion on the pipes.
Instead, the following is prescribed:
S Adjust the oil flow through the cooler by
means of the temperature regulated three-
way valve.
0178-250-EN
S Or use a temperature-regulated three-way
valve on the water side in connection with
a water pump to maintain the prescribed
water flow through the oil cooler.
Closed system
Only use the B-type oil coolers for the pre-
scribed water flow in order to minimize the
risk of corrosion as a result of the combina-
tion of high temperature and ClB content in
the cooling water.
Therefore, we recommend the use of the
same regulation system as prescribed under
Open system.
97
Refrigerantcooled oil cooler type OOSI
SAB110, SAB128/163Mk3

5 2
1 pass
1

3
6
4

2 5
2 pass
1

6 3
T0177101_0/1

97.02
1 Oil inlet 4 Refrigerant outlet
2 Oil outlet 5 Oil draining (oil side)
3 Refrigerant inlet 6 Oil draining (refrigerant side)

Construction
The oil cooler consists of a cylindrical shell
with welded-on tube plates in which is
welded a number of tubes. Each tube plate
has an end plate welded in. The oil cooler is
thus an assembled, all-welded construction.
The end plates are provided with welding
branches for oil connection and drainage.
The shell has welding branches for refriger-
ant connection, and for draining oil when op-
erating with the R717.
0171-563-EN
For cooling of the oil, liquid refrigerant from
the system receiver or a special priority tank
is fed to the oil cooler. The refrigerant partly
evaporates on the outside of the tubes, and
the mixture of liquid and gas is piped to the
condenser.
The receiver or priority tank is normally posi-
tioned at a suitable height above the oil cool-
er, thus supplying adequate refrigerant by
natural circulation. Alternatively, a pump can
be used to effect refrigerant supply.

Function Cleaning
Oil flows through the tubes, which are de- Since both the oil side and the refrigerant
signed for extremely efficient heat transfer side of the oil cooler form part of closed sys-
between oil and tube walls. tems, no cleaning will be required.

98 0178-050-EN
 Oil temperature regulating system
SAB 110, 128, 163, 202 and VMY 536

In above screw compressor units, in which The valve dimension can be read from the
the oil system is cooled by means of either a nameplate on the valve cover.
refrigerant-cooled oil cooler type OOSI or a
water-cooled oil cooler type OWSG, the oil
Function
temperature is usually regulated by a ther-
mostatic three-way valve as illustrated in Valve pos. 46 is fitted in a bypass piping sys-
fig. 1. tem as shown in fig. 2:
Fig.1

Fig. 2
To the compressor

Three-way
98.05

Oil cooler
valve
0178-277-EN

A
From oil receiver

As shown in fig. 3 and 4, it works by letting a

This thermostatic three-way valve is used in built-in thermo element, pos. 1, regulate a
the following dimensions for above-mentio- cone, pos. 2, so that cold and warm oil is
ned compressor units: mixed to the set temperature.
Compres- Valve Welded
sor unit dimension connection In fig. 3 the thermo element is shown in its
SAB 110 RT3 DN 25 cold position, i.e. the flow of cold oil has been
SAB 128 RT3 DN 25 shut off whereas the flow of warm oil is com-
SAB 163 RT5 DN 40 pletely unobstructed. Fig. 4 illustrates the op-
SAB 202 RT6 DN 50 posite situation in which the thermo element
SAB 330 RT6 DN 50 is in its warm position, hereby shutting off the
VMY 536 RT6 DN 50 flow of warm oil.

0178-085-EN 99
During operation the thermo element will ad- perature, leaving the valve through connect-
just the regulating cone modulatingly so that ing branch A.
the two oil flows are mixed to the set oil tem-

Fig. 3 Fig. 4

B B
Varm oil
from oil Varm oil
separator from oil Cooled
receiver
oil from
C oil cooler
Cooled
oil from C
oil cooler

2
1 Oil with
correct
A mixed temp.
A
Thermo element in cold position Thermo element in warm position

The thermo element is factory set to maintain
a mixed oil temperature of 48C, allowing for
a few degrees deviation and it cannot be
readjusted.
Service:
As a rule, it is not necessary to dismantle a
well-functioning three-way valve as it does
not contain any gaskets or wearing parts that
must be replaced at fixed intervals.
Dismantling:
During dismantling, if any, apply the following
procedure:
lift it up by means of a big screwdriver.
Watch out ! There may still be oil in the
system.
S The thermo element can now be extracted
from the valve housing by hand.
Assembling:
Assembling the valve is done in the reverse
order and attention should be paid to the fol-
lowing:
S The O-ring, fitted in the cover, should be
replaced by a new one. See section Spare
Parts Survey in this manual.

S After the pressure in the piping system
has been equalized to atmospheric, un-
screw the four Allen screws that keep the
cover fixed to the valve housing.
S The cover which reaches down into the
valve housing in order to keep the thermo
element in a fixed position, is most easily
dismantlled by turning it slightly and then
S No sealing ring should be fitted between
the inner guideway of the cover and the
valve cone.
S In case the three-way valve does not reg-
ulate the oil temperature correctly, the
thermo element and cone can be replaced
as one entire unit. See section Spare
Parts Survey in this manual.

100 0178-085-EN
Notes:

0178-085-EN 101
Refrigerant injection in compressor HLI
(Highstage Liquid Injection R717)
SAB 128/163Mk3

Function jection port to use as a function of evapora-

ting and condensing temperature TE/TC.
As the refrigerant vapours are compressed
from evaporator pressure to intermediate
Fig. 2
pressure, a considerable amount of heat is TC
generated, which must be dissipated in order R717

to keep the gas and oil temperature at a sui- 40

table level. This is done by injecting liquid 35
97
refrigerant from the receiver into the com-
30
pressor at a suitable stage in the compres-
sion process, controlled by a modulating in- 25
95
jection valve type TEAT. The liquid refrigerant 20
will evaporate in the hot mixture of oil and 96

96.12
15
refrigerant gas, thereby cooling the mixture.
TE
It is desirable to inject the liquid as late as 50 40 30 20 10 0

possible for reasons of compressor power
consumption. There are 2 different HLI con-
nection ports, numbered 96 and 95 on the
sketch fig. 1.
Fig. 1
0171-565-EN
T0177044_0
If operating conditions change, for example
owing to the season, and the operating point
alternates between the range for use of con-
nection port 95 and that for port 96, the latter
should generally be used.

The thermocouple, which measures the dis-

charge gas temperature above the oil bath in
the oil separator, is type A for R717 with a
working range of:

97 96 95 T0177044_0
The size of the injection valve and the tempe-
rature range of the thermocouple are chosen
according to the refrigerant, evaporating tem-
perature, condensing temperature, and coo-
ling requirement specified in the order. The
following diagrams for R717, show which in-
A: 35-65C
An economizer can be connected to the com-
pressor. An economizer is a heat exchanger
which cools the liquid refrigerant from the re-
ceiver to the plant. A minor portion of the li-
quid evaporates and is sucked into compres-
sor port no. 97; see drawing fig. 1.
The operating limit diagrams show the range
in which it is permissible to use the economi-
zer simultaneously with HLI cooling.

102 0178-050-EN
The liquid supply to the HLI system must be
tapped from a point in the installation always
certain to contain liquid refrigerant. This will
ensure that the compressor is kept cooled at
all times.
Adjustment
The injection valve is factory-set to opening
temperature at the mid-temperature range of
the thermocouple.
Before start-up of the compressor, the ope-
ning temperature of the injection valve must
be set at:
0178-050-EN
20K lower than the desired discharge
gas temperature
See Table of adjustment values and Danfoss
instructions for setting the injection valve.
Fine-adjust the valve once the installation is
in stable operation.
A thin layer of foam normally develops on the
surface of the oil in the oil separator when
operating with HLI. Vigorous foaming may
be an indication of excessive liquid supply,
in which case check that the tempe- rature of
the discharge gas is not too low in relation to
the condensing temperature! See table of
settings.
103
Throttle Valve pos. 52

It is a needle valve with an adjustment that

Fig. 1
can be varied infinitely to a steady oil flow
through the valve.
C Mount it in the pipe line so that the flow direc-
tion is the same as that of the arrow,
78.5
as shown by fig. 1.

With the handle adjust the flow of the oil, and

by means of the scale on the handle a fine
adjustment can be obtained.
B A
1/4G 1/4G
By turning the handle clockwise, the
48 velocity of the capacity slide is reduced.

95.10
By turning the handle anti-clockwise,
All dimensions are in mm velocity is increased.

The throttle valve is used for adjusting the
amount of oil flowing from the fine filter ele-
ment of the oil separator and back to the
compressor. See piping diagram in this
manual.
0178-062-EN
A locking screw Pos. C is fitted in the han-
dle which, when tightened, secures the han-
dle and consequently the adjustment.
Notice:
The throttle valve cannot be used as a
shut-off valve.

104 0178-050-EN
 Oil pump pos. 63
SAB 128/163 Mk3
The pump principle
1 2
95.10
0171-570-EN
Description
The oil pump is an internally toothed gear
pump with built-in pressure relief valve and
slide ring shaft sealing. The pump is fitted
with suction inlet facing downwards and dis-
charge connection and outlet from pressure
relief valve facing upwards. The pump is
fitted on an intermediate piece which again is
mounted on the electric motor. The electric
motor is fastened to the oil separator by
means of a small frame.
Start-up
In consideration of bearings and shaft seal-
ing, the pump may only run without an oil
flow for brief periods. On charging of oil to a
completely empty oil separator it must be
made sure that the pump is filled with oil in
accordance with the instruction: Preparations
before Start-up.
0178-050-EN
3
Service
The oil pump is designed as one unit and
should not be separated. However, the shaft
seal is regarded as a wearing part which can
be replaced in case of leaks.
If the shaft seal is going to be replaced, you
can do one of two things:
1. Drain the oil from the oil separator and
dismantle all pipe connections to the
pump. Dismantle the 2 screws that keep
the intermediate piece and the oil pump
together. The oil pump can now be pulled
out of the intermediate piece and the shaft
seal replacement can be carried out on a
workshop table.
2. Dismantle the screws between the inter-
mediate piece and the oil pump.
Dismantle the screws that keep the motor
fixed to the oil separator, at the same time
supporting the motor. The motor with the
intermediate piece can now be pulled
away from the oil pump. It may be neces-
105
 sary to dismantle the wires leading to the
electric motor in order to remove it suffi-
ciently. Now carry out the replacement of
the shaft seal with the pump still mounted
in the pipe system.
Replacement of shaft seal
The easiest way to replace the shaft seal is
to follow below procedure:
S Remove the half section of coupling and
the key fitted in the oil pump shaft.
S Unscrew shaft seal unit pos. 8, 9 and 10
from pump housing pos. 5 by means of a
pin spanner, positioned between the two
axial holes.
S After lubricating the shaft in refrigerant
machine oil, mount the carbon ring unit on
shaft and in spring pos. 7. Take care not to
106
damage the lapped surfaces on the shaft
seal parts.
S Screw shaft seal housing completely into
the pump housing. Make sure that the
spring provides the necessary tightness.
S Remount key and half-section of coupling.
S Mount oil pump on the intermediate piece
of the motor, making sure that the half-
sections of coupling engage correctly. Re-
mount pipe connections and motor.
Checking the rotating direction of
the motor
Before the initial start-up of the oil pump re-
member to check that the oil pump has the
correct rotating direction. This is done by
looking through the fan shield mounted at
the end of the motor away from the oil pump.
Seen through this shield the motor must
rotate clockwise.
0178-050-EN
Spare Parts Drawings

12 11 10

1 3 4 5 6 7 8 9

13

1. Cover
3. Shaft pin
4. Gear wheel
5. Pump housing
6. Rotor
7. Rotating shaft seal unit
8. O-ring
9. Fixed shaft seal unit
10. Bearing
11. Bearing
12. O-ring
13. Relief cylinder

0178-050-EN 107
Flow security
SAB 128/163 Mk3

Fig. 1 whenever there is no oil flow through the

housing and the power supply through the
reed switch will be interrupted. If oil passes
the float ball will lift ifself to its highest posi-
tion, hereby establishing a connection.

For compressor units with instrument

board:
Should the ball sink, hereby interrupting the
power supply, a time relay will stop the com-
pressor after 10 sec.

For compressor units with UNISAB II the

N O

95.10
N C signal is transmitted to UNISAB II, stopping
the compressor once the encoded time has
expired and after the ball has cut off the flow

0178-059-EN
T4161T010/1

connection.

For details, see the UNISAB II instruction

manual.

Note
In order to ensure a continuous lubrication of It is essential that the float valve is posi-
the compressor, the compressor block has a tioned as shown on the drawing as it will
built-in flow security which works as follows: otherwise work in the opposite direction.

The float ball contains a permanent magnet The float ball has the same text engraved as
and envelopes a pipe in which a reed switch the one shown on the drawing, and the NO
is built in. It will be in its lowest position must be facing upwards.

108 0178-050-EN
 Safety and monitoring devices
SAB 110, SAB 128/163 Mk3, SAB 202
Compressor units with relay control or termi-
nal strip for remote control are normally
equipped with the following instruments for
safety and operating control, depending on
the specific order.
Safety devices
Pos. 28 Safety valve on oil separator
with exhaust to the atmosphere.
The exhaust line must be routed
95.10
from the engine room out into
the open air.
The SAB 110 compressor has a
0171-566-EN
built-in by-pass safety valve
which, in case of too high differ-
ential pressure across compres-
sor, will lead gas from the oil
separator to the compressor
suction chamber. The opening
pressure the of safety valve is
indicated on its name plate.
Pos. 43 Flow control in the oil distributor
pipe. A spherical float with a
permanent built-in magnet is
able to actuate a reed switch in
the float guide. The switch is wi-
red up to a timing relay which
will stop the compressor if the
flow control chamber is not filled
with oil within max. 50+10 sec.
after start-up, or after 10 sec.
without oil during normal opera-
tion.
Pos. PAZ1 Pressure cut-out KP1, which
stops the compressor in the
event of the suction pressure
falling below the set value. The
0178-250-EN
pressure cut-out is not equipped
with a reset, so the compressor
starts again when the pressure
has risen above the difference
between the setpoints of the
pressure cut-out.
Pos. PAZ2 High pressure cut-out KP5. The
pressure cut-out is intended to
safeguard the compressor
against excessive discharge
pressure.
Note: On units to be approved by TV
(Germany), the KP5 is replaced
by a pressure cut-out KP 7ABS
which has been approved by
TV. This high pressure cut-out
will stop the compressor in the
event of damage to the cut-out
bellow or excessively high dis-
charge pressure.
Pos. PDAZ 11 Differential oil pressure cut-
out MP55. This pressure cut-out
is designed to ensure sufficient
lubricating pressure and oil
pressure for capacity regulation.
The pressure cut-out is equip-
ped with a time lag of 45 secs.
If the preset differential pressure
has not been obtained by that
time, the compressor will stop.
The MP55 is equipped with
manual reset.
Pos. 0376-A12
Differential pressure cut-out for
control of pressure drop across
oil filter. If pressure drop across
oil filter becomes excenssive
109
 due to impurities, the pressure
cut-out will stop the compressor
and a pilot lamp will light. Futh-
er, the differential pressure cut-
out contains a visual indication
of presure drop represented by
a green field for permissible
pressure drop and a red field in-
dicating excenssive a pressure
drop across oil filter in which
case the pressure cut-out will
stop the compressor.
Pos. TAZ12 Thermostat KP79 with sensor in
oil flow control. Designed to sa-
feguard against excessive oil
temperature.
Pos. TAZ13 Thermostat KP79 or KP81 with
sensor in oil separator.
Designed to safeguard against
excessive discharge gas tempe-
rature.
Pos. TC14 Thermostat KP77 with sensor in
oil separator. Designed to safe-
guard against too low discharge
110
pipe temperature and hence too
low oil temperature in connec-
tion with HLI oil cooling.
Please see section on setting of safety devi-
ces for various values.
Monitoring devices
Pos. 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 in
suction pipe. Supplied as extra.
Used to calculate superheat of
the suction gas. Superheat is
the temperature difference
found by deducting the tempera-
ture read off the suction pressu-
re gauge from the temperature
read off the thermometer.
0178-250-EN
 Refrigeration Plant Maintenance
Operational reliability
The prime causes of operating malfunctions
to the plant are:
1. Incorrect control of liquid supply to the
evaporator.
2. Moisture in the plant.
3. Air in the plant.
4. Anti-freezing liquid is missing.
5. Congestion due to metal shavings and
94.05
dirt.
6. Congestion due to iron oxides.
0171-464-EN
7. Congestion due to copper oxides.
8. Inadequate refrigerant charge.
Below, some information is given about ways
of keeping contaminants out of the refrigera-
ting system and at the same time facilitating
day-to-day supervision of the refrigeration
plant.
Pumping down the refrigeration
plant
Before dismantling any parts of the refrigera-
tion plant for inspection or repair, pump-down
must be carried out.
1. Open suction and discharge stop valves
on compressor.
2. Close liquid stop valve after condenser or
receiver so that liquid refrigerant can be
collected in the tank. Any solenoid valves
in the liquid line should be opened by
force, adjusting the thermostat to its low-
est position so that the liquid line can be
0171-702-EN
bled of refrigerant. Adjust any constant-
pressure valves to bring evaporator pres-
sure down to atmospheric.
3. Start up the compressor. Adjust regulat-
ing system to lower suction pressure.
4. Keep a close eye on the suction pres-
sure gauge! When the suction pressure is
equal to atmospheric, stop the compres-
sor and quickly shut off the discharge stop
valve. Shut off any stop valve in the oil re-
turn line.
If the receiver has an extra stop valve in
the feed line, this can be closed; practical-
ly the entire refrigerant charge will then
remain shut off in the receiver.
Note:
The receiver must not be overfilled! There
should be a minimum gas volume of 5%.
5. A slight overpressure should normally re-
main in the piping system - this safe-
guards the system against the penetration
of air and moisture.
6. Before dismantling parts, the operator
should put a gas mask on.
Dismantling plant
In order to prevent moisture penetrating into
the refrigeration plant during any repair work,
it is advisable to follow the rules below:
1. No component should be opened un-
necessarily.
2. When dismantling the system, the pres-
sure in the system should be a little higher
than atmospheric.
111
3. Note:
If the piping system is colder than the sur-
roundings, there is a considerable risk of
damp precipitation (condensation) on cold
plant parts. Plant components to be dis-
mantled must be warmer than the ambi-
ent temperature.
4. No two points in the system should be
opened at the same time.
5. Plug, close or at least cover opening with
oiled paper or suchlike.
6. Be aware of the possibility of filters
being very moist.
112
Tightness testing and pump-down
of refrigeration plant
Before charging refrigerant into that part of
the refrigeration plant which has been
opened, this should be pressure-tested as
described in the section entitled Pressure
testing.
Afterwards, pump down in order to eliminate
air and moisture. In this regard, consult the
section on Evacuation.
Otherwise, follow the instructions given in the
separate instruction manual on plant compo-
nents.
Note:
If the oil in the crankcase of the piston
compressor or the oil separator of the
screw compressor has been in contact
with the atmospheric air for any length of
time, it must be replaced with fresh oil of
the same grade and make.
0171-702-EN
 Troubleshooting on the Screw Compressor Plant

Operating condition Using the troubleshooting chart

Experience shows that pressure and temper-
ature variations in a refrigerant system can
provide information about the operating con-
dition of the refrigeration plant.
In particular, suction and condenser pres-
sures as well as the temperatures of suction
and discharge gases may provide important
information as to the operating conditions of
the plant.
Considerable changes in operating condi-
95.01
In the following chart each individual error
possibility is indicated by a code number in
the left hand column, with the error briefly
described in the second column. The third
column states code numbers for the possible
causes of the error.
The code numbers refer to the subsequent
chart. The section entitled Remedying mal-
functions states how to remedy the observed
error. See the following example for the cor-
rect procedure.

tions can often be produced by only very Example

slight modifications to variable pressures and Observed error: excessive suction
0171-627EN

temperatures. pressure - error code 5.

Using the following troubleshooting chart, it is
possible to ascertain the cause of and reme-
dy for any operating disturbance.
Fault Observed Fault
Code
1 Excessive suction pressure
2 Suction temperature is too low
3 Suction pressure is too low
Cause codes: 2. (compressor lacks capac-
ity) and 48. (safety valve leaky or opens pre-
maturely).The entry keys to the subsequent
section are therefore (5,2) and (5,48).
Probable causes
2, 28, 48, 49.
31, 32.
1, 14, 27, 28, 29, 30, 33, 40, 42.

4 Compressor starts and stops too frequently, at

low-pressure cut-out 1, 14, 27, 28, 29, 30, 33, 39, 42, 49.
5 Excessive suction pressure 2, 48.
6 Compressor starts and stops too frequently, at
high-pressure cut-out 38, 41, 43, 44.

7 Excessive condensing pressure 22, 23, 24, 26, 38, 41, 43, 44.
8 Condensing pressure too low 2, 22, 23, 24, 26.
9 Oil pressure too low 5, 11, 25, 31, 32.

10 Oil temperature too high 13, 18, 19, 20, 37, 48.
11 Oil temperature too low 21, 50.
12 Excessive pressure drop across oil filter 19.

13 Excessive capacity aut. controls out of order 3, 4, 12.

14 Insufficient capacity aut. controls out of order 3, 4.
15 Oil level in the reservoir falls 15, 16, 17.

16 Oil foams vigorously during standstill 31, 32.

17 Oil reservoir sweating during standstill 47, 50.
18 Abnormal noise from compressor 5, 7, 8, 9, 10, 31, 32, 48, 52.

19 Compressor motor will not start 6, 12, 13, 19, 34, 35, 36, 40, 41, 45, 46, 47
20 Compressor runs continuously 2, 3, 4, 42, 48, 49.
21 Liquid in the suction line 1, 31, 32.

0178-012-EN 113
Code Cause Code Cause

1 Compressor has excessive capacity 26 Water filter clogged

2 Compressor lacks capacity 27 Filter before valve in liquid or
3 Solenoid valve in regulating system suction line clogged
fails to open 28 Excessive suction gas superheating
4 Timer or other automatic control out 29 Freezing-up of thermostatic
of order expansion valve
5 Excessive capacity during 30 Thermostatic expansion valve has
decrease in temperature lost its charge
6 Capacity regulation not set to 0%
7 Loose foundation bolts 31 Excess flow through expansion
8 Misalignment of motor and valve (liquid in suction line)
compressor 32 Loose or misplaced sensor
9 Friction between rotors and housing 33 Solenoid valve in liquid or suction
or defective bearings line not opening
10 Loose bolts in coupling 34 Oil filter needs cleaning - pressure
cut-out has cut
11 Oil pressure regulating valve set too 35 Oil pressure too low - pressure
low cut-out has cut
12 Oil pump out of order
13 Oil too hot - oil thermostat cut out
36 Oil too hot - oil thermostat has cut
14 Too much oil circulating in system
37 Oil thermostat set too high
(evaporators)
38 High-pressure cut-out set too low
15 Filter in solenoid valve in oil-return
39 Low-pressure cut-out set too high
line clogged
40 Low-pressure cut-out shut off
16 Solenoid valve in oil return out of
order 41 High-pressure cut-out shut off
17 During initial start-up, some of the 42 Insufficient charge in plant
oil will be led out into the plant 43 Too much charge in plant
18 A valve in the oil line is being 44 Air or non-condensable gases in
throttled system
19 Oil filter clogged 45 Fuses blown
20 Insufficient water through oil cooler
21 Excessive oil cooling - oil too cold 46 Thermal relay reset
22 Insufficient water or air through 47 Main switch interrupted
condenser 48 Safety valve leaky or opening
23 Condenser tubing clogged by prematurely
sludge or scale 49 Evaporator soiled or iced up
24 Cooling water too hot 50 Heating element blown
25 Too much water through condenser 52 Liquid in suction line

114 0178-012-EN
Remedying Malfunctions

1. Excessive suction temperature

1.2 Inadequate capacity Increase capacity

1.28 Excessive superheating of suction Check and regulate thermostatic valves on eva-
gas porators
Safety valve leaky or opening pre- Check condenser pressure and adjust or repair
1.48
maturely safety valve

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 contact
with suction pipe and whether correctly posi-
tioned

3. Suction pressure is too low

3.1 Excessive capacity Reduce compressor capacity

3.14 Too much oil in evaporators Draw oil off evaporators

3.27 Filter in liquid line clogged Examine and clean filters in the liquid lines

3.28 Excessive superheating of suction Regulate expansion valves

gas

3.29 Freezing in thermostatic expan- De-ice thermostatic expansion valve with hot wet
sion valve cloths and run the liquid from the receiver
through the drying filter
Note:
Never add methanol to the system to avoid
freezing, as this will give rise to corrosion and
chemical attacks in compressor, etc.
3.30 Thermostatic expansion valve has Valve fails to open - change the valve
lost its charge

3.33 Solenoid valve in liquid or suction Coil may have blown - change the coil
line not opening

3.42 Insufficient charge Charge more refrigerant into the plant

0178-012-EN 115
4. Compressor starts and stops too frequently at low-pressure cut-out

4.1 See point 3.1

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- Adjust or repair valve

maturely

6. Compressor starts and stops too frequently at high-pressure cut-out

See point 7

7. Excessive condensing pressure

7.22 Insufficient water or air through Regulate water supply or clean condenser
condenser

7.23 Condenser tubing clogged by Clean condenser tubing

sludge or scale

7.24 Cooling water too hot Procure colder cooling water or reduce compres-
sor capacity

116 0178-012-EN
 7.26 Water filter clogged
7.38 High-pressure cut-out set too low
7.43 Too much charge in plant
7.44 Air or non-condensable gases in
system
8. Condensing pressure too low
8.2 Compressor lacks capacity
8.25 Too much water through conden-
ser
9. Oil pressure too low
9.5 Excessive capacity during
decrease in temperature
9.11 Oil pressure regulator set too low
9.31 Excess flow through expansion
valve (liquid in suction line)
9.32 Loose or misplaced sensor
0178-012-EN
Clean water filter
Adjust pressure cut-out
Draw fluid off into empty vessel
Blow air out at condenser
Check whether compressor capacity corres-
ponds to load on plant. Regulate water supply to
condenser.
Adjust water supply
Excessive capacity during temperature decrase
(run-down) may result in liquid being sucked
along in suction line. This liquid may cause the
oil in the oil reservoir to foam vigorously so that
the oil pressure drops, thus stopping the ma-
chine. Before restarting, check whether there is
liquid in the oil reservoir.
This liquid must be boiled off using a heating
element or by heating the oil reservoir with hot
water or steam. The plant must therefore be run-
down at reduced capacity.
The regulator is set to the 2.5 kp/cm prescribed
by the manufacturer, but must be checked during
operations.
See comments under point 9.5
Loose sensor on expansion valve may cause
liquid throughflow to suction line - see also com-
ments under point 9.5.
117
10. Oil temperature too high

10.13 Thermostat cut out See section Pressure and temperature settings
for setpoint.. The reason for the oil overheating
must be found in the following points

10.18 A valve in the oil line is being Check whether all valves are open
throttled

10.20 Insufficient water or refrigerant Check whether valves are open or whether
through oil cooler water filter or oil cooler need cleaning

10.48 Safety valve leaky or opening pre- Adjust or repair valve

maturely

11. Oil temperature too low

11.21 Excessive cooling of oil Regulate oil cooling

11.50 Heating element in oil reservoir Change heating element

out of order

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- Change valve or coil

tem fails to open

13.4 Timer or other automatic control Change or fix

out of order

13.12 Auxiliary pump out of order When the compressor stops, the auxiliary pump
must ensure capacity regulation is set to 0% ca-
pacity so that the compressor is ready for re-
starting.
Check whether the pump is being energized or
whether pump or motor is out of order.

14. Insufficient capacity - automatic controls out of order

14.3 See point 13.3

14.4 See point 13.4

118 0178-012-EN
15. Oil level in the reservoir falls

15.15 Filter for solenoid valve in oil-re- Clean filter

turn line clogged

15.16 Solenoid valve in oil return out of The oil return line must be hot during operation.
order

15.17 During initial start-up, some of the On HCFC plants, particularly, some of the oil will
oil will be let out into the plant circulate in the plant.
When the system is balanced, top up with oil, if
necessary.

16. Oil foaming vigorously during standstill

16.31 Excess flow through expansion Check expansion valve

valve (liquid in suction line)

16.32 Loose or misplaced sensor Check sensor positioning

17. Oil reservoir sweating during standstill

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

17.50 Heating element blown See point 17.47

0178-012-EN 119
18. Abnormal noise from compressor
If any abnormal noise is coming from the compressor, the machine must be stopped immediately,
and the cause pinpointed and remedied before restarting.

18.5 Excessive capacity during Excessive capacity during run-down may result
run-down in liquid being sucked along into the compressor
suction line. Therefore, operate at reduced capa-
city during run-down.
18.7 Loose foundation bolts Tighten bolts

18.8 Misalignment of motor and com- Adjust alignment

pressor

18.9 Friction between rotors. Do not start the compressor. Open and repair.
Friction between rotors and
defective bearings

18.10 Loose bolts in coupling Stop compressor and tighten bolts

18.31 Liquid in suction line Check and adjust the valves with excess
throughflow
18.32 Loose or misplaced sensor Check sensor positioning

18.48 Safety valve opens Check opening pressure of safety valve

19. Compressor motor will not start

19.6 Capacity regulation not set to 0% See under points 13.3-13.4 and 13.12

19.12 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-out Clean oil filter. Reset pressure cut-out
has cut
19.35 Oil pressure too low See under point 9

19.36 Oil too hot See under point 10

19.40 Low-pressure cut-out interrupted The compressor will restart after a rise in suction
pressure sufficient to re-activate the 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

19.46 Thermal relay has interrupted Check cause of overloading

19.47 Main switch interrupted Switch power on

120 0178-012-EN
20. Compressor runs continuously

20.2 Compressor lacks capacity See under point 14

20.3 Solenoid valve in capacity regula- See under point 13.3

ting system fails to open

20.4 Timer or other automatic control See under point 13.4

out of order

20.42 Insufficient charge on plant Top plant up with refrigerant

20.48 Safety valve leaky or opening pre- See point 10.48

maturely

20.49 Evaporator soiled or iced up Clean or defrost evaporators

21. Liquid in suction line

21.1 Compressor has excessive capa- Reduce capacity

city
21.31 Excess flow through expansion Adjust expansion valve
valve
21.32 Loose or misplaced sensor for ex- Check sensor positioning and rectify
pansion valve

0178-012-EN 121
Selecting lubricating oil for SABROE compressors
During the past few years YORK
Refrigeration has experienced a number of
problems with mineral oils, particularly in
R717 plants. The problems can be divided
into two groups:
a: The oil changes viscosity
b: The oil decomposes (becomes very black)
The problems have been seen with several
mineral oil brands, often occuring within a
few operating hours and resulting in severe
consequences for both compressor and
plants.
Following the careful investigation undertak-
en by YORK Refrigeration during the past
few years, it has been decided to introduce a
range of synthetic oils which can fulfil the de-
mands of modern refrigeration plants.
Mineral oils may continue to be used in re-
frigeration plants, providing the lubricating
quality is carefully monitored. For modern,
high capacity refrigeration plants, where long
lifetime for both lubricants and moving parts
is expected, YORK Refrigeration recom-
mends the choice of synthetic lubricating oils.
The application areas and specifications for
these synthetic oils can be found in the fol-
lowing pages. Installers and/or users are at
liberty to choose either YORK Refrigerations
own or alternative oil brands which fulfil the
necessary specifications.
General
This recommendation only deals with the lu-
brication of the compressor. The perfor-
mance of the lubricant in the plant (receiver,
evaporator, etc.) must, however, also be tak-
en into consideration.
122
Lubricating oils with relatively high viscosities
must be used to ensure satisfactory lubrica-
tion of refrigeration compressors.
To obtain the best lubrication, the oil must:
S Provide the required fluidity at the lowest
evaporating temperature encountered in
the plant and at the highest permissible
temperatures in the compressors.
S Provide acceptable fluidity at start-up.
S Provide sufficient oxidation stability (the oil
must be moisture-free when added to the
system).
S Provide sufficient chemical stability when
99.02
used together with the particular refriger-
ant.
In addition, the extent to which different re-
0170-151-EN
frigerants dissolve in the oil must be deter-
mined, so that the oil return systems, etc. can
be designed to function properly.
Stratification
It should be noted that in certain plants, par-
ticularly with HFC and HCFC refrigerants, the
oil may stratify into layers in the refrigerant
receivers and evaporators at certain operat-
ing conditions and at particular oil concentra-
tions.
The Oil recommendation diagrams for
SABROE compressors for HFC and HCFC
will indicate the limits for Sabroe oils at which
this stratification occurs. The oil concentra-
tions stated in these diagrams must not be
exceeded. This will enable suitable oil rectifi-
cation/return systems to be designed to bal-
ance with the compressor oil carry-over so
that the maximum concentration is not ex-
ceeded.
For area A in the diagrams, the max oil con-
centration in liquid phase must not exceed
0170-151-EN
2%. For the other area, the max. oil con-
centration must not exceed 5%. For area B:
please contact YORK Refrigeration.
Plants with several different compressor
types/makes
In plants comprising several different inter-
connected compressor types and makes, it is
strongly recommended that all compressors
should use the same type of oil. This is es-
sential where automatic oil return systems
are employed.
If it is intended to change the oil from one
type to another, please refer to the Oil chang-
ing on SABROE compressors later in this
publication.
Selecting the lubricating oil
There are a number of operating diagrams
for the selection of lubricating oils for Sabroe
compressors operating with various refriger-
ants. Once the general conditions concern-
ing the lubrication of the compressor and oil
type in the plant have been considered, the
specific plant conditions must be taken
into consideration.
Use the Oil recommendation diagrams to se-
lect the appropriate oil code number.
The oil code number consists of letters des-
ignating the oil type together with the Sabroe
viscosity grade number.
Code
Oil types
design
M Mineral oil
Synthetic oil based on
A
Alkylbenzene
Synthetic oils based on
PAO
Polyalphaolefin
AP Mixture of A and PAO-oils
E Synthetic ester-based lubricants
0170-151-EN
In the oil recommendation diagrams for each
refrigerant and compressor type, it is pos-
sible to determine the code number for the
oil best suited to the operating conditions.
With this code number, it is possible to se-
lect the correct Sabroe oil for the application.
The marked area on each side of the sepa-
rating line in the diagram shows the zone
where both oils are useable.
Oil types and oil companies
As a result of the large number of oil compa-
nies world-wide that deals in oil for refrigera-
tion plants, it is impossible for YORK
Refrigeration to test the many different
brands of oil on the market. It is our experi-
ence, however, that some oil brands during
use can change character and thus no longer
fit the specifications given by the companies
at delivery. We have thus experienced
changes in the specifications as well as in
the formula and performance without having
had any information about this from the oil
company. This makes it very difficult for
YORK Refrigeration to give a general ap-
proval of the various oil brands.
For this reason YORK Refrigeration has, in
cooperation with a large recognised oil com-
pany, developed a series of three oils which
cover most purposes. YORK Refrigeration
has however, also listed a limited number of
oils which can be supplied through YORK
Refrigeration. The typical data of these oils
can be found in the Data Sheet for Sabroe
Oils. We suggest you to use these Sabroe
oils, which are delivered in 20 litre pails and
208 litre drums and can be ordered using the
parts no. listed in the List of Oils.
It is of course possible to use similar oils from
other oil companies, and in this connection,
123
the Data Sheet for Sabroe Oils may be help-
ful.
Please note, however, that YORK
Refrigeration has not tested any other oils
than our own brand, and hence we cannot
answer for the quality, the stability or the suit-
ability of other oils for any purposes. The oil
company in question is thus solely responsi-
ble for the quality and suitability of the oil de-
livered, and if any problems are experienced
with these oils in the compressors or in the
refrigeration plant, the oil supplier should be
contacted directly.
When choosing oils from other oil compa-
nies, please pay particular attention to the
oils effectiveness in the compressor and the
refrigeration plant as a whole.
Pay particular attention to the following as-
pects:
S Oil type
S Refrigerant type
S Compressor type
S Miscibility between refrigerant and oil
S Operating data for the compressor
Discharge gas temperature
Oil temperatures:
Reciprocating compressors:
Normal oil temp. in the crankcase
50-60 C
Max. permitted oil temperature = Set-
ting point for alarm
Min. permitted oil temperatures = set-
ting point for alarm - if fitted
124
Screw compressors:
The oil temperature before injection in
the compressor, but after the oil cooler
Max. permitted oil temperature = set-
ting point for alarm
Min. permitted oil temperature = set-
ting point for alarm
Condensing pressure
Evaporating pressure
S Oil viscosity in the compressor during
operation and under the influence of:
Refrigerant type and solubility of refrig-
erant in the oil
Operating temperatures
Vapour pressure in the oil reservoir
Reciprocating compressor: Suction
pressure and oil temperature in the
crankcase.
Screw compressor: Discharge pressure
and gas temperature.
S Compatibility with the neoprene O-rings:
the aniline point gives an indication of how
the O-ring material reacts to the oil.
At an aniline point less than approximately
100C the material tends to swell, and at
an aniline point higher than approximately
120C it tends to shrink.
For this reason it is not recommended to
change oil type from M oil to PAO oil as a
leakage may occur if the O-rings are not
changed. YORK Refrigeration therefore
recommends using the Sabroe AP68 oil
as it reduces the risk of leaks considerably
in this case.
0170-151-EN
YORK Refrigeration can supply a calculation
showing the operating data on request.
Attention is drawn to the following viscosity
limits during operation:
S Optimum viscosity range
(to be designed for) = 20 to 50 cSt
S Max. permissible viscosity =100 cSt
S Min. permissible viscosity =10 cSt
(only applicable to HCFC and HFC under
cartain operating conditions: 7cSt)
S Max. permissible viscosity during the
starting of the compressor = 500 cSt
Maximum refrigerant concentration in the oil
at running condition: 25% - also if viscosity
requirements are met.
Use of mineral oil
Lately we have experienced a number of
problems with mineral oil, particularly in R717
plants. The problems can be divided into two
groups:
a: The oil changes viscosity within a few
operating hours.
b: The oil decomposes (becomes very
black) within a few operating hours.
The problems have been seen with several
oil brands and have resulted in severe con-
sequences for both compressors and plants.
When using mineral oil, it is thus important
that the plant is monitored very closely, that
oil samples are taken regularly (every
1-2,000 hours) and that the condition/colour
of the oil is checked on a weekly basis.
YORK Refrigeration therefore recom-
mends only to use M oil at moderate oper-
ating conditions - cf. the attached oil rec-
ommendation diagrams.
0170-151-EN
YORK Refrigeration is aware, however, that
several customers have been using mineral
oils for many years without problems. Those
customers who wish to continue using miner-
al oils in existing, as well as new, compres-
sors can do so, providing the compressor
type and operating conditions are similar to
the existing ones (excepting the HPC and
HPO series compressors).
YORK Refrigeration has therefore decided to
market a brand of mineral oil which has been
tested and found to be suitable for most gen-
eral refrigerating purposes.
If another brand of mineral oil is chosen, the
specifications in the data sheet in this recom-
mendation should be followed as a guideline.
Mineral oil can be used in refrigerating
plants, providing the lubricating quality is
carefully monitored. For modern, high capac-
ity refrigeration plants, in which a long life-
time for both lubricant and moving parts is
expected, YORK Refrigeration recommends
using synthetic lubricating oils.
A benefit of using the synthetic lubricant oil is
a much lower oil carry-over to the plant and
longer intervals between oil changes.
A better fluidity at lower temperatures also
gives an easier drainage at the cold parts of
the plant.
How to use the oil recommendation dia-
grams:
To determine the code number, first refer to
the Oil recommendation diagram for the re-
frigerant and compressor type and then plot
the proposed operating conditions.
125
 Example (recip. compressors): the example above, a oil code number E5
Refrigerant: R134a can be selected.
Condensing temp. TC +35C
Evaporating temp. TE 3C Code no Area no
1 2
Please observe !
E5 Y
Plants may operate at different conditions
from time to time, for example at different E9 Y
evaporating temperatures due to plant
In plants which incorporate both screw and
variations or at different condensing tem-
reciprocating compressors and where the
peratures due to seasonal changes.
recommendations indicate the use of differ-
By plotting TC and TE in the oil recom-
ent oil types, please contact YORK
mendation diagram, this example would
Refrigeration for advice.
require a No 1 oil. If, however, TE
changes at certain times, e.g. from 3 to Changing oil on Sabroe compressors
+7C, a No 2 oil should be utilised. But, as
The oil should never be changed to another
+7C is inside the marked area, the No 1
type without consulting the oil supplier. Nor is
oil can be utilised also at this TE.
it advisable to top up compressors with an
R134a other oil than the one already used for the

TC
particular plant and compressor.
F C
158 70

140 60
2
Mixing different oils may result in operating
problems in the refrigerant plant and damage
122 50


to the compressors. Incompatibility between
Condensing temperature

104 40
the different oil types may degrade the lubri-
86 30

68 20 1

cating properties or may cause oil residues to
form in the compressor or oil separator or in
50 10
the plant. These oil residues can block filters
32 0
and damage the moving parts in the com-
14 -10
pressor.
-4 -20

-22 -30 Furthermore, changing the oil from one type

-60 -50 -40 -30 -20 -10 0 10 20 30 C
or make to another should only be undertak-
TE
-76 -58 -40 -22 -4 14 32 50 68 86 F en in connection with a careful procedure in-
Evaporating temperature
volving the drainage and thorough evacua-
By referring to the Oil recommendation table tion of the refrigeration plant. Information on
placed at the bottom of each oil recommen- a suitable procedure can be obtained from
dation diagram, it is possible to select the YORK Refrigeration as well as from a num-
code number for the appropriate oil type. In ber of oil companies.

126 0170-151-EN
It is imperative that oil is only used from the
original container and that both the make and
type complies with the specification for the
plant.
Ensure that the original container is sealed
during storage to prevent moisture from the
air being absorbed into the oil - many oils,
particulary the polyolester oils, are extremely
hygroscopic. Consequently, it is recom-
mended that the oil is only purchased in con-
tainers corresponding to the amount to be
used on each occasion.
If the oil is only partially used, make sure that
it is effectively re-sealed in the original con-
tainer and that it is stored in a warm, dry
place. Ideally with nitrogen blanking of the oil
to keep the water content below 50 ppm.
Oil recommendation diagram symbols:
Y : In case of a new plant. Very suitable.
l : In case you wish to change from mineral oil
A : Max oil concentration in liquid phase at: TE: 2% W
B : Max oil concentration in liquid phase: contact YORK Refrigeration
C : Min suction temperature 50C: at TE< 50C superheating must be introduced.
* : Dry expansion systems only. Flooded systems to be considered individually: contact YORK Refrigeration
SH : Suction gas superheat, K (Kelvin)
: Zone in which both oils are useable
: Calculation must be performed using COMP1
0170-151-EN
Oil drums should, ideally, be racked and
mounted with a proper barrel tap to ensure
an effective airtight seal.
Oil changing intervals
A list of the recommended intervals for
changing the oil can be found in the com-
pressor instruction manual. These are pro-
vided for guidance only. The actual interval
between oil changes will often be determined
by a variety of operating parameters within
the plant.
It is strongly recommended to monitor the
quality of the oil by carrying out oil analyses
with regular intervals. This will also give a
good indication of the condition of the plant.
The service can be supplied by YORK
Refrigeration or the oil suppliers.
127
Data sheet for listed Sabroe oils
Typical data for lubricating oils for Sabroe compressors

Sabroe Viscosity Viscosity Spec. Flash p. Pour p. Anilin Acid no.

code cSt cSt Index grav. at COC C C mg
40C 100C 15C C point KOH/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
E3
Due to the big difference between polyolester-based lubricants from various suppliers, it is
E5
not possible to present typical data for these oils. When using another oil brand than the one
E9 recommended by YORK Refrigeration, please contact the oil supplier to select the correct
oil type.
E11

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

128 0170-151-EN
List of part numbers for available Sabroe oils

Part no.
Oil brand Oil code no.
20 litre pail 208 litre pail
Mobil Gargoyle Arctic 300 M 1 (M68) 1231-264 1231-296
Sabroe Oil A100 A 3 (A100) 1231-263 1231-262
Sabroe Oil AP68 AP 1 (AP68) 1231-257 1231-260
Sabroe Oil PAO68 PAO 3 (P68) 1231-256 1231-259
Mobil Gargoyle Arctic SHC 228 PAO 5 (P100) 1231-282 1231-283
Mobil Gargoyle Arctic SHC 230 PAO 9 (P220) 1231-284 1231-285
Mobil EAL Arctic 68 E 3 (E68) 1231-272 1231-273
Mobil EAL Arctic 100 E 5 (E100) 1231-274 1231-275
Mobil EAL Arctic 220 E 9 (E220) 1231-279
Sabroe H oil E11 (E370) 3914 1512 954 1) 9415 0008 000
1) 18.9 litre pail (5 US gallons)

The oils recommended by the former Stal Refrigeration correspond to the following oils:

Stal Refrigeration oil type Sabroe oil

A Mobil Gargoyle Arctic 300 M1 (M68)

B Sabroe Oil PAO 68 PAO 3 (PAO 68)
C Mobil Gargoyle Arctic SHC 230 PAO 9 (PAO 220)
H Sabroe H oil E 11 (E 370)

0170-151-EN 129
R717 TC
one-stage
F C
reciprocating
122 50
compressors
104 40
Condensing temperature
86 30

68 20 1

50 10

32 0

Code no Area no 14 -10

1
-4 -20
PAO 3 Y

-22 -30
AP 1 l/Y -60 -50 -40 -30 -20 -10 0 10 20 C
TE
M1 See note -76 -58 -40 -22 -4 14 32 50 68 F
Evaporating temperature

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

130 0170-151-EN
R717 TC
two-stage
F C
reciprocating
122 50
compressors
104 40
Condensing temperature
86 30
1
68 20

50 10

32 0

Code no Area no 14 -10

1
-4 -20
PAO 3 Y

-22 -30
AP 1 l/Y -60 -50 -40 -30 -20 -10 0 10 20 C
TE
M1 See note -76 -58 -40 -22 -4 14 32 50 68 F
Evaporating temperature

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

0170-151-EN 131
R717 TC
HPO and HPC
F C
reciprocating
176 80
compressors
158 70
Condensing temperature
140 60
1
122 50

104 40

86 30

68 20

50 10
Code no Area no
1 32 0
PAO 5 Y -30 -20 -10 0 10 20 30 40 50 C
TE
-22 -4 14 32 50 68 86 104 122 F
Evaporating temperature

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

132 0170-151-EN
R22 TC Contact YORK Refrigeration

one-stage
F C
reciprocating 2
122 50
compressors
104 40
Condensing temperature
86 30
1
68 20

50 10

32 0

14 -10 A
Code no Area no -4 -20
1
-22 -30
A3 Y
-60 -50 -40 -30 -20 -10 0 10 20 C
TE
-76 -58 -40 -22 -4 14 32 50 68 F
C Evaporating temperature

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

A : Max oil concentration in liquid phase at: TE: 2% W
C : Min suction temperature 50C: at TE< 50C superheating must be introduced.

0170-151-EN 133
R22 TC
two-stage
F C
reciprocating
122 50
compressors
104 40
Condensing temperature
86 30 1
A
68 20

50 10

32 0

14 -10

Code no Area no -4 -20

1
-22 -30
A3 Y -60 -50 -40 -30 -20 -10 0 10 20 C
TE
-76 -58 -40 -22 -4 14 32 50 68 F
C Evaporating temperature

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

A : Max oil concentration in liquid phase at: TE: 2% W
C : Min suction temperature 50C: at TE< 50C superheating must be introduced.

134 0170-151-EN
R134a
TC

F C
one-stage

158 70
reciprocating

140 60 2
compressors
122 50


Condensing temperature

104 40

86

68
30

20 1


50 10

32 0

14 -10
Code no Area no
-4 -20
1 2
-22 -30
E5 Y
E9 Y
-60 -50 -40 -30 -20 -10 0 10 20 30 C
TE
-76 -58 -40 -22 -4 14 32 50 68 86 F
Evaporating temperature

Y:

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

0170-151-EN 135
R134a TC

two-stage F C
reciprocating 158 70
compressors 140 60

122 50
Condensing temperature 1
104 40

86 30

68 20

50 10

32 0

14 -10

-4 -20
Code no Area no
-22 -30
1
-40 -40
E5 Y
-70 -60 -50 -40 -30 -20 -10 0 10 20 30 C
TE
-94 -76 -58 -40 -22 -4 14 32 50 68 86 F
Evaporating temperature

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

136 0170-151-EN
R407C TC
one-stage
F C
reciprocating
122 50
compressors
104 40
Condensing temperature
86 30

68 20

1
50 10

32 0

14 -10
B
Code no Area no -4 -20
1
-22 -30
E3 Y -60 -50 -40 -30 -20 -10 0 10 20 C
TE
-76 -58 -40 -22 -4 14 32 50 68 F
C Evaporating temperature

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

B : Max oil concentration in liquid phase: contact YORK Refrigeration
C : Min suction temperature 50C: at TE< 50C superheating must be introduced.

0170-151-EN 137
R407C TC
two-stage
F C
reciprocating
122 50
compressors
104 40
Condensing temperature
86 30 1
68 20 B

50 10

32 0

14 -10

Code no Area no -4 -20

1
-22 -30
E3 Y -60 -50 -40 -30 -20 -10 0 10 20 C
TE
-76 -58 -40 -22 -4 14 32 50 68 F
C Evaporating temperature

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

B : Max oil concentration in liquid phase: contact YORK Refrigeration
C : Min suction temperature 50C: at TE< 50C superheating must be introduced.

138 0170-151-EN
R404A TC
one-stage
F C
reciprocating
compressors
122 50

104 40


2

Condensing temperature
86 30

68 20

50 10 1

32 0

Code no Area no 14 -10

1 2
-4 -20
E3 Y
-22 -30
E5 Y -60 -50 -40 -30 -20 -10 0 10 20 C
TE
-76 -58 -40 -22 -4 14 32 50 68 F
C Evaporating temperature

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

C : Min suction temperature 50C: at TE< 50C superheating must be introduced.

: Zone in which both oils are useble

0170-151-EN 139
R404A TC
two-stage
F C
reciprocating
122 50
compressors
104 40
Condensing temperature
86 30
1
68 20

50 10

32 0

14 -10

Code no Area no -4 -20

1
-22 -30
E3 Y -60 -50 -40 -30 -20 -10 0 10 20 C
TE
-76 -58 -40 -22 -4 14 32 50 68 F
C Evaporating temperature

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

C : Min suction temperature 50C: at TE< 50C superheating must be introduced.

140 0170-151-EN
R410A TC
HPO og HPC
F C
reciprocating
122 60
compressors
50
104
40
86
Condensing temperature

30
68 20

10 1
50

0
32
A
-10
14
-20
Code no Area no -4
-30
1
-22 -40
E5 Y

-60 -50 -40 -30 -20 -10 0 10 20 30 40 50

TE
-76 -58 -40 -22 -4 14 32 50 68 F
Evaporating temperature

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

A : Max oil concentration in liquid phase at: TE: 2%

0170-151-EN 141
R507 TC
one-stage
F C
reciprocating
122 50
compressors
104 40
Condensing temperature
86 30

68 20
1
50 10

32 0

14 -10

Code no Area no -4 -20

1
-22 -30
E5 Y -60 -50 -40 -30 -20 -10 0 10 20 C
TE
-76 -58 -40 -22 -4 14 32 50 68 F
C Evaporating temperature

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

C : must be introduced.
Min suction temperature 50C: at TE< 50C superheating most

142 0170-151-EN
R507 TC
two-stage
F C
reciprocating
122 50
compressors
104 40
Condensing temperature
86 30
1
68 20

50 10

32 0

14 -10

Code no Area no -4 -20

1
-22 -30
E5 Y -60 -50 -40 -30 -20 -10 0 10 20 C
TE
-76 -58 -40 -22 -4 14 32 50 68 F
C Evaporating temperature

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

C : Min suction temperature 50C: at TE< 50C superheating must be introduced.

0170-151-EN 143
 R717 TC

Screw compressors F C

122 50


Condensing temperature
104 40



86 30

68 20


1

50

32
10

0

14 -10
Code no Area no
1 -4 -20
PAO 3 Y
-22 -30
AP 1 l/Y 20 C
-60 -50 -40 -30 -20 -10 0 10
TE
M1 See note -76 -58 -40 -22 -4 14 32 50 68 F
C Evaporating temperature

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

C :

:
Min suction temperature 50C: at TE< 50C superheating must be introduced.
Calculation must be performed using COMP1.

144 0170-151-EN
R22 TC

SH25
Screw compressors F C

122 50
2
104 40








SH20
Condensing temperature

86 30 SH5

68 20



1
SH10

50 10


32 0
A

Code no Area no
14 -10



1 2* SH20
-4 -20
A3 Y
-22 -30
PAO 5 Y -60 -50 -40 -30 -20 -10 0 10 20 C
TE
-76 -58 -40 -22 -4 14 32 50 68 F
C Evaporating temperature

Using the calculating programme COMP1 it is possible to optimize the requirement for suction superheat values
(SH) as stated in the diagram. See Oil types and oil companies in this section. Due to the ongoing development of
lubrication oils, please contact YORK Refrigeration for an update on the requirement for superheat.

HLI: Calculation must be performed using COMP1.

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

A : Max oil concentration in liquid phase at: TE: 2% W
C : Min suction temperature 50C: at TE< 50C superheating must be introduced.
* : Dry expansion systems only. Flooded systems to be considered individually: contact YORK Refrigeration

SH : Suction gas superheat, K (Kelvin)

: Calculation must be performed using COMP1

0170-151-EN 145
R134a TC

Screw compressors F C


SH30
158 70





140 60





SH20

122 50





Condensing temperature
104 40





2 SH10

86 30
SH5
68 20



50 10

1

Code no Area no
32 0



(See note) 14 -10
1 2 SH20
E5 Y -4 -20
E9 Y -50 -40 -30 -20 -10 0 10 20 30 C
TE
-58 -40 -22 -4 14 32 50 68 86 F
Evaporating temperature

Note: For the compressors type S, Rotatune, SAB 81, SAB 83, and SAB 85 only Sabroe oil H is approved.
Using the calculating programme COMP1 it is possible to optimize the requirement for suction superheat values
(SH) as stated in the diagram. See Oil types and oil companies in this section. Due to the ongoing development
of lubrication oils, please contact YORK Refrigeration for an update on the requirement for superheat.
HLI: Calculation must be performed using COMP1.
Y : 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

146 0170-151-EN
R404A TC

Screw compressors



F C

SH15
104 40

Condensing temperature
86 30



3 SH10
2 (3)

68 20

50 10




32 0



1
(2)

14 -10



B

Code no Area no
(See note) -4 -20

1 2 3 SH15

E3 Y -22 -30
E5 Y -70 -60 -50 -40 -30 -20 -10 0 10 C
E9 Y TE
-94 -76 -58 -40 -22 -4 14 32 50 F
C Evaporating temperature
Note: For the compressors type S, Rotatune, SAB 81, SAB 83, and SAB 85 only Sabroe oil H is approved.
Using the calculating programme COMP1 it is possible to optimize the requirement for suction superheat values
(SH) as stated in the diagram. See Oil types and oil companies in this section. Due to the ongoing development
of lubrication oils, please contact YORK Refrigeration for an update on the requirement for superheat.
HLI: Calculation must be performed using COMP1.

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

B : Max oil concentration in liquid phase: contact YORK Refrigeration

C : Min suction temperature 50C: at TE< 50C superheating must be introduced.

SH : Suction gas superheat, K (Kelvin)

: Zone in which both oils are useable

: Calculation must be performed using COMP1

0170-151-EN 147
R407C TC

Screw compressors
F
122
C
50





SH10

104 40
SH5

Condensing temperature
86 30 2

68 20

50 10



1
32 0
B
14 -10



Code no Area no -4 -20
(See note) SH5
1 2
-22 -30
E3 Y -70 -60 -50 -40 -30 -20 -10 0 10 20 C
E9 Y TE
-94 -76 -58 -40 -22 -4 14 32 50 68 F
C Evaporating temperature

Note: For the compressors type S, Rotatune, SAB 81, SAB 83, and SAB 85 only Sabroe oil H is approved.
Using the calculating programme COMP1 it is possible to optimize the requirement for suction superheat values
(SH) as stated in the diagram. See Oil types and oil companies in this section. Due to the ongoing development
of lubrication oils, please contact YORK Refrigeration for an update on the requirement for superheat.
HLI: Calculation must be performed using COMP1.
Y : In case of a new plant. Very suitable.
B : Max oil concentration in liquid phase: contact YORK Refrigeration
C : Min suction temperature 50C: at TE< 50C superheating must be introduced.

SH : Suction gas superheat, K (Kelvin)

: Zone in which both oils are useable

: Calculation must be performed using COMP1

148 0170-151-EN
R507 TC

Screw compressors



F C

104 40




2

86 30 SH5

Condensing temperature







68 20

50 10




1 SH5

32 0
SH15

14 -10

Code no Area no -4 -20

(See note) SH30
1 2
-22 -30
E5 Y -70 -60 -50 -40 -30 -20 -10 0 10 C
E9 Y TE
-94 -76 -58 -40 -22 -4 14 32 50 F
C Evaporating temperature

Note: For the compressors type S, Rotatune, SAB 81, SAB 83, and SAB 85 only Sabroe oil H is approved.
Using the calculating programme COMP1 it is possible to optimize the requirement for suction superheat values
(SH) as stated in the diagram. See Oil types and oil companies in this section. Due to the ongoing development
of lubrication oils, please contact YORK Refrigeration for an update on the requirement for superheat.
HLI: Calculation must be performed using COMP1.

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

C : Min suction temperature 50C: at TE< 50C superheating must be introduced.

SH : Suction gas superheat, K (Kelvin)

: Zone in which both oils are useable

: Calculation must be performed using COMP1

0170-151-EN 149
List of major oil companies
The oil from the companies listed below are NOT tested by YORK Refrigeration and are there-
fore NOT approved by YORK Refrigeration either. The following list reflects the information pro-
vided by the companies themselves. The assessment of durability and suitability of specific oils
for specific purposes are entirely at the companies own discretion. Oils tested and approved by
YORK Refrigeration can be found in the List of part numbers for available Sabroe oils.

Oil Oil Types

Company 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

150 0170-151-EN
Notes:

0170-151-EN 151
Alignment of compressor unit and coupling
SAB 128/163 Mk3 Coupling series 52
The following is a schematic description of
what to do in connection with the installation
of a compressor unit.
1. Alignment of compressor unit on founda-
tion.
2. Connecting electricity and refrigerant sup-
plies as well as cooling water, if any.
3. Alignment of coupling.
4. Mounting of coupling guard.
In order to assure compressor and motor a
long life and a noiseless and vibrationless
running, compressor unit and coupling need
to be aligned with care. Misalignment of com-
pressor unit or coupling may produce
stresses and vibrations which can be trans-
mitted to the compressor bearings and thus
be the cause of break-down.
Vibrations may be caused by the following:
S Distortion between compressor unit and
foundation.
S Distortion between compressor and base
frame.
S Distortion between motor and base frame.
S Strains from pipe connections between
compressor and plant.
152
S Incorrect alignment of coupling between
compressor and motor.
S Untruth in compressor or motor shafts.
S Untruth in coupling.
S Imperfect balancing of coupling.
S Imbalance in compressor and motor.
The fitter who sets up the unit is responsible
for the points up to and including the align-
ment of the coupling. The other points must
be checked by the compressor or motor
95.10
manufacturer prior to delivery.
The following sections will deal with the indi-
0178-055-EN
vidual points concerning the fitter.
1.0 Alignment of unit on
foundation
When installing the unit on the foundation or
the machine floor, the unit must stand free
from stress and be even on all supports.
The unit can be installed as follows:
S on vibration dampers,
S directly on foundation, with foundation
bolts.
In both cases the unit must be aligned be-
fore fitting the connecting pipes to the instal-
lation.
0178-050-EN
1.01 Fitting of vibration dampers

Fig. 1

Industrial type

A1 A2
H H max.

Marine type

A1
A2

T0177040_0

Depending on whether the compressor unit is kept within the ajustment measures stated on
to be used on land or on board a ship, the the drawing submitted.
vibration dampers shown at the top or bottom
To make each individual vibration damper
of fig. 1 are included in the supply.
function properly, it must be sufficiently
The purpose of the vibration dampers is to loaded. Measure A1 and H in an unloaded
damp the propagation of vibrations from the and A2 in a loaded situation.
compressor unit to the foundation. In addi-
tion, the marine vibration dampers serve to Industrial Marine
type 1 type 2
cushion vibrations from the foundation to the
compressor unit, at the same time securing
Flexion min 1,0 min 3,0
the unit on its foundation.
A1-A2 max 2,0 max 5,0

It is extremely important that the vibration Height adjustment H = H+12

dampers be fitted correctly, as shown in the
filled in drawing forwarded to the customer or
the distributor. This drawing is valid only for
the unit in question.
When using vibration dampers, it is a condi-
tion that the foundation possesses the neces-
sary bearing strength and is level so that the
adjustment of the vibration dampers can be
max
All measures are in mm
The flexion of the industrial type is adjusted
by increasing or reducing the load in propor-
tion to the other supports. The foot can be
raised by screwing the adjusting spindle
down, thereby increasing the load and hence
also the flexion.

0178-050-EN 153
Vibration dampers of the marine type are
not adjustable. Therefore, it is essential that
the foundation is even within a max. devi-
ation of 2 mm.
If the foundation is not even within max. 2
mm, line under the vibration dampers until
the prescribed flatness is obtained.
Once the plant has cooled down, check dur-
ing operation that the flexion of the dampers
is still correct!
1.02 Mounting directly on the
foundation
When mounting directly on a foundation with
embedded foundation bolts, it must be care-
fully checked that all 4 legs are stable. Alter-
natively, liner plates must be used in order to
avoid distortion of the compressor unit.
1.1 Alignment of compressor
against base frame
Since the compressor stands on a three-
point fixture there is no risk of distorting the
compressor housing.
Check that all screws are properly tightened.
1.2 Alignment of motor against
base frame
Check that the motor stands with all feet on
the base frames milled off surfaces. Make
sure that all surfaces are clean and free from
burrs.
Perform this check with the fixing bolts loos-
ened. If there is a slip at one or more resting
surfaces, line up before securing. If this is not
done, there is a risk that the motor will be
submitted to stresses which will damage the
bearings.
154
Besides, coupling alignment becomes con-
siderably easier when there is no distortion
between the electric motor and the founda-
tion.
2.0 Making various connections
Connect the compressor unit to refrigerant
and electricity supplies as well as to cooling
water, if any.
Pipes which are exposed to sizeable temper-
ature fluctuations must be laid so as to allow
deflection at appropriate points. This will en-
sure that no excessive forces are transmitted
to the compressor and the unit. Enclosed
pipes may give rise to very large strains, for
instance in connection with temperature
changes from installation temperature to op-
erating temperature.
Once the installation has cooled down, check
the vibration dampers on the compressor unit
for correct flexion.
In Fig 2 is shown a rigid and unacceptable
piping (1) and a more flexible one (2).
Fig. 2
> 1.5 m
1 2
T0177057_0
0178-050-EN
With the coupling intermediate section dis-
mounted, check that the rotating direction of
the compressor motor is correct as shown by
the cast arrow on the suction cover above
the rotor shaft.
Large motors can be lifted with the screws
supplied as shown in fig. 3.1 for insertion of
liner plates. The clamps shown in fig. 3.2 are
used for sideways shifting of the motor.

3.0 Alignment of coupling between Fig. 3.1

compressor and motor

When the suction and discharge pipes are
connected to the unit, align compressor and
motor so that the two shafts are placed end
to end.

The mounting of the two types of coupling is

described in the following section and the
alignment procedure is the same for both
couplings. Fig. 3.2

Auxiliary tools for coupling

alignment
Four clamps with adjusting screws are
supplied with each unit as shown in
fig. 3.2, as well as four sets of liner plates.

Each set consists of:

T0177059_0

No. Thickness (mm)

1 3,0 Further, an alignment tool and a feeler gauge
2 1,0
3 0,25 are delivered for alignment of the coupling as
2 0,15 shown in fig. 8.
2 0,10

0178-050-EN 155
Mounting of Series 52 coupling
Series 52 is a coupling of the flexible disc
type which is torsionally stable and as such
does not cause any torsional fluctuations be-
tween motor and compressor.
The flexible discs and the intermediate
section provide the coupling with the neces-
sary radial and axial flexibility to absorb
the minor radial and axial displacements
between motor and compressor.
These displacements occur as a conse-
quence of the heat and power impacts
during operation.
Mounting
Assemble coupling as shown in fig. 4 and
mount it on the compressor and motor shafts
as described in the following:
S On mounting, pay attention to the mea-
sures C and E in the table below fig. 4.

Fig. 4

C
T0177120_0/V1

Compressor Coupling Bolt dimension C E

type type spanner mm mm

SAB 128Mk3 225 1/2 14 0.5

127 0.5
SAB 163 Mk3 262 9/16 +1.0
10 0

S Before mounting the coupling flange on Next, lubricate all parts in a little of the re-
the compressor shaft, clean coupling frigerant machine oil. Do not lubricate with
flange, the individual parts in the bushing Molybdndisulfid, high-pressure oil or
and the rotor shaft. grease.

156 0178-050-EN
S Assemble bushing as shown in fig. 5 and
loosen screws pos. 1 1 turn.
Fig. 5 1 then with Ms as indicated in the following
In the dismantling holes with thread mount
some of the screws pos. 1 as shown in fig.
6 and adjust by hand so that the surfaces
are even as indicated
by the mark .
Fig. 6
1
Next mount the bushing in the coupling
flange and push it right to the bottom as
shown in fig. 7 marked . crosswise until the two taper rings have
Fig. 7
S Remove screws from the dismantling
holes and remount in the bushing as
shown in fig. 5. Tighten screws by hand.
0178-050-EN
S By means of the torque key tighten all
screws pos.1 crosswise by first tightening
with half the torque moment of Ms and
table:
Torque moment Ms
Compressor Screws pos.1 Torque
type number x dim. moment
Ms [Nm]
SAB 128 Mk3 8 x M6 15
SAB 163 Mk3 8 x M8 35
Repeat the tightening with torque moment
Ms crosswise until none of the screws
can be turned any more.
Dismounting of coupling flange
On dismounting the coupling flange from the
compressor shaft apply the following proce-
dure:
S Loosen screws pos. 1 a few turns.
S Mount screws pos. 1 in the dismantling
holes as shown in fig. 6 and tighten evenly
been pressed apart and have loosened
the coupling flange from the shaft.
S Now take out coupling flange with bushing
by hand.
It is recommended to press on the coupling
flange on the motor by means of a threaded
rod with nut and tightening bar.
If the coupling flange is knocked on, this
may cause damage to the bearings.
Fasten coupling flange to the motor shaft
with pointed screw and tongue connection.
157
In case the coupling is delivered unbored
because of the motor being unknown at the
time of delivery, the coupling flange must be
balanced acc. to VDI 2060 Q 6.3 to a max. of
3600 rpm without tongue, but with the
pointed screw.
Dismantling of coupling
On dismantling the coupling it is important to
note the position of bolts, washers, and nuts
as they must be fitted again in the same or-
der. Tie a string or a piece of thread through
one of the bolt holes in the coupling discs in
order to avoid that the plates are turned in
relation to each other and in relation to the
flange.
158
Mounting
S Mount the two coupling parts, motor
flange F and compressor flange G as
described earlier. See fig. 8.
Pay attention to the measure E as shown
in fig. 4.
S Mount motor and compressor and secure
to the base frame as described in sections
1.1 and 1.2
Check distance C as shown in fig. 4.
S Mount the coupling intermediate sections
and the two flexible discs and secure with
the bolts as shown in fig. 8. The torque
moment is shown in the table below fig. 8.
However, do not mount the bolts that se-
cure the flexible discs to the motor flange
until the alignment has been completed.
0178-050-EN
Alignment procedure indicated in the table below fig. 8.

The series 52 coupling is aligned as de- In principle, the alignement is a question of

scribed in the following, and the accuracy moving the motor so that its shaft is placed in
whereby the coupling must be aligned is continuation of the compressor shaft.

Fig. 8 1

Z 2

X
a

F
H
G C
T0177120_0/V1

Max. variation at 180 rotation

Coupling Diam. Distance Torque Pos. 1 Pos. 2

No A C moment Horizontal Vertical
mm mm Nm mm mm mm

225 145 34
127 0.5 0 0.05 0 0.10 0 0.10
262 168 41

0178-050-EN 159
Parallel shafts on a horizontal level
1. Turn the coupling so that the alignment
tool is in top position.
2. Guide measuring pin (pos. 2) towards the
coupling flange with a 1 mm feeler gauge
in between and secure the pin.
Remove the feeler gauge.
3. Turn the coupling 180. Motor and com-
pressor are turned at the same time. Mea-
sure with feeler gauges how much the dis-
tance from measuring pin to coupling part
has changed. The change is called X.
4. Measure the distance b between the mo-
tors feet, as shown in fig. 9. Measure the
distance a from the middle of pin 2 to the
centre line of the motor as shown in fig. 8.
5. Insert liners with thickness Y either under
both front feet or both rear feet, tilting the
motor at the desired end. Use the follow-
ing formula for calculation of the liner
thickness:
b 1. Turn the coupling so that the alignment
Y=X 2a
Fig. 9
y original one millimeter on both pins.
b
T0177056_0
6. After having tightened the motor bolts, re-
peat the measuring and compare the re-
sult with the table values.
160
Parallel displacement to correct
centre height
1. Turn the coupling so that the alignment
gauge faces downwards.
2. Guide the measuring pin pos. 1 towards
the coupling part with a 1 mm feeler
gauge in between. Secure the pin and re-
move the feeler gauge.
3. Turn the coupling 180 and measure with
feeler gauges how much the distance has
increased.
The increase is called Z.
4. Then lift the motor by placing liners with
half the thickness. i.e. Z/2 under all four
feet.
5. After securing the motor, repeat the mea-
suring and compare the result with the
table values.
Parallel shafts on a vertical level
gauge faces horizontally out to one side.
2. Move both measuring pins towards the
coupling with a 1 mm feeler gauge in be-
tween. Lock the pins and remove the feel-
er gauges.
3. Turn the coupling as close to 180 as al-
lowed by the cap cover and measure with
feeler gauges the deviations from the
4. Moving and turning the motor sideways
with the adjustment screws and repeating
the measuring, align the motor in accor-
dance with the table.
Remember that the motor must be se-
cured during each measuring.
0178-050-EN
Final installation
1. Tighten the fixing bolts on the motor.
2. Dismantle the alignment tool.
6. Recheck the coupling with a compressor
still warm from operation and with pres-
sure on pipe connections.

3. Mount bolts between the flexible discs and Fig. 10

the coupling flange of the motor. Tighten
all bolts with the torque moment as indi-
cated in the table below fig. 8.

4. Check distance C.

5. Once the coupling alignment has been

carried out correctly, fit the outer shell of
the coupling guard on the adaptor plate
which is secured on the compressor shaft
seal cover.

Push the outer shell, which is placed in- T0177045_0

side the inner shell, so far towards the

driving motor that access to the rotating
parts is made impossible. See fig. 10.

0178-050-EN 161
Key to Piping Diagrams

PT1 Pressure transducer PDAZ10 Oil pressure difference cut-out

(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
(oil pressure - discharge pressure)
PDAZ11 Oil pressure difference cut-out
(oil pressure - suction pressure) -
for classified systems only
TAZ12 Thermostat
(oil temperature in manifold)
TAZ13 Thermostat
(discharge gas temperature)
TC14 Thermostat
(pilots solenoid valve pos. 82)

99.11
PI15 Suction pressure manometer
(discharge gas temperature)
PI16 High-pressure manometer
TT6 Temperature transducer

0171-575-EN
(oil temperature in flow control) PDI17 Oil difference manometer

TT7 Temperature transducer FT18 Level switch

(suction gas temperature) 19 Compressor safety valve
GT8 Position transmitter (capacity 20 Suction stop valve
slide) 21 Non-return valve
GT9 Position transmitter (Vi slide) 22 Flanged joint discharge pipe -
PAZ10 Safety pressure cut-out compressor
(for TV, SDM and SA only) 23 Suction filter built into compressor
PAZ1 Low-pressure cut-out 24 Service valve - air purge valve
(only for classified systems) 25 Oil separator
PAZ2 High-pressure cut-out 26 Non-return valve in outlet pipe
PDAZ3 Differential pressure cut-out from oil separator
(pressure drop across oil filter) 27 Stop and non-return valve in out-
TI5 Thermometer let pipe from oil separator
(discharge gas temperature) 28 Safety valve - the unit
TI6 Thermometer (oil temperature) 29 Change-over valve for double
safety valve
TI7 Thermometer (suction gas tem-
perature) - only if specially or- 30 Immersion heater in oil separator
dered 31 Oil level indicators (2 pieces)
GT8 Position transmitter 32 Oil cooler OOSI (refrigerant-
(capacity slide) cooled)

162 0178-085-EN
33 Oil cooler (water-cooled) 60 Stop valve
34 Stop valve for oil purging (oil side) 61 Oil filter
35 Stop valve for oil purging 62 Oil charging valve
(refrigerant side) 63 Oil pump
36 Oil outlet branch to oil cooler/filter 64 Stop valve for air purging of pump
37 Oil branch to pump suction end 65 Stop valve
38 Stop valve before oil filter 66 Non-return valve for oil charging
39 Oil filter 67 Solenoid valve (NC) - open during
40 Oil inlet from pump prelubrication

41 Non-return valve built into oil filter 68 Stop valve

42 Stop valve after oil filter 69 Non-return valve

70 Solenoid valve (NC) - capacity
43 Combined flow control and
regulation min. > 100%
oil distributing manifold
71 Solenoid valve (NO) - capacity
44 Check valve, rotor lubrication
regulation 100 -> min.%
45 Nozzle in injection pipe
72 Throttle valve for regulation of
46 Thermostatically-controlled 3-way slide velocity
valve for oil temperature
73 Solenoid valve (NC) - capacity
regulation
regulation min. > 100%
47 Service valve for oil drainage
74 Solenoid valve (NO)
48 Oil purge valve on oil filter
75 Non-return valve
49 Thermostatic water valve for
76 Three-way non-return valve
water-cooled oil cooler
80 Stop valve
50 Stop valve
81 Liquid refrigerant filter
51 Oil filter
82 Solenoid valve (NC)
52 Nozzle/throttle valve
TC83 Liquid injection valve TEAT
53 Oil level indicator
84 Stop valve
54 Stop valve
90 Oil supply to bearings at
55 Oil separation element discharge end
(fine separation)
91 Oil supply to shaft seal and bear-
56 Non-return valve ings at suction end
57 Hand-regulated valve 92 Oil injection in compressor
58 Temperature regulated main valve 93 Oil return from capacity regulation
59 Oil receiver 94 Oil to and from regulating cylinder

0178-085-EN 163
95 Liquid supply for HLI cooling 127 Stop valve
Vi 4.0
128 Stop valve
96 Liquid supply for HLI cooling 129 Solenoid valve (NC)
Vi 2.6
130 Stop valve
97 Economizer connection
131 Stop valve
98 Oil connection from flow switch
132 Liquid filter
99 Oil to and from Vi regulation
140 Stop- and non-return valve
(only by auto-Vi)
141 Main valve
100 Oil return from fine oil separator
142 Pilot valve
101 Bypass throttle valve at suction
stop valve 143 Solenoid valve
144 Stop valve
102 Non-return valve
145 Float valve
103 Stop valve
147 Liquid filter
104 Nozzle
148 Stop valve for oil purge
105 Flow switch
149 Non-return valve
106 External oil filter
150 Stop valve
107 Oil filter for units with full flow
151 Safety valve
oil pump
152 Solenoid valve
108 Oil regulating valve
153 Stop valve
110 Stop valve
154 Stop valve
TC111 Thermostatic valve
160 Stop valve
112 Solenoid valve (NC)
200 Gas-powered stop valve
113 Liquid filter
201 Solenoid valve (NC)
114 Stop valve
202 Stop/non-return valve
115 Stop valve for oil purge
203 Non-return valve in discharge pipe
116 Economizer vessel
204 Stop valve after oil separator
120 Stop valve 205 Filter
122 Main valve 206 Nozzle
123 Solenoid valve (NC) 207 Solenoid valve (NO)
124 Stop valve for oil drainage 208 Solenoid valve (NC)
125 Safety valve FT209 Oil level switch in oil separator
126 Float valve 210 Non-return valve

164 0178-085-EN
211 Stop valve 223 Brake motor for capacity slide
212 Service valve - air purge valve 224 Three-way solenoid valve

213 Non-return valve 225 Oil return pump

214 Filter 226 Solenoid valve for baby slide (NC)

215 Non-return valve (5 bar) 227 Quick closing oil drain valve

220 Compressor protecting valve Note:

(main valve) On units supplied without valves the
bracketed figures near the branches refer
221 Compressor protecting valve
to the component numbers in this list.
(pilot valve for pos. 220)
These components are to be fitted by the
222 Filter in economizer pipe customer.
connection

0178-085-EN 165
Ordering Spare Parts
When placing an order for spare parts,
please state the following:
1. Shop No.
All compressors are fitted with an identifica-
tion plate, which states the type and shop no.
of the compressor and indicates what refrig-
erant is to be used.
2. Part No.
Spare parts drawings and parts lists inserted
in an instruction manual identify spare parts
with the following:
a) Spare part no. which is a reference
number to facilitate finding a part in the
drawing and cross-referencing in the parts
list or vice versa.
b) Designation of the part.
c) Part no. a 7-digit number which refers to
SABROEs stores.
When you order spare parts, please always
advise at least the designation and part num-
166
ber. If you are in any doubt, add the spare
part no. too.
3. Forwarding instructions
When ordering spares, please advise the for-
warding address, and the address to which
the invoice should be sent. If appropriate,
please state the name of your local bank, the
way in which you want the goods transported
and required delivery date.
4. Classification certificate
94.05
If you require a certificate from a Classifica-
tion authority, please mark the order
appropriately, as the inspection and issuing
0171-466-EN
procedures take extra time and incur extra
expenses.
5. Quotation No.
If a quotation no. has been given during earli-
er correspondence, please refer to this when
placing your order it will help us to identify
and execute your order quickly.
0178-925-EN
 Spare Part Sets for screw compressor and unit
Types: SAB 110 128 163 202 VMY 347/447 and
VMY 336436536

It is always an advantage to have a stock of spare parts for both compressor and unit. In this
way the customer or a SABROE service engineer is able to carry out the necessary replace-
ments without wasting time while waiting for new spare parts to arrive.

On contacting SABROES local representative you may receive specifications for the follow-
ing spare part sets for compressor and unit.

Compressor block: Safety valve:

S Standard set of spares Gaskets, cone, O-rings
This set contains a representative select- Oil by-pass system:
ion of O-rings and gaskets. Gaskets, teflon ring

S Certificate set of spares Oil pump:

98.03

Besides the parts from the standard set O-rings

of spares this set further includes all S Certificate set of spares:
0171-945-EN

bearings as well as shaft seal. Further to the parts contained in the stan-
dard set of spares this set also includes
Basic Unit: spare parts for the below-mentioned com-
S Standard set of spares: ponents:
This set includes the following spare parts Coupling:
for the below-mentioned components: Screws and discs
Oil separator: Oil separator:
O-rings, gasket Sight glass, oil separator element,
heating element
Service valves:
Gaskets, O-rings Capacity regulating system:
Solenoid valve
Capacity regulating system:
Gaskets, O-rings Safety valve:
Spring
Pressure outlet stop valve:
Gaskets Solenoid valves:
Coils
Suction Inlet stop valve:
O-rings, sealings rings, gaskets, Oil pump:
teflon ring Shaft seal, filter

0178-085-EN 167