SAB - 202 - EN Instruction Manual

Instruction Manual
SAB 202
Screw Compressor Unit
0178-251-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
99.10
Instruction manual
for
SAB 202
The screw compressor and the unit may

differ in equipment, depending on their
functions and requirements.
Part of these variants are treated in this
instruction manual although they may not be

fitted on your particular unit.
In the below table the x-mark indicates
which variants are fitted on your particular
unit with shop no stated below.
Type of drive
Male drive
Female drive
Refrigerant
R717
R22
Other_________
Shop no
Designation
Transducers and manual regulation of Vi slide
Instrumentation
UNISAB II and manual regulation of Vi slide

UNISAB II and automatic regulation of Vi slide
Internal
Oil filter
External
Oil cooling
Water-cooled oil cooler
Type B
Water-cooled oil cooler
OWSG/OWRG
Refrigerant oil cooler

Oil separator
OOSI
With 1 discharge valve

With 2 discharge valves
Oil temp.reg.
Thermostatisc oil valve

PM3 Main valve
Ex-execution
0178-250-EN
Both compressor and unit are
safeguarded
Preface
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
To prevent accidents during dismantling and

assembly of compressors and components,
these should only be carried out by
authorized personnel.
The contents of this instruction manual must
not be copied or passed on to any
unauthorized person without Sabroes
permission.
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
Phone:
Telefax:
+45 86 27 12 66
+45 86 27 44 74
0171-702-EN
96.06
S the function and maintenance of the

individual components;
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.
0171-500-EN
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:
Table of Contents
Preface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Table of Contents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Description of SAB 202 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Handling of the compressor, areas of application,

safety equipment and symbols, safety at servicing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
11
First Aid for accidents with Ammonia . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
15
First aid for accidents with HFC/HCFC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
16
Protecting the operator as well as the environment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
17
Sound data for reciprocating and screw

compressor units all types of compressors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
20
Vibration data for compressors - all types . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
24
Data for SAB 202 compressor & unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Type of compressor unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
25
25
Compressor data SAB 202 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
26
Compressor and unit operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
30
Service Schedules for screw compressors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Assessing the oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
34
39
Major Service Intervals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
42
Oil charging, weight and shipping volume . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
43
Temperature and pressure settings SAB 202 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Table 1 Screw compressors Measured and calculated pressures . . . . . . . . . . . . .
Table 2 Screw compressors Measured and calculated temperatures . . . . . . . . . .
44
44
45
Servicing the refrigeration plant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
47
Maintenance of compressor SAB 202 Dismantling and assembly . . . . . . . . . . . . . . . . .

Oil filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Suction filter and compressor protecting valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Non-return valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Shaft seal, balancing piston and cap cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Thrust cover and regulating cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Regulating slide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Slide stop for Vi regulation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
49
50
52
56
57
59
60
61
Position transmitter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
64
Magnetic coupling for Vi-indication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Suction cover and bearings at compressor shaft end . . . . . . . . . . . . . . . . . . . . . . . . . . .
Rotors and bearings at compressor discharge end . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Capacity indicator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
65
66
68
75
Transmitter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
77
System for regulating the capacity and the Vi-ratio of SAB 202 . . . . . . . . . . . . . . . . . . . . .
79
Torque moments for screws and bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
85
0178-250-EN
Oil separator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
87
Water-cooled oil cooler type OWSG/OWRG for screw compressors . . . . . . . . . . . . . . . . .
90
Refrigerant-cooled Oil Cooler type OOSI . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
93
Water-cooled oil cooler, type B . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
95
Oil temperature regulating system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
97
Heating rods for heating the oil in reciprocating and screw compressors . . . . . . . . . . . . .
100
External oil filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
101
Oil pump pos. 63 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
103
The oil pump filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
106
Safety and monitoring devices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
107
Refrigeration Plant Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
109
Troubleshooting on the Screw Compressor Plant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Remedying Malfunctions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
111
113
Selecting lubricating oil for SABROE compressors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
120
Alignment of VMY/SAB 202 unit and coupling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
149
Key to Piping diagrams for screw compressors type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
157
Ordering Spare Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
161
Spare Part Sets for screw compressor and unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
162
Spare parts drawing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
0661-855
List of parts for SAB 202 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
0661-856
Spare parts survey for SAB 202 unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
0661-853
Tools for compressor SAB 202 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
0661-854
Piping diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
order specific
Wiring diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
order specific
Dimension drawings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
order specific
Placing the vibration dampers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
order specific
Instructions for control and regulating equipment . . . . . . . . . . . . . . . . . . . . . . . . .
order specific
0178-250-EN
0178-253-EN
96.12
Description of SAB 202

The SAB 202 compressor is a capacity
adjustable screw compressor with oil
injection.
pressor from running backwards whenever

the power to the driving motor is
disconnected.
The two rotors are equipped with 4 lobes

(male rotor) and 6 lobes (female rotor),
respectively, executed with asymmetric
profile according to SRM licence.
The driving shaft is fitted with a shaft seal of

the slide ring type, consisting of a fixed cast
iron ring with an O-ring sealing against the
shaft seal cover and a rotating springloaded
carbon ring with O-ring sealing against the
shaft.
As indicated on the spare parts drawing at

the end of this manual, the rotors at the
suction end are fitted with slide bearings,
whereas the bearing at the discharge end
consists of a combined bearing set with slide
bearings, absorbing the radial load, and ball
bearings, absorbing the axial forces. The
axial forces are partly relieved by means of
the rotating balance pistons mounted on the
rotors.
The rotors are designed for both male drive
and female drive. The driving rotor is fitted
with a shaft.
The compressor is fitted with a large built-in
suction filter, which effectively prevents dirt
particles from the refrigeration plant from
being led with the suction gas into the compressor.
The suction filter housing also has a built-in
compressor protection valve which - controlled by a pilot valve - safeguards the compressor against any unwanted high
compression pressures.
For efficient filtration of the oil that lubricates
the bearings in the compressor, an oil filter
cartridge has been inserted in the compressor block.
Furthermore, the compressor contains a
built-in non-return valve, preventing the com-
0178-250-EN
It is possible to regulate the compressor capacity steplessly from approx. 10% to 100%
by means of a regulating slide mounted
under the rotors. Once the slide has moved
away from the slide stop a gap is created so
that some of the sucked-in gas is returned to
the suction side. The bigger the gap, the
lower the compressor capacity.
The regulating slide is moved hydraulically by
a regulating piston and controlled by a
solenoid valve system.
The compressor also features a regulating
system by which the built-in Vi volume ratio
can be adjusted.
The result hereof is that the compressor
works optimally at varying operational
pressures in the plant.
To optimize the compressor volume ratio the
position of the Vi regulating slide must be
changed whenever the compressor works at
max. capacity. This is done by changing the
position of the slide stop.
At partial load the Vi volume ratio will only be
approaching the optimum.
Regulating the built-in Vi volume ratio can be
done in the following two ways, depending on
the compressor type (as to your type of compressor, see page 1).
S Manual regulation of the Vi slide:

By turning the spindle, pos. 180, in
accordance with the curves in the
instruction manual.
S Automatic regulation of the Vi slide:
By means of the oil pressure and two
solenoid valves, controlled by a UNISAB II
control system.
The type of screw compressor can be
determined by means of the nameplate,
placed on the compressor block.
Fig. 1
SABROE
AARHUS DENMARK
Type
Shop no
Max. speed
Swept volume
Working pressure
Test pressure
Refrigerant
Year
r.p.m.
m3/h
bar
bar
T0177093_2
The name-plate indicates the compressors

serial number as shown in fig. 1.
When contacting SABROE about the compressor, remember to state the serial
number.
0178-250-EN
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.
0170-124-EN
98.03
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.
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.
Use safety protective equipment. Wear
approved eye or face protection when
operating parts containing refrigerant. Protective shoes with slip-proof soles can also help
avoid injuries. Always keep the protective
equipment in good condition.
These precautions are to be used as a guide

to supplement the safety precautions and
warnings in the following:
Never operate or service this equipment if

affected by alcohol, drugs or other
substances or conditions which decrease
alertness or judgement.
a. All other manuals pertaining to the

machine.
Work area safety
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
0178-015-EN
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.
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.
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.
When the compressor is installed, be sure

that the motors rotate in the right indicated
direction.
0178-015-EN
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
0178-015-EN
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.
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 express statement or advice exists,
working with electrical power ON
should be performed by a Sabroe
Refrigeration 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.
FAILURE TO FOLLOW THIS
INSTRUCTION MAY RESULT IN
DEATH OR SERIOUS PERSONAL
SHOCK INJURY.
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 electrical system to determine the possible use of
power retaining devices such as capacitors.
Such power retaining devices must be disconnected, discharged, or made safe before
maintenance is performed.
Working space around electrical equipment
must be clear of obstructions. Provide adequate illumination to allow for proper operation 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 precautions that you need to pay attention to as described in the following sections:
S First aid for accidents with Ammonia.

S First aid for accidents with HFC/HCFC.
Whenever maintenance is to be performed in

an area away from the disconnect and the
10
S Protecting the operator as well as the environment.
0178-015-EN
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 compressor cover as shown on the following sketch.
Please, notice that male and female drive
have different directions of rotation.
Female
Male
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
Seen towards shaft ends
Handling of compressor and unit

For lifting of the compressor it has been
equipped with a threaded hole for mounting
of the lifting eye. As to the weight of the compressor, see table on compressor data.
WARNING
The compressor block alone may
be lifted in the lifting eye.
The same applies to the motor.
0178-015-EN
In view of preventing an unintended application of the compressor, which could cause

injuries to the operating staff or lead to technical damage, the compressors may only be
applied for the following purposes:
S As a refrigeration compressor with a number 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.
11
S In an explosion-prone environment, provided the compressor is fitted with approved explosion-proof equipment.
WARNING
The compressor must NOT be
used:
S For evacuating the refrigeration 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.
It must not be possible to block the emergency stop without a stop instruction being released.
It should only be possible to set back the
emergency device by a deliberate act, and
this set back must not cause the compressor
to start operating. It should only make it possible to restart it.
Other demands to the emergency device:
S It must be possible to operate it by means
of an easily recognizable and visible
manual handle, to which there is free access.
Safety equipment
S It must be able to stop any dangerous situation, which may occur, as quickly as
possible without this leading to any further
danger.
Emergency device
Combustion motors
The compressor control system must be

equipped with an emergency device.
In case the compressor is delivered with a
SABROE-control system this emergency device is found as an integrated part of the control.
If combustion motors are installed in rooms

containing refrigeration machinery or rooms
where there are pipes and components containing refrigerant, you must make sure that
the combustion air for the motor is derived
from an area in which there is no refrigerant
gas, in case of leakage.
The emergency device must be executed in

a way to make it stay in its stopped position,
following a stop instruction, until it is deliberately set back again.
Failure to do so will involve a risk of the lubricating oil from the combustion motor mixing
with the refrigerant; at worst, this may give
rise to corrosion and damage the motor.
12
0178-015-EN
DANGER: The high voltage sign
Safety symbols
Before putting a compressor/unit into operation they must be provided with warning
signs corresponding to the actual design of
compressor/unit and in accordance with the
rules and regulations in force.
The CAUTION sign
A CAUTION tag is fixed on the compressor
like the one illustrated below. This sign imposes upon the users to read the Safety Precautions section in the manual before handling, operating or servicing the compressor
and unit.
CAUTION
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
is always available.
This sign must not be removed nor be
damaged in any way.
Antes de manejer, instalar, poner en marcha o dar servicio al compresor y la unidad, leer la seccin Precauciones de
seguridad en el Libro de Instrucciones.
Es respondabilidad del operaro o de su
patrn, que el libro de instrucciones
permanezca siempre al alcance de la
mano.
Esta seal no debe de ninguna manera
suprimirse o daarse.
2516-297
0178-015-EN
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 express statement or advice exists, working with electrical power
ON should be performed by a Sabroe Refrigeration 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.
WARNING
Failure to follow this instruction
may result in death or serious
personal shock injury.
Explosion-proof electrical execution

If the compressor is delivered in an explosion-proof electrical execution it will, further
to the SABROE name plate, be equipped
with an Ex-name plate like the one illustrated below.
13
In such cases a yellow label like the one

shown below are stuck on the compressor
surface.
Pfyldt beskyttelsesgas
Charged with inert gas
Enthlt Schutzgas
Charg du gaz protecteur
Contiene gas protector
N2
0,2 bar
3 PSI
1534-169
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 depends 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.
Safety at servicing
WARNING
Read related safety precautions before 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 compressor and other parts of the refrigeration
plant.
S Make sure that the motor cannot start up
inadvertently. It is recommended to remove 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.
Compressor blocks and units are usually

delivered without any refrigerant or oil content in the crankcase.
S Use gloves and protective glasses and

make sure to have a gas mask ready to
be used in connection with the current refrigerant.
In order to protect the compressors against

internal corrosion, they are delivered evacuated of all athmospheric air and charged
with Nitrogen (N2) to an overpressure of
0.2 bar.
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.
Internal protection
14
0178-015-EN
First aid for accidents with ammonia

Chemical formula: NH3 refrigerant no.: R717)
Inhalation
WARNING
No plant can ever be said to be
too safe.
Safety is a way of life.
General
Ammonia is not a cumulative poison. It has a
distinctive, pungent odour that even at very
low, harmless concentrations is detectable by
most persons. Since ammonia is self-alarming, it serves at its own warning agent, so
that no person will voluntarily remain in concentrations which are hazardous. Since ammonia is lighter than air, adequate ventilation
is the best means of preventing an accumulation.
Experience has shown that ammonia is extremely hard to ignite and under normal
conditions is a very stable compound. Under
extremely high, though limited concentrations, ammonia can form ignitable mixtures
with air and oxygen, and should be treated
with respect.
1. Move affected personnel into fresh air immediately, and loosen clothing restricting
breathing.
2. Call a doctor/ambulance with oxygen
equipment immediately
3. Keep the patient still and warmly wrapped
in blankets.
4. If mouth and throat are burnt (freeze or
acid burn), let the conscious patient drink
water, taking small mouthfuls.
5. If 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 respiration.
Eye injuries from liquid splashes or concentrated vapour
1. Force the eyelids open and rinse eyes immediately for at least 30 minutes with the
salt water solution just mentioned
2. Call a doctor immediately.
Basic rules for first aid

2. Be prepared: Keep an irrigation bottle
available, containing a sterile isotonic
(0.9%) NaCl-solution (salt water).
3. A shower bath or water tank should be
available near all bulk installations with
ammonia.
4. When applying first aid, the persons assisting should be duly protected to avoid
further injury.
0178-015-EN
Skin burns from liquid splashes or concentrated vapour

1. Wash immediately with large quantities of
water and continue for at least 15 minutes,
removing contaminated clothing carefully
while washing.
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.
15
First aid for accidents with HFC/HCFC

Refrigerant no.: R134a - R505A R507 R22, etc
WARNING
too safe.
2. Adrenalin or similar heart stimuli must not

be used.
Inhalation
1. Move affected person into fresh air immediately. Keep the patient still and warm
and loosen clothing restricting breathing.
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 normal 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 lowlying or poorly ventilated rooms where
high gas concentrations are suspected,
the rescuer must be wearing a lifeline, and
be under continuous observation from an
assistant outside the room.
16
2. If unconscious, call a doctor/ambulance

with oxygen equipment immediately.
3. Give artificial respiration until a doctor authorizes 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 burntout hermetic compressors.
0178-015-EN
Protecting the operator as well as the environment

High concentrations of refrigerant vapours
are suffocating when they displace air; if high
concentrations of refrigerant vapours are inhaled they attack the human nerve system.
WARNING
too safe.
When halogenated gasses come into contact

with open flame or hot surfaces (over approx.
300C) they decompose to produce poisonous chemicals, which have a very pungent
odour, warning you of their presence.
Increasing industrialisation threatens our

environment. It is therefore absolutely imperative that we protect nature against pollution.
In high concentrations, R717 causes respiratory problems, and when ammonia vapour
and air mix 15 to 28 vol. %, the combination
is explosive and can be ignited by an electric
spark or open flame.
To this end, many countries have passed legislation in an effort to reduce pollution and
preserve the environment. These laws apply
to all fields of industry, including refrigeration,
and must be complied with.
Oil vapour in the ammonia vapour increases

this risk significantly as the point of ignition
falls below that of the mixture ratio stated.
Be especially careful with the following substances:

S refrigerants
Usually the strong smell of ammonia will

give ample warning of its presence before
concentrations become dangerous.
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 extremely harmful if they come into contact with
skin or eyes.
The following table shows the values for refrigerant content in air, measured in volume %.
Certain countries may, however, have an official limit which differs from those stated.
Halogenated refrigerants
Ammonia
R134a
R404A
R507
R22
R717
0.1
0.1
0.1
0.1
0.005
Unit
TWA
Time weighted ave-
vol.%
rage during a week

Warning smell
0178-015-EN
vol.%
0.2
0.002
17
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 stratosphere. 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 refrigerant into the plants condenser/receiver
or into separate refrigerant cylinders.
S Most halogenated refrigerants are miscible with oil. Oil drained from a refrigeration plant will often contain significant
amounts of refrigerant. Therefore, reduce
the pressure in the vessel or compressor
as much as possible before draining the
oil.
S Ammonia is easily absorbed by water:
At 15C, 1 litre of water can
absorb approx. 0,5 kg liquid
ammonia (or approx. 700 litres
ammonia vapour).
S Even small amounts of ammonia in water
(2-5 mg per litre) are enough to wreak
havoc with marine life if allowed to pollute
waterways and lakes.
S As ammonia is alkaline it will damage
plant life if released to the atmosphere in
large quantities.
Refrigerant evacuated from a refrigerant
plant shall be charged into refrigerant cylinders intended for this specific refrigerant.
If the refrigerant is not to be reused, return it
to the supplier or to an authorized incinerating plant.
18
Halogenated refrigerants must never be

mixed. Nor must R717 ever be mixed with
halogenated refrigerants.
Purging a refrigeration plant
If it is necessary to purge air from a refrigeration plant, make sure you observe the following:
S Refrigerants must not be released to the
atmosphere.
S When purging an R717 plant, use an approved air purger. The purged air must
pass through an open container of water
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 absorbed by water. An approved air purger
must be fitted to the plant. This must be
checked regularly using a leak detector.
Cooling media
Salt solutions (brines) of calcium chloride
(CaCl2) or sodium chloride (NaCl) are often
used.
In recent years alcohol, glycol and halogenated compounds have been used in the brine
production.
In general, all brines must be considered as
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 containers, clearly marked with the contents, and
sent to an approved incinerating plant.
0178-015-EN
Lubricating oils
alkyl benzene-based synthetic oil
Refrigeration compressors are lubricated with

one of the following oil types, depending on
the refrigerant, plant type and operating
conditions.
polyalphaolefine-based synthetic oil
mineral oil
semi-synthetic oil
glycol-based synthetic oil.

When you change the oil in the compressor
or drain oil from the refrigeration plants vessels, always collect the used oil in containers
marked waste oil and send them to an approved 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.
0178-015-EN
19
Sound data for reciprocating and screw

compressor units - all types of compressors
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.
A-weighted sound pressure level LP

(Sound Pressure level)
The values for LW constitute an average of a
large number of measurings on various units.
The measurings have been carried out in accordance with ISO 9614-2.
The values are further stated as average
sound pressure in a free field above a reflecting plane at a distance of 1 meter from
a fictional frame around the unit. See fig. 1.
Normally, the immediate sound pressure
lies between the LW and LP values and can
be calculated provided that the acoustic data
of the machine room is known.
For screw compressors the average values
are indicated in the tables for the following
components.
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
Dimensional tolerances are:
3 dB for SAB, SV and FV screw compressors
5 dB for VMY screw compressors
As to the reciprocating compressors the
values are stated for the compressor block
only.
The dimensional values are stated for 100%
capacity.
Fig. 1
Fictional frame
Dimensional plane
1 meter
20
1 meter
99.06
A-weighted sound power level LW

(Sound Power Level)
Reflecting plane
0170-114-EN
0170-114--EN
In the following tables the noise data of the

compressors is stated in:
Note the following, however:

S at part load or if the compressor works
with a wrongly set Vi the sound level can
sometimes be a little higher than the one
indicated in the tables.
S additional equipment such as heat exchangers, pipes, valves etc. as well as the
choice of a different motor type can increase the noise level in the machine
room.
S as already mentioned, the stated sound
pressures are only average values above
a fictional frame around the noise source.
Thus, it is sometimes possible to measure
higher values in local areas than the ones
stated for inst. near the compressor and
motor.
0170-114-EN
S the acoustics is another factor that can

change the sound level in a room. Please
note that the sound conditions of the site
have not been included in the stated
dimensional values.
S by contacting SABROE you can have
sound data calculated for other operating
conditions.
The tables have been divided into reciprocating and screw compressors, respectively.
The reciprocating compressors are further
divided into one- and two-stage compressors
as well as in a heat pump. In each table the
operating conditions of the compressor during noise measuring have been stated, just
as the refrigerant used has been mentioned.
21
RECIPROCATING COMPRESSORS
One-stage
Evaporating temperature
= 15C
Condensing temperature
=+35C
Refrigerant
= R22/R717
Number of revolutions
=1450 rpm.
Two-stage
Refrigerant
Compressor block
Compressor block
LW
LP
CMO 24
84
69
CMO 26
86
71
CMO 28
87
72
SMC 104 S
95
79
SMC 106 S
96
80
SMC 108 S
97
81
SMC 112 S
99
82
SMC 116 S
100
83
SMC 104 L
96
80
SMC 106 L
97
81
SMC 108 L
98
82
SMC 112 L
100
83
SMC 116 L
101
84
SMC 104 E
96
80
SMC 106 E
97
81
SMC 108 E
98
82
SMC 112 E
100
83
SMC 116 E
101
84
Refrigerant
Compressor block
= 15C
= +35C
= R22/R717
= 900 rpm.
LW
LP
= 35C
= +35C
= R22/R717
=1450 rpm.
LW
LP
TCMO 28
81
66
TSMC 108 S
95
79
TSMC 116 S
97
81
TSMC 108 L
96
80
TSMC 116 L
98
82
TSMC 108 E
96
80
TSMC 116 E
98
82
Refrigerant
= 35C
= +35C
= R22/R717
= 900 rpm.
Compressor block
LW
LP
TSMC 188
100
82
Heat pump
Refrigerant
Compressor block
= +20C
= +70C
= R22/R717
=1450 rpm.
LW
LP
HPO 24
91
76
HPO 26
93
78
HPO 28
94
79
HPC 104
97
81
SMC 186
101
83
HPC 106
98
82
SMC 188
102
84
HPC 108
99
84
22
0170-114-EN
SCREW COMPRESSORS
Refrigerant
*Number of revolutions
Compressor block
= 15C
= +35C
= R22/R717
= 2950 rpm.
= 6000 rpm.
LW
LP
98
98
98
98
81
81
81
81
SAB 128 HM Mk2

SAB 128 HF Mk2
SAB 128 HM Mk3
SAB 128 HF Mk3
SAB 128 HR*
102
106
101
104
102
84
88
84
86
84
SAB 163 HM Mk2

SAB 163 HF Mk2
SAB 163 HM Mk3
SAB 163 HF Mk3
SAB 163 HR*
105
109
103
106
103
86
90
86
87
85
SAB 202 SM
SAB 202 SF
SAB 202 LM
SAB 202 LF
104
105
104
105
85
86
85
86
SAB 330 S
SAB 330 L
SAB 330 E
106
106
106
87
87
87
SV 17
SV 19
100
101
83
84
FV 19*
SV 24
101
103
86
85
FV 24*
SV 26
104
103
86
85
FV 26*
107
85
SAB 81
SAB 83
SAB 85
SAB 87
SAB 89
101
102
103
105
108
86
85
86
86
85
SAB 110 SM
SAB 110 SF
SAB 110 LM
SAB 110 LF
= 35C
= 5C
Refrigerant
= R22/R717
= 2950 rpm.
Compressor unit
LW
LP
SAB 163 BM
106
88
SAB 163 BF
110
92
= 15C
=+35C
Refrigerant
= R22/R717
= 2950 rpm.
Compressor block
LW
LP
VMY 347 H
97
82
VMY 447 H
100
85
VMY 536 H
104
88
= 0C
=+35C
Refrigerant
= R22/R717
= 2950 rpm.
Compressor block
LW
LP
VMY 347 M
99
84
VMY 447 M
101
86
VMY 536 M
105
89
Min liquid pressure for liquid injection, suction

pressure bar (a) x 2+2 bar
0170-114-EN
23
Vibration data for compressors all types

Vibration data for SABROE screw compressors 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 machines (Class II), large machines (Class III) and turbo machines (Class IV)
Examples of quality judgement
for separate classes of machines
Ranges of vibration severity
0.28
0.45
0.71
1.12
1.8
2.8
4.5
7.1
11.2
18
28
45
Class I
0.28
0.45
0.71
1.12
1.8
2.8
4.5
7.1
11.2
18
Class II
Class III
Class IV
95.06
ms-velocity V (in mm/s)

at the range limits
A
A
B
A
A
B
C
B
C
28
B
C
C
D
D
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 occur if:
24
Motor and compressor have not been

aligned as described in the Instruction
Manual.
For screw compressors, if the compressor runs at a wrong Vi ratio.
The pipe connections have been
executed in a way that makes them force
pull or push powers on the compressor
unit or they may transfer vibrations to the
unit, caused by natural vibrations or connected 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
0170-115-EN
Range
Data for SAB 202 compressor & unit

For removal of the fine separator element
IEC 355
UNISAB II
Height
700
0178-254-EN
98.04
Length
Compressor
type
Refrigerant
Oil cooling
system 1)
SAB 202
R717
R22
R134a
R404A/R507
R407C
OWSG,
OOSI
1) OWSG = Heat exchanger w/shell (water)

OOSI = Heat exchanger w/shell (refrigerant)
Fig. 1
T290927_0
Width
Max. dimensions
Width
mm
Length
mm
Height
mm
Max. net
weight
Kg 2)
1905
3234
1915
4000
2) Excl. motor, oil, water and refrigerant
Type of compressor unit

On the base frame of the compressor unit a
name plate has been fitted as shown in fig 1.
This name plate provides you with all relevant information in accordance with CE labelling.
AARHUS
DENMARK
Type
Approval
no.
Serial no.
Max. operating
pressure
bar
Test pressure
bar
Compressor and vessel data:

See their nameplates
0178-250-EN
25
Compressor data SAB 202

Compressor Rotor Intern. Rotor L/D DP
Motor at 2950
Motor at 3550
type
drive volume dia.
max. male rotor swept vol. male rotor swept vol.
ratio
1)
mm
bar r/min
m3/h
r/min
m3/h
Vi
SAB 202 S-M
SAB 202 S-F
SAB 202 L-M
SAB 202 L-F
male
female 1.8-4.5
male
female 2.0-4.5
L = Rotor length
202
202
1.7
20
202
202
2.2
16
2950
1229
3550
1479
4425
1843
5325
2218
2950
1590
3550
1914
4425
2385
5325
2870
D = Rotor diameter
1) See permissible operating limits, however, in the Operating Limits Diagrams
Block weight
Kg
Centre height
mm
SAB 202 S-M
950
315
SAB 202 S-F
950
315
SAB 202 L-M
1050
315
SAB 202 L-F
1050
315
Operating limits
Please observe the following:
The enclosed diagrams for R717, R22,

R134a, R404A/R507 and R407C indicate the
limits within which the compressor is permitted to work.
S The upper operating limits are for Male

Drive and Female Drive, respectively
(see compressor type on p.1)
S The use of an economizer is allowed
within the entire permissible operating
area of the compressor.
26
0178-250-EN
SAB202S SAB202L
Operating
limits
Max. limit for model S
Max. limit for model L
60
MALE DRIVE
R717
50
40
FEMALE DRIVE
30
20
10
0
10
R717
20
30
60
50
40
30
20
10
10
20
(T250842_0)
SAB202S SAB202L
Operating
limits
Max. limit for model S

Max. limit for model L
60
R22
MALE DRIVE
50
40
FEMALE DRIVE
30
20
10
0
10
R22
20
30
60
(T250841_0)
0178-250-EN
50
40
30 20 10
0
10
20
27
SAB 202S/L VMY 447H/M
Operating
limits
R134a
Max. limit for model L/M
Max. limit for model S/H
MALE DRIVE
70
60
SAB 202:
FEMALE DRIVE
50
HLI
40
HLI + ECO
SAB 202:
no HLI
operation
30
20
10
VMY 447:
Below curve
full flow oil
pump required
R134a
10
20
50
40
30
(T250821_1)
Operating
limits
0
10
20
20 10
30
SAB202S/L VMY447H/M
R404A - R507
Max. limit for model S/H
Max. limit for model L/M

MALE DRIVE
50
HLI
40
SAB 202:
FEMALE DRIVE
30
HLI + ECO
20
10
SAB 202:
no HLI
operation
0
10
VMY 447:
Below curve
full flow oil
pump required
20
R404A-R507
30
70
(T250830_2)
28
60
50
40
30
20
10
10
0178-250-EN
Operating
limits
R407C
SAB 202 S/L, VMY 447 H/M

VMY 436 MB/B, VMY 536 H/M/B
LIMIT FOR MODEL S/H, SAB110L
TC C
60
LIMIT FOR MODEL M, SAB202L
MALE DRIVE
50
HLI
40
FEMALE DRIVE
30
HLI +
econ
20
SAB 202:
No HLI
operation
10
Limit model MB/B

SAB 110
standard units not
for Booster opr.
0
10
VMY 447:
Below curve full flow
oil pump required
20
R407C
30
-70 60 50 40 30 20 10
10
20
TE C
(T250133_1)
0178-250-EN
29
Compressor and unit operation

SAB 128 Mk3, SAB 163 Mk3 and SAB 202
2. Initial start.
3. Current control requirements at normal
operation.
4. Normal stop.
5. Preparations before a lengthy standstill
period.
6. Pressure testing.
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 refrigerant, water and electricity, instruments and
safety switches have been established, carry
out the following:
a) Check that the rotating direction is correct
with the coupling dismounted. The rotating
direction is marked by an arrow on the
suction cover of the compressor.
b) Check the rotating direction of the oil
pump.
c) Mount coupling and check that tolerances
and alignment are in accordance with the
coupling instruction.
d) Connect the vacuum pump to valve pos.
24 and empty unit to a vacuum of approx.
30
e) Top up with new oil of a quality recommended 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 removed. 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 order 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 refrigerant 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.
0178-250-EN
97.02
1. Preparations before starting up.
4-5 mm Hg. If necessary, use a thermostatic vacuum gauge for measuring of

pressure and fill up with dry air or
nitrogen until the pressure reaches 1 bar.
Then empty again to 4-5 mm Hg.
0178-255-EN
During operation of the compressor, the below points should be observed. These are
described in detail in the following sections.
c) Open suction and discharge stop valves

completely. Open the remaining internal
valves.
Check that all external valves on the refrigeration plant are open or closed in accordance with the piping diagram.
d) Check the free access of the cooling water
to the oil cooler, if any.
e) Check the supply of power to the compressor.
f) Check the position of the Vi-slide and
make sure that the capacity slide is in its
minimum position.
g) Start compressor as described in the UNISAB II manual.
h) Watch out for abnormal sounds and check
that the compressor works up a differential
pressure.
If nothing abnormal has been observed,
allow the compressor to work at normal
operating pressure, and adjust the capacity regulation to its immediate requirement
or to automatic operation. Currently check
pressure, temperatures and power consumption.
Important
Pay attention to the procedures for running down of the evaporating pressure as
indicated in the instruction on refrigeration
plants.
i) Do not leave the compressor for the first
60 mins.
0178-250-EN
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. capacity.
Set the change-over switch on stop.
5. Preparations before a lenghty

standstill period
Once the compressor has been pressure
equalized, close the stop valves of the compressor unit as well as all other valves connecting the unit to the plant, e.g. those of oil
coolers or economizers.
Switch off and safeguard the compressor
main switch.
6. Pressure testing
Before charging the plant with refrigerant, it
must be pressure tested and emptied.
Pressure test the plant using:
S Dry air - Pressurized cylinders containing
dry atmospheric air may be used - never
use oxygen cylinders.
S Air compressor for high pressure.
S Nitrogen.
31
Important
Do not use the plant compressors for
pressurizing the plant. Water or any other
liquid must not be used in connection with
pressure testing.
In case nitrogen is used it is important to
place a reduction valve with pressure
gauge between the nitrogen cylinder and the
plant.
During pressure testing it is important that
pressure transducers and other control
equipment are not exposed to the test pressure. Similarly, the compressor stop valves
must be closed during testing.
Normally, the plant safety valves should be
blanked off during the pressure testing as
their opening pressure is lower than the test
pressure.
Important
During this pressure testing no persons
are allowed in the rooms with plant components or in the vicinity of the plant outside the rooms.
S The entire plant is strength tested according to the local rules for pressure testing.
S Usually, the test pressure must not be
allowed to exceed the design pressure.
However, also in this case the local rules
and regulation apply.
S In case there is a request for the compressor to be pressure tested together with the
unit, the test pressure on the compressor
must not exceed 24 bar.
S Hereafter, lower the pressure to 10 bar for
24 hours as a first leak testing as a
tight plant will maintain this pressure during the entire period.
32
During leak testing, it is permitted to enter the

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

Who carried out the testing.
Test pressure
Comments.
7. Evacuation
After pressure testing the refrigeration plant
must be evacuated in order to remove atmospheric air and moisture. Evacuation must be
carried out on all types of refrigeration plants
regardless of the type of refrigerant to be
filled into the plant.
Note that HCFC, HFC and CFC refrigerants
hardly mix with water. Consequently, it is important to make a particularly thorough evacuation of these plants.
The boiling point of a liquid is defined as the
temperature by which the steam pressure is
equal to atmospheric pressure.
The boiling point of water is 100C. If the
pressure is lowered, so is the boiling point of
water.
The following table indicates the boiling point
of water at very low pressures:
Boiling point
of water C
At pressure
mm HG
6,63
10
9,14
15
12,73
20
17,80
0178-250-EN
S Carry out an evacuation to a pressure below 5 mm Hg.
For evacuation, use a vacuum pump which

empties the plant of both air and water vapour.
S Next blow in dry air or nitrogen in the system to a pressure equal to atmospheric.
The vacuum pump must be able to lower the

pressure to approx. 0.1 mm Hg (mercury
column), and it must be equipped with a gas
ballast valve. Use this valve to the greatest
extent possible in order to prevent condensation of water vapour in the vacuum pump.
S Evacuate again to a pressure below 5 mm

Hg.
S Shut off the vacuum pump from the refrigeration plant and check that the pressure
does not rise within the next few hours. If
there is still water in the system, it will
evaporate and cause a pressure increase.
This means that the evacuation has not
been satisfactorily carried out and has to
be repeated.
Important
Never use the refrigeration compressor for
emptying of the plant.
In order for an evacuation to be satisfactorily
carried out the final pressure must be below
5 mm Hg. Attention should be paid to the fact
that there is a risk that the water still present
in the refrigeration plant may freeze in case
the ambient temperatures are below 10C.
In that case it is necessary to heat up the
surroundings of the components as ice only
evaporates slowly.
8. Operating log
To be in control of the operating conditions of
the plant it is recommended to keep an operating log in order to be able to keep an eye
on any changes that may occur in the operating conditions.
Below table is an example of such an operating log. The information in this log is needed
in order to make a satisfactory diagnosis.
Evacuation is recommended carried out as

follows:
kW
0178-250-EN
Cooling water
Inlet
Outlet
lh
Temperature
Machine
room
rpm C
Number of
revolutions
Disch. man.
C C
Suction pipe
temperature
Condenser
Discharge
pipe temp.
Compressor
Suct. man.
Time
Power consump.
Electric motor
Fact.:
No.:
CV/kW:
COS :
n:
rpm
1
Air
Inlet
2
Suction pipe
Outlet
Pres.
Air
Suction pipe
Temp. Inlet Outlet Pres.
C C
Temp.
Temp. of
ambient
air
C
33
Service Schedules for screw compressors

SAB 110, 128/163Mk3, 202 & VMY
Good and careful servicing of the compressor and the unit is of great importance for
their proper functioning and service life.
S Remove main fuses for the compressor

motor in order to prevent it from starting
inadvertently.
It is therefore recommended that these service instructions be followed; based on the

number of operating hours, they indicate the
service tasks to be carried out.
Compressor and unit are now ready for inspection and dismantling, if required.
S Regulate the compressor down to its lowest capacity stage and stop it.
S Now close all stop valves in the pipe connections to the unit except for the suction
stop valve pos. 20, which remains open
until the pressure in the unit has been
equalized to the suction pressure. This is
described in the passage called The nonreturn valve.
S Close suction stop valve pos. 20.
S Any excess pressure in the unit is equalized to atmospheric through stop valve
pos. 24. See the Key to Piping Diagrams
and the chapter on: Protecting the Environment.
The heating element in the oil separator
must remain connected until the pressure
is completely equalized, thus boiling the
refrigerant out of the oil.
34
SAB 110, SAB/163 and SAB 202

Above-mentioned compressors all have builtin oil filters.
Follow the procedure described in the previous passage: Preparations before compressor inspection.
Remove oil filter as described in section:
Maintenance of the compressor.
VMY with external oil filter
As the units may be fitted with one or two oil
filters (mounted in parallel) apply procedures
A or B.
A: Units with one oil filter only
Bring compressor to minimum capacity, and stop it.
When pressure in unit is equalized
to suction pressure, close stop valves before and after oil filter.
Any over pressure in filter housing
is equalized to atmospheric pressure through the evacuation valve
on filter housing.
Cover on filter housing can now be
dismantled, as described in section
Oil filter.
0178-028-EN
99.05
Before dismantling any part of the compressor or unit for inspection or repair, the pressure must be reduced to atmospheric
pressure. This is done as follows:
In case only the oil filter has to be replaced,

follow below procedure depending on the the
type of your compressor:
0178-028-EN
Preparations before compressor

inspection
Replacement of oil filter
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, however, right after initial start-up of compressor.
Although an effort should be made to keep
the plant free of any impurities when assembled, experience shows that it may be
difficult to avoid impurities in tubes and vessels.
These impurities will be conveyed by the suction gas to the suction filter, where largesized impurities are intercepted. Smaller impurities will pass through the filter and be
conveyed to the oil separator, where they are
suspended in the oil. From here they are tak-
0178-028-EN
en to the lubricating system of the unit and

absorbed by the oil filter.
These impurities may result in a need to
change the oil filter cartridge shortly after
initial start-up.
It is equally important to check the oil at
regular intervals as specified in the sections
Checking the oil and Assessing the oil.
Purification of the oil may be done by means
of a 3 micron filter in a closed system.
During this process, the oil must not come
into contact with the oxygen and moisture in
the air.
In addition, it is important that all pressures
and temperatures be kept within the specified
values and that filters be kept clean; provided
inspection is carried out to the schedules
prescribed below, compressor and unit will
work efficiently and achieve a long service
life.
The following charts indicate the schedules
for checking the oil in the compressor unit
and a more detailed description of the operations to be performed during scheduled service inspections.
35
Checking the oil

Service schedules
Operating hours between main inspections

See chart for main inspections
20000h
30000h
40000h
HCFC
R717
HCFC
R717
HCFC
R717
Number of operating
hours from initial startup and after each main
inspection (see footnote)
50
200
1000
2500
5000
10000
15000
20000
25000
30000
35000
40000
It is advisable to assess the oil as described in the following chart.
It is advisable to assess the oil as described in the following chart.

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

Service
schedules
after
initialigangstning
start-up of compressor.
Serviceterminer
efter
frste
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.
36
0178-028-EN
Activities during a service inspection

Periodic service
1
Daily
Activity
1.1 External inspection and leak check.
1.2 Check the oil level in the oil separator.
1.3 Check pressures and temperatures.
1.4 Check for unusual vibrations or noise.
1.5 Record operating data in the log book.
After 50 hours operation
2.1 Clean the suction filter.
After 200 hours

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

operation
After 2500 hours

operation
4.2 Take an oil sample from the oil separator and appraise it visually, or send the sample to a laboratory for
analysis.
Both methods are described in the section entitled
Assessing the oil.
5.2 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.
the compressor.
5.6 Check that the pressure switches and thermostats
function correctly (refer to the set values in the instruction book).
If UNISAB II computerized control is fitted, check the
transducers
(see the instruction manual for UNISAB II )
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
37
Periodic service
6
Activity
After 5000 hours.

operation
This service should be

repeated after every
5000 hours of operation
the compressor.

function correctly (refer to the set values in the instruction manual).
transducers (see the instruction
manual for UNISAB II)
6.6 Take an oil sample from the oil separator and send
the sample to a laboratory for analysis, as descri
bed in the section entitled Assessing the oil. Please
also refer to the table entitled Checking the oil.
Major service
Carried out as specified
for the individual screw
compressor type.
(See the diagram for major
service)
7.1 Total overhaul of the compressor, including fitting

new gaskets. As the compressor is already open,
inspect the bearings and, if necessary, fit new ones.
Check the regulating system.
7.2 Overhaul and clean the compressor motor.
N.B.
Follow the service schedule specified by
the motor manufacturer.
7.4 Drain off the compressor oil and charge with new,
fresh oil.
function correctly (refer to the set values in the instruction book).
transducers
(see the instruction manual for UNISAB II)
38
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
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 entering the rotor bearings.
An analysis of the oil can give important information on how the compressor is running.
We would, therefore, advise that the oil ana
lyses be carried out at the intervals prescribed.
An oil sample must be drawn off while the
compressor is in operation, which gives a
representative sample. Before taking the
sample, clean the drain valve and 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, transparent glass bottle or a test-tube and hold it up
to a clear light source, it will be easy to assess the quality. You can also compare the
sample with the fresh oil of the same make
and grade.
An oil which you approve on the grounds of a
visual assessment must:
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
0178-028-EN
bottle with subsequent risks of explosion.

Never fill a bottle up completely. Do not
send glass bottles through the postal service use purpose-made plastic bottles.
Please, see below.
Analytical evaluation
Naturally, the oil sample can be analysed by
the oil company which supplies the oil. As
a special offer to our customers SABROE
has developed an analytical concept, in
cooperation with Mobil Oil, which is able to
analyse all oil makes. This will mean a uniform reporting of the results. The analysis
allows the following to be determined:
S Whether or not the oil is still usable - after
filtering, if necessary - or whether it should
be replaced.
S Whether solid particles that may be present in the oil originate from the bearings or
other components exposed to wear and
tear in which case the compressor must
be inspected.
S Each report will include the corresponding
measuring results from the previous 3 oil
analyses. In this way you will be able to
follow up on the state of both the oil and
the compressor from one analysis to the
next.
Procedure
S A form set with a plastic sampling bottle
and a dispatching envelope can be requested from the local Sabroe Refrigeration 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-
39
frigerant contained in the oil sample to

evaporate before sending it to the laboratory.
The analysis
S Please follow the Sampling and Shipping

Instructions enclosed in the form set in
which the address of the laboratory in Holland is also mentioned.
The following table states some average values that can be applied in practice. However,
you should be on the alert whenever the results of the analyses approach these values.
In some cases the water content of 100 ppm
in HCFC plants may be too much and thus
lead to Cuplating in the shaft seal.
Limiting values
Parameter
Unit
Method
Sabroe Oil PAO 68
Sabroe Oil AP 68
Target
Spec.
Target
Spec.
Min.
Max.
Min.
Target
Spec.
Max.
Min.
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
Water
ppm
Karl Fisher
100
100
100
Appearance
report
report
report
Colour
ASTM D
1500
report
report
report
Pentane Insolubles
W%
MM 490
(5mm)
0.05
Oxidation
abs/cm
IR,1700-1720
/cm
Nitration
abs/cm
IR,1627-1637
/cm
Nitro Compounds
abs/cm
IR,1547-1557
/cm
Viscosity @ 40C
Max.
Sabroe Oil A 100
0.05
0.05
0.5
0.5
0.5
Maximum values for metal content in the oil

Lead
ppm
ICP
10
10
10
Copper
ppm
ICP
10
10
10
Silicium
ppm
ICP
25
25
25
Iron
ppm
ICP
100
100
100
Chromium
ppm
ICP
Aluminium
ppm
ICP
10
10
10
Tin
ppm
ICP
10
10
10
1): TAN (Total Acid Number) is only reported for non-ammoniaapplications
40
2): SAN (Strong Acid Number) is only reported for non-ammonia-applications
0178-028-EN
A report is drawn up for every sample received. This report concludes:

S Whether the oil can still be used without
taking any further action.
S Whether the oil can be used after it has
been filtered through a very fine filter. If
this is necessary, the oil must be pumped
directly from the compressor unit through
a 3 micron filter and back to the unit. The
0178-028-EN
system must be completely closed, to prevent the oil being affected by moisture in
the air.
Whether the oil is no longer fit for use.

The report will always be sent to the address
stated on the sample label included in the
form set. A copy will be sent to SABROE
REFRIGERATION so that we are in a
position to advise you, if required.
41
Major Service Intervals

SAB 110, SAB 128/163 Mk3, SAB 202
Condensing temp.
Normal operat. cond.

30000 hour interval
Extreme operating conditions

20000 hour interval
TC (C)
55
55
50
50
40
40
35
35
30
30
25
20
95.10
45
25
20
0178-030-EN
45
15
15
10
5
0
5
10
20
30
50
10
5
0
5
10
15
20
30
Booster conditions
40000 hour interval
50
R22
R717
50
30 20
10 5
10
15
20
25
Evaporating temp.
50
30 20
10 5
10
15
20
25
TE (C)
T0177068_0
42
0178-250-EN
Oil charging, weight and shipping volume

SAB 128/163 Mk3 and SAB 202
Oil charging (oil level at the middle of upper sight glass during operation)
Oil cooler
Type
SAB
128
0178-256-EN
96.02
OOSI
OOSI
OOSI
OOSI
OOSI
OWSG
OWSG
OWSG
OWSG
OWSG
OWSG
OWSG
HLI
1614
2114
2714
3214
4114
1615
1619
2115
2119
2719
3219
4119
11
20
Litres
SAB
163
SAB
202
11
20
31
48
11
20
31
48
86
25
25
Oil separator
Litres
SAB
SAB
SAB
128
163
202
Compressor + pipes
Litres
SAB
SAB
SAB
128
163
202
80
89
103
112
123
140
216
225
236
253
291
117
230
131
155
244
278
283
324
205
87
25
60
39
39
63
Total, unit
Litres
SAB
SAB
SAB
128
163
202
80
180
12
25
39
63
78
119
0
97
69
92
Weight (excl. motor, refrigerant, oil and water)

Oil cooler
Type
SAB
128
OOSI
OOSI
OOSI
OOSI
OOSI
OWSG
OWSG
OWSG
OWSG
OWSG
OWSG
OWSG
HLI
1614
2114
2714
3214
4114
1615
1619
2115
2119
2719
3219
4119
78
130
Kg
SAB
163
SAB
202
78
130
180
215
78
130
98
180
215
130
380
Basic Unit
Kg
SAB
SAB
SAB
128
163
202
Compressor block
Kg
SAB
SAB
SAB
128
163
202
1008
1060
1528
1580
1630
1665
3218
3270
3320
3355
3520
1580
3270
1660
1760
3350
3450
3580
3880
3160
1050
120
700
185
210
310
20
Total, unit
Kg
SAB
SAB
SAB
128
163
202
20
210
310
440
740
20
950
2100
230
500
1040
1115
950
1470
Shipping volume (excl. motor)

Oil cooler
Type
Compressor type
m3
SAB
SAB
SAB
128
163
202
OOSI
2114
OOSI
3214
OOSI
4114
OWSG 2115
OWSG 2719
OWSG 4119
HLI
0178-250-EN
5
8
11
6
9
4
12
10
43
Temperature and pressure settings SAB 202

The setting of pressures and temperatures
must be made in accordance with tables 1
and 2, supplemented by the numbered
notes.
Any deviation from the factory settings can,

in view of the current operating conditions, be
written down in the column Current plant.
Table 1 Screw compressors Measured and calculated pressures

Notes
Suction pressure
[bar]
High alarm
High warning
Low warning
Low alarm
Discharge pressure
[bar]
High alarm
High warning
Low warning
Low alarm
16,0
15,0
1,0
Low warning
Low alarm
4,0
2,5
2+4
2+4
Low warning
Low alarm
0,0
0,0
2+6
2+6
Oil press. [bar]

Calculated value
Low warning
Low alarm
1,0
0,5
2+6
2+6
SAB Mk 3 compressors
SAB 202 compressor
Stop/start of oil pump
Set point 1
Set point 2
2,5
4,0
Oil press. [bar]

Calculated value
Low warning
Low alarm
2,0
1,5
2+6+10
2+6+10
Oil press. [bar]

Calculated value
Low warning
Low alarm
4,0
3,0
2+6
2+6
VMY Mk 3 compressors
Stop/start of full flow
pump
Set point 1
Set point 2
5,5
7,0
Diff. pressure across

oil filter [bar]
Calculated value
High alarm
High warning
1,0
0,7
Oil press. [bar]

Calculated value
3
3
3
1
1
1
Oil press. [bar]

Calculated value
VMY Mk 2-2,5 compressor
44
2+7
2+7
0178-250-EN
96.12
Settings
Current plant
Factory
5,0
1,5
1,0
0178-275-EN
Measuring
Table 2
Screw compressors Measured and calculated temperatures
Settings
Measuring
Factory
Current plant
Notes
1
1
Discharge temp.
[C]
High alarm
High warning
Low warning
Low alarm
100,0
90,0
65,0
Oil temperature
[C]
High alarm
High warning
Low warning
Low alarm
60,0
55,0
25,0
20,0
2+4
2+4
2+4
2+4
Brine temperature
[C]
High alarm
High warning
Low warning
Low alarm
60,0
50,0
4,0
2,0
1
1
1
1
Suction gas superheat

[C]
High alarm
High warning
Low warning
Low alarm
110,0
100,0
2,0
0,0
2+4
2+4
2+4
2+4
Low warning
Low alarm
10,0
0,0
2+4
2+4
Calculated value
Disch. gas superheat
[C]
Calculated value
0178-250-EN
45
Notes:
Note 1
The alarm cannot be switched off until the cause has been removed.
Note 2
The alarm can be switched off immediately
Note 3
The alarm is switched off automatically.
Note 4
Alarm monitoring 300 sec delayed after compressor start.
Note 5
(not defined for screws)
Note 6
Alarm monitoring 45 sec delayed after compressor start.
Note 7
A delay of 30 sec, no matter when the limits are exceeded.
Note 8
Note 9
Note 10
For VMY Mk 2-2.5 calculate the following:

Oil pressure = oil pressure (after oil filter) discharge pressure.
For all other compressor types calculate:
Oil pressure = oil pressure (after oil filter) suction pressure
46
0178-250-EN
Servicing the refrigeration plant

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

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 plant otherwise works as it is supposed to.

The service instructions outline some general
guidelines for servicing the refrigeration
plant, with some references to the instruction
manual. The service instructions should
therefore be read and followed carefully.
S the oil pressure and discharge pipe

temperature on the compressor are
correct,
Check
0171-470-EN
97.07
S the desired temperatures are observed,
Interval
Condensing pressure
Pressure
and temp.
Filters
Daily
Excessively high pressure may be

due to:
reduced cooling effect
air in the condenser.
Too low condenser pressure implies a risk of restricting the refrigerant supply to the evaporator.
Discharge pipe temperature
Normal discharge pipe temperature acc. to instructions.
Filter in
liquid line
thermostatic valve
suction line
oil return
Accumulated dirt causes reduced

refrigerant supply to the evaporator.
Clean when
needed
Moisture in the sight-glass

(on HFC/HCFC installations)
Dehumidifier
Activity
When
needed
If a filter has a hot inflow and cold

discharge, this may be due to
clogging of the component.
Some installations are provided

with a sight-glass featuring moisture indicator; if the indicator colour switches from green to yellow,
there is moisture in the refrigerant.
Change the drying filter regularly.
0178-250-EN
47
Check
Interval
Refrigerant charge
Refrigerant
Automatic
controls
Leak detection
Safety pressure controls

Automatic operating
controls
Alarms
Inadequate charge results in reduced plant capacity and often

leads to an excessively high discharge pipe temperature.
Periodically
Periodically
Lubrication of electric motors
Electric
motor
Periodically
Corrosion
Periodically
normally
min. 4
times a
year
Frosting-up
When
needed
Evaporator
Oil draining (ammonia plant)
48
The plant must be searched regularly for leaks. Flanges and joints
settle during the plants initial operation period. They must therefore be tightened and checked.
Adjust operating point and check
the function. Replace switch system if sticking.
Clean and lubricate according to
suppliers instructions. At temperatures lower than -25C, use special lubricant.
Alignment of coupling
V-belt drive
Condenser
Activity
Periodically
Check in accordance with the

instructions of the instruction
manual.
Tighten loose V-belts, if any,
or replace by new ones.
Marine condensers are normally
protected against galvanic corrosion by the mounting of corrosion
plugs in the condenser covers.
Metallic contact between corrosion plug and cover is essential to
proper functioning.
Problem-free operation is conditional on the evaporator being
kept free of ice. Defrost as and
when required.
Check evaporator, intermediate
cooler, receiver, etc. for oil accumulation. Exercise caution; use a
gas mask.
0178-250-EN
Maintenance of compressor SAB 202

Dismantling and assembly
Service work on the SAB 202 compressor
must be carried out of by professional and
well-trainied staff who are familiar with the
compressor.
This instruction is a description of the complete dismantling and assembly of the compressor, although this will not always be required.
0178-260-EN
99.01
When dismantling, parts should be marked to

ensure that they can be remounted in the
same position as before.
Torque moments for screws and bolts as
stated in the table on Torque moments
should be strictly observed.
Preparations before dismantling

The following is a description of a complete
dismantling, inspection and assembly of the
compressor.
Partial dismantling and inspection can be
undertaken while the compressor is secured
to the base frame. To allow a complete
dismantling, however, the compressor must
be lifted off the baseframe. For further
details, see the section below entitled
Sequence for dismantling the compressor.
It is important that dismantling and handling
of the various parts be done as described in
this instruction in order to avoid damage
when restarting the compressor.
Therefore, read the instructions carefully
before commencing the work.
Before disassembly of the compressor or
dismantling of its pipe connections, the
pressure must be equalized to atmos
pheric.
0178-250-EN
As O-ring gaskets have a tendency to

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

discharge side of the compressor to the
49
plant and oil separator (in case of total

dismantling).
3. Oil pipes connected to the compressor.
Note:
There may be oil in these pipes. They
should therefore be loosened carefully in
order to allow for collection of this oil.
When the oil pipes have been removed,
they should be stored to prevent them
from being bent or damaged.
4. Electrical connections to the compressor
block
In the following section the pos. numbers
refer to the spare parts dwg. 0661-850 for
SAB 202.
Draining oil from the compressor:
Following dismantling of the oil pipes, some
oil may still be left in the compressor. Most of
it can be removed by unscrewing the
threaded plug pos. 24 on the bottom side of
the compressor while still suspended, for
example, in the crane. (see weights under
Compressor Data SAB 202)
Note:
For cleaning or wiping of compressor
parts, never use twist or any other fluffy
material.
Dismantling the compressor
Sequence for dismantling of the
compressor:
Parts to be dismantled
Sequence
Oil filter
Suction filter and compr.protect.system
Non-return valve
Shaft seal, balance piston
and cap cover
Thrust cover/regulating cylinder
Regulating slide
1
2
3
Slide stop for Vi-regulation

Suction cover and bearings
in compressor shaft end
Rotors and bearings at compressor
discharge end
Capacity indicator
7
8
4
5
6
9
10
Each point is described in the following

sections, in connection with the stated
numbers.
Reassembling the compressor
Clean all parts carefully before reassembly.
Examine the parts for damage and wear.
Replace damaged or worn parts with new
ones. Examine all gasket to see if they can
be reused. If in doubt, replace with new
parts.
Before remounting, lubricate all parts,
including screws, with clean fresh refrigerant
oil.
1. Oil filter
Oil filter pos. 470 is a replaceable filter
cartridge, mounted in the compressor block
as shown on the spare parts drawing. As the
filter capacity of the filter cartridge is being
used the pressure loss across the filter will
increase. This is registered by the two
pressure transducers pos. 752 and pos. 753.
Make sure that a new filter cartridge is at
hand as the replaced oil filter cannot be
cleaned.
Before removing the filter cartridge from the
compressor block, stop the compressor and
50
0178-250-EN
the pressure will be equalized to atmospheric

pressure. Further, empty the oil filter
housing of oil, which is done by using
drainage valve pos. 48 see piping diagram
as well as fig. 1.1. This drainage is most easily carried out while there is still some excess
pressure left in the compressor.
1.2
Fitting of oil filter
1.2.1. After cleaning cover pos. 450 on the
inside, mount filter cartridge pos. 470
and O-ring pos. 453. Fasten these
parts with nut pos. 455.
1.2.2. Position the complete cover, pos. 450,
together with O-ring, pos. 452, in the
compressor and fasten with screws,
pos. 456. Make sure that the O-ring,
pos. 475, has been fitted.
Fig. 1.1
48 Cutting ring connection

Pipe dia.OD = 10 mm
ID = 8 mm
magnetic particles with a clean and

fluff-free piece of material.
1.2.3. Mount and fasten screws, pos. 476.

1.2.4. Mount the electric connection to
pressure transducer, pos. 753.
Replacement of oil filter
Once the pressures in the compressors has

been equalized to atmospheric and oil
drained off the oil filter housing, the oil filter
can be removed in the following way:
1.1.1. Remove the four screws, pos. 476,
while keeping the flange for the oil
pipe fixed to the cover, pos. 450.
1.1.2. Dismantle wiring connections on
pressure transducer pos. 753.
1.1.3. Remove the four screws, pos. 456,
and cover, pos. 450, and oil filter
cartridge, pos. 470, can now be
extracted manually as one entity. Pay
attention to O-rings, pos. 475 and pos.
452.
1.1.4. By dismantling nut pos. 455 the filter
cartridge pos. 470 can be pulled out
across stay bolt pos. 458. Pay
attention to O-ring pos. 453. As it is
not possible to clean the filter
cartridge, replace it by a new one.
1.1.5. Solenoid filters pos. 459/460 are not
dismantled but are wiped clean of any
0178-250-EN
51
2. Suction filter and compressor

protecting valve
2.1
remove the cover, pos. 705, as

follows:
Suction filter
The suction filter is built into the
compressor housing above the rotors.
2.1.2. Remove the screws, pos. 721, that

keep the pipe connection, pos. 720,
fixed to the manifold, pos. 710.
The purpose of the filter is to collect

the impurities conveyed from the
evaporator system with the suction
gas.
2.1.3. Before removing screws, pos. 706, it

is a good idea to support the cover,
pos. 705, by suspending it in eye bolt
no 28 from the tools kit. Fit the eye
bolt in the threaded hole in the outer
diameter of the cover. Total weight of
the cover is approx. 45 kg.
Experience shows that a good deal of

impurities is collected in the filter
during the initial period following
start-up of a new refrigeration plant.
It is important, therefore, to clean the
suction filter when the compressor has
operated for 200 hours after the initial
start-up.
If the suction filter is not taken out and
cleaned, there is a risk of it bursting as
a result of too high a differential
pressure across the filter.
Removal and cleaning
2.1.1. When the pressure in the compressor
has been equalized to atmospheric,
2.1.4. After the screws, pos. 706, have been

dismantled, lift the cover a few
millimetres and carerully pull it out of
the compressor block. Take care that
the long valve, pos. 704, does not do
any damage to the suction filter, and
pay attention to the O-rings, pos. 707
and 722.
2.1.5. The suction filter, pos. 170, is
available in an old and a new
construction of which the new suction
filter is fitted with a collar as illustrated
in the drawing:
52
0178-250-EN
pos. 705. Additionally, the new suction

filter must be turned for the notch,
pos. C, to point slantwise to the right
as shown in the drawing in section
2.1.5. The two holes, pos. D, must be
positioned horizontally.
The two different filters can be

mounted on the compressor randomly.
Remove the suction filter manually or
pull it out using the two extraction
fittings in the old construction, or the
two 7 mm diameter holes, pos D, as
illustrated in the drawing.
Make sure that filth does not get into
the compressor when dismantling the
suction filter.
2.1.6. Cleanse the suction filter in oil solvent
and blow clean it with compressed air.
Mounting
2.1.7. Before mounting check that the filter
mesh in the suction filter is
undamaged. Further, the filter housing
in the compressor and cover pos. 705
together with valve pos. 704 must be
completely clean without any further
dismantling taking place. Make
sure that non-return valve pos. 259
moves easily back and forth.
2.1.8. Mount the suction filter in the filter
housing manually so that the abovementioned two extraction fittings or
the flange, pos. A, front the flange,
0178-250-EN
2.1.9. Position the cover, pos. 705, and

make sure that the valve does not
damage the suction filter during
mounting. It is a good idea to use eye
bolt no 28. Remember the O-rings,
pos. 707 and 722.
2.1.10.Mount and fasten the screws, pos.
706 and 721, by first giving them a
light turn so that the cover fits in with
the two plant surfaces. Then fasten
the screws with the prescribed torque,
in accordance with the table on
Torque moments.
2.2
Compressor protecting system

To protect the compressor against
inadmissible high pressures the
compressor has a built-in protecting
valve type POV, pos. 704, controlled
by pilot valve type BSV8, pos. 700.
The protecting system is described
below:
53
Fig. 1
Pilot valve, BSV8, pos. 700
Main valve, POV, pos. 704
Evaporator
Oil separator, condenser
Condensing pressure
Evaporating pressure
Compressor
Functional description
The pilot valve, shown in fig. 1, is actuated by
the high pressure P1. The valve is supplied
with a stainless metal bellow . The
reference pressure in the bellow is the
atmospheric pressure. The effective area of
the bellow is exactly equivalent to the area of
the valve seating, which means that the back
pressure P2 does not affect the opening
pressure of the valve.
The main valve is a normal closed valve. The
high pressure P1 is affecting the lower side of
the valve cone propagating up through the
piston rod to the upper chamber of the
valve, producing a pressure on the piston .
The area of the piston is larger than the area
of the valve seating. Together with the power
of the spring this will keep the valve closed.
increase. The pressure of the lower chamber

is limited by flow through the nozzle . When
the flow through the pilot valve exceeds the
capacity of the nozzle, the pressure of the
chamber will increase, providing the
opening of the main valve. When the
pressure P1 is reduced, the pilot valve will
close, and the pressure P2 is equalized
through the nozzle . The spring will then
close the main valve. The closing time is < 30
seconds, depending on the size of the
nozzle. The spring is dimensioned to the effect that the difference pressure (P1-P2) of 7
bar will make the valve open completely.
The pilot valve BSV 8 is designed to a max.
opening pressure < the set pressure +10%
and the closing pressure > the set pressure
-10% in the pressure area 10-25 bar.
When the pressure P1 reaches the set pressure of the pilot valve, it will start opening.
The pressure P2 of the pilot line and of the
lower chamber of the main valve will
54
0178-250-EN
Dismantling and assembly

Usually, it is not necessary to dismantle the
compressor protecting system from flange
pos. 705, and it is not advisable to dismantle
the individual components.
b: Put a pressure of approx. 7 bar on the

system and apply soap water to the pipe
connection pos. 1 right to the pilot valve.
Fig. 2
1
POV main valve
Any checking of the correct opening

pressure, which is stamped on the nameplate
on the pilot valve, should be done on the
entire system.
Test pressure is added through a flange
mounted on the manifold pos. 710. That is
where the pipe connection pos. 720 is
usually fitted. Once the opening pressure has
been reached, the BSV8 pilot valve opens
and the compressed air flows out through
the lateral connecting piece on the POV main
valve, which opens modulating, thus
equalizing the pressure.
7 bar
BSV 8 pilot valve
Pipe connection pos. 720
At the same time pipe connection pos. 1 in

fig. 2 should be leak tested. This is done as
follows:
As it appears from fig. 3 the pipe connection,

pos. 720, has a bigger cross-section for HFC
and HCFC compressors than for R717
compressors.
a: Shut the flange just mentioned on the manifold pos. 710 tightly and jam in flange
pos. 2 with the lateral connecting piece on
the POV valve, as shown in fig. 2.
However, the two models have one thing in

common: they follow the same procedure for
cleaning the suction filter as described in
section 2.1.
Fig. 3
with main valve POV 50
705
with main valve POV 80
705
710B
710A
721A
722A
721B
722B
720
720B
715
0178-250-EN
55
3. Non-return valve
The non-return valve is mounted on the
intermediate flange pos. 253 and positioned
in the suction chamber. While the
compressor is idle the non-return valve is
closed by means of spring pos. 261. See
sectional drawing.
After start-up of the compressor the
non-return valve opens and the compressor
is able to suck in refrigerant gas.
When the compressor stops, the non-return
valve shuts off immediately and hereby
prevents the compressor from running
backwards.
In valve cone pos. 259 a hole of dia. 6 mm
has been bored which slowly equalises the
pressure in compressor and oil separator to
suction pressure at compressor standstill.
Dismantling
S Dismantle the compressor protection
valve and the suction filter as described
in section 2.
S Seal the opening to the rotors with a cloth
free of flocks in order to prevent foreign
particles from falling down to the rotors.
Do never use twisted yarn, paper or
several small cloths.
S Now the suction nonreturn valve can be
dismantled by means of the screw
pos. 258.
S Dismantle the valve cone pos. 259 by removing the countersunk screw pos. 265.
56
S Dismantle the valve spindle pos. 260 by

pushing the spindle guide pos. 256 so that
the locking ring pos. 268 is clear of the
spindle guide. Dismandle the locking ring
and extract the spindle from the spindle
guide. Note that the spindle is springloaded.
S Tape bearings, pos. 262 and pos. 263,
usually remain in the groove of the
intermediate flange, pos. 253, and must
normally not be replaced. However,
replacement should take place in case the
tape of the bearing bushing is removed.
The tape must then be positioned with its
perforated side against the spindle for
non-return valve.
Mounting
Assemble the non-return valve in the reverse
order from described above. Note the
following, however:
S The bearing tapes, pos. 262 and pos. 263,
must be undamaged and correctly fitted in
the grooves in the spindle guide, pos. 256.
The perforated side of the tape must face
the spindle, pos. 260.
S The O-ring, pos. 707, must be in one
piece and mounted on the flange, pos.
705, before it is fitted on the compressor
housing with the screws, pos. 706.
After the mounting has been completed,
check that the non-return valve is easy to
push into the suction filter and that the spring
forces the valve cone back correctly.
0178-250-EN
4. Shaft seal, balancing piston

and cap cover
Fig. 4.1
3-4 mm
The rotating part of the shaft seal, in which

the carbon ring is mounted, is fastened at the
rotor shaft by the 3 pointed screws, pos.
160E, and sealed by means of the stationary
O-ring, pos. 160C.
167
166
165
160D
161
110
113
160E
162
160B
160C
134
160A
T0177135_13
Pos. No.
Rotating part with carbon face
160 A
Cast-iron seat
160 B
Inner O-ring
160 C
Outer O-ring
160 D
Pointed screw
160 E
O-ring for cover
166
The shaft seal must ensure complete tightness between the compressor shaft and the
compressor housing, so that the inside of the
compressor is completely sealed off from the
atmosphere.
The shaft seal shown in fig. 4.1. has a built-in
rotating part, which, apart from ensuring
tightness, also assimilates axial displacement
and provides the necessary compressive
force between the two slide faces mentioned
below.
The shaft seal is a slide ring type, consisting
of a stationary cast-iron seat, pos. 160B,
which is positioned in the shaft seal cover
pos 165. Rotation is prevented by retaining
the pin, pos. 161.
0178-250-EN
Be very careful with the lapped slide

surfaces on the cast-iron slide ring and
the carbon slide ring as the slightest
scratch will impair their sealing effect.
Dismantling of shaft seal
135
Designation
The end surface of the cast-iron seat is

lapped in order to create tightness as a slide
surface. The O-ring, pos.160D, seals against
the shaft seal cover, pos. 165.
S Take the pressure off the compressor as

described earlier and dismantle the
coupling.
S Remove screws, pos. 167, and pull the
shaft seal cover out of the shaft. In case
the cover sticks it can be pushed out by
mounting two screws, pos. 167, in the two
threaded holes of the cover.
S The oil throw-off ring, pos. 162, and the
cast-iron seat, pos. 160B, will emerge with
the cover.
S After the 3 screws, pos. 160E, have been
loosened a couple of turns, the rotating
part of the carbon ring can now be pulled
out over the shaft. Normally, no auxiliary
tools are needed.
Mounting of shaft seal

S Give the shaft seal cover, pos. 165, and
the rotor shaft a thorough cleaning. Check
that the shaft is free of scratches and
marks that could cause leaks.
S Then lubricate the shaft and the shaft seal
parts with the same refrigeration oil as the
one used in the compressor.
57
S Carefully press the rotating part over the

rotor shaft until it touches the balance
piston, pos. 134.
S Tighten the 3 pointed screws, pos. 160E,
in turns by means of the Allen key
included in the delivery.
S Mount the cast-iron seat, pos. 160B, and
the O-ring, pos. 160D, in the shaft seal
cover and make sure that the retaining
pin, pos. 161, catches the slot in the seat,
pos. 160B.
S Guide the shaft seal cover carefully over
the shaft until resistance is felt from the
rotating part. Before the screws, pos. 167,
are tightened there must be a gap of 3 to
4 mm between the two flanges as shown
in fig. 4.1.
S Check that the O-ring, pos. 166, is
positioned correctly.
S Tighten the screws, pos. 167, in turns in
order to avoid damaging the shaft seal
due to an uneven tightening. Tighten the
screws with a torque as described in the
instruction manual.
58
S Mount the oil throw-off ring, pos. 162.

Mount the coupling as described in the
instruction manual and turn the shaft by
hand in order to check its smooth running.
Balance piston at suction end

Position the balance pistons, pos. 134/137,
on the rotors so that the screws, pos. 113,
catch the holes in the rotors as shown on the
spare parts drawing.
Tighten the screws with the torque as described in the instruction manual.
Position the spacer rings, pos. 135/138,
around the balance pistons, pos. 134/137.
Note, that the retaining pins, pos. 136/139,
must be mounted so that the slot faces the
housing.
Cap cover
After dismantling the screws, pos. 167,
dismantle the cap cover, pos. 163, by
mounting two of the screws in the free
threaded holes in the flange of the cap cover.
Hereby the cap cover can be pushed out.
The cap cover is remounted in the same
way as the shaft seal cover.
0178-250-EN
5. Thrust cover and regulating

cylinder
The purpose of the regulating cylinder in
thrust cover, pos. 40, the built-in piston
system and the capacity slide, pos. 200, is to
adapt the capacity of the compressor to the
immediate cooling requirements of the plant.
The system works by letting the piston consisting of parts pos. 201, 202, 203 and 204
move the capacity slide pos. 200 back and
forth hydraulically. This opens modulatingly
for an internal by-pass channel which - when
the position of the piston is to the extreme
right on the drawing - is most open. The
compressor now runs at its lowest capacity.
Dismantling
S First, dismantle the pipe connections to
the cover, pos. 60.
,pos. 200, and the piston, loosen the cover,

pos. 60. The cover is now pulled straight out
in order to avoid damaging the spindle, pos.
210.
Watch out, there may be oil behind the cover, pos. 60.
S It is now possible to pull the complete
capacity slide with piston, pos. 201 and
202, out of the cylinder. Please note that
the Vi slide, pos. 190, can also be
extracted from here if necessary. First dismantle the blank-off screw and the gasket,
pos. 24/25, however and push the Vi slide
slightly forward so that screw, pos. 192
,can be removed through the side hole.
S The thrust cover, pos. 40, weighs approx.
80 kg and must therefore be suspended in
a crane before the screws, pos. 41 are
removed.
S During manual Vi regulation it is an

advantage to unscrew the Vi slide as far
as possible by turning the spindle, pos.
180 , clockwise. This slackens the spring,
pos.
191, as much as possible.
S Now mount the two pointed screws no. 45

from the tools kit in the holes A, see fig.
5.2, and insert them by turning them only
3 to 4 turns into the thread. Next, fit the
two screws no. 16.1 in the thread of the
thrust cover on top of the two pointed
screws in holes A.
S Next, dismantle the complete capacity

indicator by unscrewing two diagonally
positioned screws, pos. 62. Mount two
threaded spindles no. 22 in their place as
well as nuts no. 9.2 from the tools kit as
shown in fig. 5.1.
S By tightening screws no 16.1 alternately,

the thrust cover is pulled free of the two
guide bushings, pos. 22, that guide the
thrust cover towards the compressor
block. The bushings are positioned in
holes B.
Fig. 5.1
Fig. 5.2
62
60
9.2
22
T0177135_14
Now remove the remaining screws, pos. 62

,and by loosening nuts no. 9.2 alternately the
large spring, pos. 191, will, via capacity slide
0178-250-EN
A description of the mounting of the thrust

cover, pos. 40, and the capacity indicator
with cover, pos. 60, can be found in section
6: Regulating slide.
59
6. Regulating slide
Dismantle the complete capacity slide with
piston, pos. 201 og 202, as described in
section 5: Thrust cover and regulating
cylinder.
Any dismantling of the piston rod, pos. 207A,
and the slide, pos. 200, can be done by
removing the set screw, pos. 311, as well as
the locking device, pos. 312.
The circlip, pos. 207D, and the steel ball,
pos. 207E, act as a kind of non-return valve.
At an emergency stop this non-return valve
ensures the quick movement of the capacity
regulating slide to its minimum position as
the oil is emptied through the non-return
valve.
In case the sealing ring, pos. 204, has been
damaged it must be replaced. This is done
be removing the groove nut, pos. 206, and
the locking plate, pos. 208, whereby the
outer and inner rings of the piston can be
dismantled. Pay attention to the O-ring, pos.
203.
Antifriction tapes, pos. 209, have been fitted
on the end surface of the capacity slide.
Their length is adapted so that they can be
placed loosely in the groove of the capacity
slide.
Mounting
Mounting of the thrust cover, capacity slide
and capacity indicator is done in the following
order:
S Mount the two guide bushings, pos. 22, in
holes B of the compressor block, see fig.
5.2.
S Position the thrust cover with the O-rings,
pos. 43 and 49, against the compressor
block and guide it into its place by means
60
of the guide bushings which are pulled

towards each other with the screws, pos.
41. Remember to place washers, pos. 23
,under the screws fitted in holes A and B cf. fig. 5.2 - and to tighten all screws, pos.
41, with the prescribed torque moment.
S In case the Vi slide has been removed it
must be refitted. Fit and tighten the
screws, pos. 192 and 24/25.
S Assemble the complete capacity slide on
the work bench while paying special
attention to the following:
that the screw, pos. 311, with locking
device, pos. 312, has been tightened
correctly.
that the two antifriction tapes, pos. 209,
are fitted correctly in the capacity slide,
pos. 200.
that the steel ball, pos. 207E, and the
circlip, pos. 207D, have been fitted.
that the piston parts, pos. 201 and 202
,have been mounted on the piston rod,
pos. 207A, fastened with the groove
nut, pos. 206, and secured with the
locking plate, pos. 208. Remember that
the opening of the sealing ring, pos.
204, must be facing the capacity slide.
Do not forget the O-ring, pos. 203.
S Mount the spring, pos. 191, and insert the
complete capacity slide in the thrust cover
while guiding it carefully into place until
the spring starts resisting.
S Mount the two threaded spindles no. 22
in the end surface of the cylinder and
position the cover, pos. 60 on the
threaded spindles, while first letting the
spindle, pos. 210, catch the pin, pos.
207C.
By an alternate tightening of nuts no. 9.2
the cover is pressed against the capacity
0178-250-EN
slide and the entire system is pressed

against the spring.
Take special care not to damage the
sealing ring, pos. 204, while inserting it
in the cylinder.
S Tighten two of the screws, pos. 62. Next,
dismantle the two threaded spindles and
nuts which are replaced by the two other
screws, pos. 62.
S Mount pipe connections.
7. Slide stop for Vi regulation

The purpose of the Vi-regulating system is to
regulate the built-in volume ratio of the
compressor so that the compression ratio of
the compressor is equal to the pressure ratio
between the condensing pressure and the
evaporating pressure in the refrigeration
plant.
The system works by displacing the slide
stop, pos. 190, hereby - via the regulating
slide, pos. 200 - changing the size of the discharge port of the compressor. This change
of the size of the discharge port increases or diminishes - the compression chamber
and consequently the compression ratio.
As described in the following, the
Vi-regulation can be done in two ways:
A: Manual Vi-regulation
B: Automatic Vi-regulation
The two systems cannot be mounted
simultaneously, however.
A: Manual Vi-regulation
Manual adjustment of the Vi slide stop
position is described in a separate section in
this instruction manual. Please refer to table
of contents and fig 7.1.
0178-250-EN
Dismantling
S After dismantling the screws, pos. 198, the
entire unit with the slide stop cover, pos.
181, and the bearing retainer, pos.185,
can be unscrewed by turning the spindle,
pos.180, anti-clockwise.
When the spindle has been unscrewed
completely from the thread in the threaded
washer, pos. 189, the unit can be removed
manually.
S By dismantling the screws pos. 196, the
cover, pos. 181, is dismantled from the
bearing retainer, pos. 185, and the sealing
washer, pos. 182, the sealing ring, pos.
183, and the O-ring, pos. 184, can be removed manually.
S The spindle, pos. 180, and the ball
bearings, pos. 186, can now be pushed
out of the bearing retainer, pos. 185.
S The slide stop, pos. 190, and the slide
guide, in which the spring has been fitted,
are pressed together and should normally
not be disassembled.
The whole unit cannot be extracted from
the compressor until the suction cover,
pos. 20, has been dismantled. Cf. section
8 or the description found in section 5.
61
S The screw, pos. 192, acts as a slide stop

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

pos. 196.
Check that the spindle is easy to turn.
S Mount the whole unit in position by
screwing the spindle into the thread
washer, pos. 189, until the slide stop cover, pos. 181, bears against the suction
cover, pos. 20.
Pay attention to the O-ring, pos. 197.
S Secure with screws, pos. 198.
B: Automatic Vi-regulation
By automatic Vi regulation, the slide stop is
moved by oil pressure controlled by solenoid
valves and a position transmitter pos. 410.
Adjustment of the system is described in the
following chapter: System for regulating the
capacity and the Vi-ratio of SAB 202 of this
instruction manual.
Fig. 7.2
T0177135_1
62
0178-250-EN
Dismantling of the Vi-regulating system

S First dismantle the electrical connection to
the position transmitter pos. 410.
S Dismantle the pipe connection to the
cover, pos. 380.
S After dismantling the screws, pos. 382,
it is possible to extract the cover, pos. 380
including its parts as one unit, but care
must be taken not to damage the spindle,
pos. 390, and the sealing ring, pos. 371.
S Dismantle the magnetic coupling, pos.
405, by removing screws, pos. 403. This
makes it possible to remove the position
transmitter, pos. 410, with the flange, pos.
402.
S Dismantle the driving disk, pos. 395, and
the screw, pos. 396, while holding it back
by means of a screwdriver of a suitable
size inserted in the slot of the driving disk.
S By removing the screws, pos. 401, it is
possible to dismantle the housing, pos.
400, and the magnetic coupling, pos. 405,
can be dismantled from the flange, pos.
380 and be taken apart.
See Dismantling of magnetic coupling in
the following section.
S Dismantle the piston in the flange, pos.
380, by removing screws, pos. 387,
whereby the flange, pos. 384, the sealing
ring, pos. 371, and the ball bearing, pos.
393, can be dismantled.
S Slide guide and slide stop, pos. 190, cannot be extracted before the suction cover,
0178-250-EN
pos. 20, has been removed. See section 8

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

retaining pin, pos. 413, must engage in
the slot in driving disk, pos. 395.
63
Position transmitter
S In case arm no. 4 has been dismantled
from the transmitter, it must be fitted
correctly as follows:
S Find the 4mA point of the transmitter
by turning the shaft as described in
the Instruction manual for UNISAB
II.
5
4
3
S Mount arm no. 4 so that pin no. 3 is

positioned as shown on the sketch.
S Tighten the pointed screw no. 5.
S Mount the transmitter, pos. 410, as shown
in fig. 7.2 with the connection facing downwards.
64
0178-250-EN
Magnetic coupling for Vi-indication

The rotating movement from the spindle, pos.
390 - see fig. 7.2 - is transferred to the transmitter, pos. 410, through a magnetic
coupling, pos. 405, which is completely tight
so that neither oil nor refrigerant can pass
through the coupling.
Usually, it is not necessary to dismantle the

magnetic coupling, but on dismounting
spindle, pos. 390, proceed as follows:
Fig. 7.3
3
9
AA
S
NS
SN
N
S
N
S
N
S
N
S
N
S
10
4
11
N
S
SN
NS
390
1
A
6
7
406
from T4161061_0
Dismantling:
S After the magnetic coupling has been dismounted from the compressor as already
described, dismantle circlip no. 1. The
magnet retainer no. 2 and bearing no. 3
can now be pulled out against the magnetic force which is rather strong.
S After removing screw no. 4 spindle pos.
390 can be dismantled.
S Bearing no. 3 can be released once circlip
no. 5 has been removed.
S Should it be necessary to dismantle the
magnetic coupling, screw no. 6 can be
loosened by inserting a 2.5 mm Allen key
0178-250-EN
in the hole in the magnet retainer no. 7.

Pay attention to washer no. 11. Magnet
retainer no. 7 and flange no. 8 an now be
pulled apart.
S After removing circlip no. 9, ball bearing
no. 10 can be pulled out.
Assembly of magnetic coupling
Assembly is done in the reverse order to the
dismantling. Note the following, however:
S We recommend not to insert magnet
retainer no. 2 in the coupling until the
spindle, pos. 390, has been fitted as the
magnetic force makes it very difficult to
dismantle the parts again.
65
8. Suction cover and bearings

at compressor shaft end
Fig. 8.1
17.1
Before the bearing cover at the suction end,

pos. 20, can be dismantled, the following
parts must be removed as described earlier:
20
45
Shaft seal cover, pos. 165, and shaft seal

Cap cover, pos. 163.
Slide stop cover, pos. 181, for man. Vi and
380 for auto. Vi.
T0177135_2
S Carefully pull out the bearing cover across

the shaft pins and the slide bearings, pos.
111, will follow.
Dismantling
S Dismantle the screws, pos. 113, at the
balance pistons, pos. 134 and 137.
Fig. 8.2
Holes for pointed screws
S Pull out the balance pistons, pos. 134 and

137 as well as the spacer rings, pos. 135
and 138 manually.
S Suspend the bearing cover in a crane with
shackle and wire. (Weight 101 kg)
Holes for
stay bolts
S Dismantle the screws, pos. 26, 27 og 28.

S Mount the pointed screws no. 45 from the
tools kit in the two threaded holes at the
top of the bearing cover as shown in fig.
8.1 and fig. 8.2. Screw the pointed screws
completely into the compressor housing.
T0177135_3
S Mount the stay bolts no. 11 from the tools

kit in the two top holes, in which the bolt,
pos. 28, has been mounted. The stay
bolts must guide the suction cover while it
is being pulled across the shaft pins. See
fig. 8.2.
S With an arrangement as shown in fig. 8.3

the slide bearings can be pulled out of the
bearing cover. Screw the threaded pins
no. 3 into the threaded holes of the slide
bearing. Puller no. 2 is pushed against the
threaded pins and kept in place by nuts
no. 9.2.
S Mount the screws no. 17.1 in the same

holes as the pointed screws. By tightening
the screws the bearing cover will come
loose. See fig. 8.1.
S Position the thrust plate for puller no. 1 at

a right angle to the first plate. By
tightening screw no. 4 the slide bearing
will be pulled out.
66
0178-250-EN
Fig. 8.4.b
Fig. 8.3
4 9.2 2
111
20 111
20
112
112
T0177135_7
T0177135_6
Mounting
To mount the slide bearings, pos. 111, carry
out the following procedure:
S Before the slide bearing, pos. 111, is
pushed into place on the cover, pos. 20,
the guide pin, pos. 112, should be
mounted as illustrated in fig. 8.4.a.
The guide pin is knocked just 5 mm into
the hole in the slide bearing and is
straightened up to stand at a right angle to
the end plate.
Fig. 8.4.a
S The slide bearing is pushed into the cover,

pos. 20. The tools arrangement in fig.
8.4.c should be used for this purpose.
Fig. 8.4.c
111
112
S When the slide bearing, pos. 111, is

placed on the cover the bearing should be
positioned for the guide pin to reach the 6
mm hole in the cover - as illustrated in fig.
8.4.b.
0178-250-EN
112
40
9.1
111
20
T0177135_7
S The guide pin, pos. 112, will at the same

time be pushed into the slide bearing, pos.
111, and this guarantees that the slide
bearing is positioned correctly.
S The suction cover, pos. 20, is mounted on
the compressor housing, pos. 10, when
the rotors have been mounted. Cf. chapter
9.
67
9. Rotors and bearings at

compressor discharge end
Before the rotors can be removed from the
compressor, the parts mentioned in section 7
must be disassembled. Then proceed as
follows:
Remember to dismantle the tools again

before pressing out the rotors.
S It is now possible to push out the rotors,
pos. 110, - one at a time - by means of the
tools shown in fig. 9.2.
Fig. 9.2
Dismantling
17.3
14
16.1 17.3
S The thrust cover, pos. 40, must be

dismantled as described in section 5.
S Loosen the four locking screws pos. 45,
next loosen adjusting screws pos. 44
3-4 turns. Dismantle cross bar pos. 46 by
removing screws pos. 47.
S Remove inner covers pos. 153 by mounting tools no. 26 and 27 in the threaded
holes in the cover which is now carefully
pulled out.
Take care not to lose the two
cylindrical steel rolls pos. 155.
S Next dismantle screws, pos. 115, and the
thrust washer pos. 114 can be removed.
During their dismantling the rotors should
be locked in order to prevent them from
rotating.
For this purpose use arrangement in fig.
9.1 at the shaft end of the rotors.
Fig. 9.1
13
110
17.2
68
132
18
16.2
15
17.3
14
16.1
17.3
15
S Screw no. 16.2 and washer no. 18 from

the tool set should be mounted in the
thread hole at the end of the rotor to
protect the centre hole.
S Then mount the plate no. 14 with the
screws 17.3 and the bushes no. 15. Screw
no. 16.1 is mounted hereafter.
17.2
12
133
T0177135_0 V13
S By tightening the screw no. 16.1 the rotor

is automatically pushed out of the ball
bearing, pos. 132.
S When plate no. 14 is dismantled again,
the outer ring and the shim, pos. 133, can
be dismantled manually.
0178-250-EN
The innermost inner ring of the ball

bearings can later on be dismantled from
the rotors with tool no. 49 when the rotors
have been removed from the compressor
block.
Fig. 9.4
141
140
10
143
142
S Both rotors should be pushed as far out of

the block to allow a soft lifting sling to be
placed around them.
Since the weight of a set of rotors
amounts to approx. 170 kg, a crane or
another approved lifting device should be
used to lift the rotor set off the block.
S Pull out the main bearings, pos. 111, using
the tools shown in fig. 9.3. The bearings
should normally not be reused.
Fig. 9.3
T0177135_15
S Dismantle the screw, pos. 144, in each

discharge port as shown in fig. 9.4.a.
Fig. 9.4.a
A
AA
144
141 111 10
3
4.2
T0177135_8
S The discharge ports, pos. 140 and 141,

are dismantled in the following way:
S Dismantle the screws, pos. 142 and the
sealing plates, pos. 143, as shown in
fig. 9.4.
0178-250-EN
S An adjustment device fitted at each discharge port must be loosened before the
discharge ports can be dismantled. The
adjustment device exists in two different
designs dependent on whether the compressor was delivered before or after
January 1999.
S Design 1 (before January 1999)
As shown in fig. 9.4.b., the locking
screw, pos. 146, is first dismantled by
means of an NV5 Allen key, and then
the adjusting screw, pos. 145, is loosened 2 turns with the same Allen key.
69
Fig. 9.4.b
surfaces that are going to adjoin the rotor

housing.
10
145
Likewise, check the rotor housing for similar

defects on the corresponding contact surfaces.
146
Push the discharge ports into place in the

rotor housing and fasten with screws pos.
142 and new steel gaskets, pos. 143.
140
141
T0177135_15
S Design 2 (after January 1999)

This design is easier to use as the adjustment is made from the outside as
illustrated in fig. 9.4. c.
Fig. 9.4.c
141
140
148
147
10
S Tighten the screws, pos. 142, with half the

torque moment required (cf. the torque
table) to ensure that the discharge ports
stay close to the end plate in the rotor
housing.
Now loosen the screws and tighten them
slightly again to facilitate the following adjustment which is the same for both designs. Cf. the section Dismantling.
149B 149A
Mount the capacity slide, pos. 200, and

tighten the adjusting screw, pos. 148 (145)
slightly.
First, the blank off screw, pos.149A,

and the gasket, pos. 149B, are
dismantled. Then the locking screw,
pos. 147, is dismantled with the Allen
key no. 27-1. Loosen the adjusting
screw, pos. 148, two turns with the
same Allen key.
S The discharge ports, pos. 140 and 141,
can now be pulled out carefully using a
wooden stick or the wooden handle of a
hammer.
Mounting
Before positioning discharge ports pos. 140
and 141 in the rotor housing, check that they
are free of burrs and marks, especially on the
70
S While the capacity slide is pushed back

and forth, tighten the screws, pos. 148
(145) alternately until the capacity slides
can be moved back and forth easily.
S Then mount the locking screw, pos. 147
(146), and tighten well.
S In the case of design 2 the blank off
screws, pos. 149A, and the gaskets, pos.
149B, should be mounted and tightened.
S The screws, pos. 142, must be tightened
with the prescribed torque moment.
Please remember that the used steel
gaskets, pos. 143, must not be reused.
They must be replaced by new ones to
ensure tightness.
S Finally, the screws, pos. 144, should be
mounted in the two discharge ports - cf.
0178-250-EN
fig. 9.4.a - and tightened with the prescribed torque moment.
Fig. 9.5.c
7
141 140 10
S Before the slide bearings, pos. 111, are

fitted the guide pins, pos. 112, should be
mounted as illustrated in fig. 9.5.a.
Fig. 9.5.a
40
111
112
The guide pin is only knocked 5 mm into the

hole in the slide bearing and it is straightened
up to stand at a right angle to the end plate.
The guide pin, pos. 112, will at the same time

be pressed into the slide bearing, pos. 111,
and it is thereby ensured that the slide bearing is positioned correctly.
Mounting of the rotors
Before the rotors, pos. 110, are mounted in
the rotor housing it is recommended that the
Vi-slide, pos. 190, is fitted in the rotor housing to support the rotors.
Fig. 9.6
When placing the slide bearing on the compressor block, turn the bearing for the guide
pin to reach the 6 mm hole in the discharge
port - as illustrated in fig. 9.5.b.
8
8
8
Female
Fig. 9.5.b
140 141 112
10
Male
111
The rotors are marked with a number on the

end surface that faces the suction end of the
compressor.
The marking must have the same number on
both rotors and the catching between the rotors must, on mounting, be as shown in fig.
9.6.
The number 8 is given as an example.
Press the slide bearing into place against the
discharge port, pos. 140/141, using the tools
arrangement shown in fig. 9.5.c.
0178-250-EN
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.
71
Mounting of covers and bearings

After fitting the rotors in the compressor
block, mount the following:
1. Tighten the suction cover, pos. 20, with
the screws, pos. 26. Mounting must be
done using the staybolts no. 11 mounted
as as in fig. 8.2. The suction cover must
be fastened with the screws, pos. 26, 27,
and 28.
Remember the O-ring, pos. 21.
Check that the slide stop, pos. 190, moves
easily back and forth.
4. As shown in fig. 9.8, the thinnest spacing

washer, pos. 133, from the set of adjustment washers is fitted, i.e. the washer
which is 5.6 mm thick.
5. The ball bearing, pos. 132, is fitted. The
outermost inner ring is not yet to be
mounted.
6. Fit the inner covers, pos. 153, without the
O-rings, pos. 154.
2. Lock the rotors as shown in fig. 9.1.
7. Mount the cross bar, pos. 46, with the

screws, pos. 47. The adjustment screw,
pos. 44, should be mounted but not tightened.
3. Lubricate the rotor shaft with Molykote

grease.
8. Dismantle the locking tools mentioned in

item 2.
Press the inner ring of the ball bearing into

place by using the tools arrangement
shown in fig. 9.7.
Fig. 9.7
9. Mount the balance pistons, pos. 134/137,

in the suction side and tighten with the
screws, pos. 113. Push the spacer rings,
pos. 135/138, into place. They should
reach the retaining pins, pos. 136/139.
Inner ring for pos. 132

110
10
25.2
14
Fig. 9.8
10
T0177135_10
72
110 141
111 133 132 153
46
44
45
T0177135_12
0178-250-EN
Adjusting the axial play of the

rotors
After mounting of the bearings, as described
in the previous section, the axial play of the
rotors can be adjusted with the tools arrangeFig. 9.9
22
25.1 20
21
ment shown in fig. 9.8.

The dial meter measures on balance piston
pos. 134 for the female rotor and on pos. 137
for the male rotor.
Start by adjusting the female rotor.
20 134/137 111 110
50
Female
19
23
24
Adjustment
9.1
Use the tools arrangement in fig. 9.8.

By tightening nuts no. 25.1 until cover
no. 20 touches pipe pieces no. 21 the
spring will push the rotor up against
the discharge port at the other end of
the compressor frame.
Leave adjusting screw pos. 44 loose.
Position dial meter on 0.
9.2
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 may, f.inst., be 0.430

mm.
b:
As the correct movement must be

between 0,13 and 0,22 mm the medium figure to be used is 0,175 mm,
which is deducted from the measured
value that in example point a amounts
to:
0,430 0,175 = 0,255 mm
0178-250-EN
Male
T0177135_9
9.3
From the set of adjusting shims select

the shim that is 0,255 mm thicker than
the one that was first mounted and
which in the example pt. 3 was 5,600
mm. The thickness is stamped on the
shims. In the example given this
means: 5,600 + 0,255 = 5,855. The
shim that measures 5.85 is then
chosen in accordance with this
example.
9.4
By inserting the new shim as shown in

fig. 9.7 (pos. 133) and repeat the
adjustment mentioned in point 9.2 it is
made sure that that the movement
keeps within the tolerances mentioned
in point 9.2 (0.13 and 0.22 mm), and
the exact measure is noted for later
application (see section 9.10).
The exact measure for the female rotor
may, f.inst., be 0,171 mm after the adjustment mentioned in sections 9.3
and 9.4. In order to be able to insert
the shims, proceed as follows:
Loosen adjusting screw pos. 44.
73
Dismantle toggle pos. 46.

Remove inner cover pos. 153.
Remove by hand the outer ring of the
ball bearing with the balls.
Do not dismantle the remaining parts in the
tools arrangement.
9.5
9.6
The adjustment completed, loosen adjusting screw pos. 44 and toggle pos.
46 and dismantle inner cover pos. 153.
With tools as shown in fig. 9.5 mount
the outermost inner ring, and fasten
the thrust washer, pos. 114, by means
of the screw, pos. 115.
Tighten screw with 70 Nm.
9.7
Insert the cylindrical steel roll, pos.

155, in the groove of the outer ring of
the ball bearing turning it so that it the
groove faces upwards.
9.8
Position the O-ring, pos. 154, on the

inner cover, pos. 153, and mount tools
no 26 and 27 on the cover.
Replace the inner cover and turn it
with tools until the groove in the cover
catches steel roll pos. 155. This is felt
as the cover during the turning is
carefully pressed inwards and then
can be pressed in a little further when
the steel roll is caught by the groove in
the cover.
9.9
Mount toggle and tighten the adjusting

screw with 32 Nm. Check the movement of the dial meter once more. It
must now be within 0.13-0.22 mm.
Should the measure, against all
expectations, not be within the stated
limits, the entire adjusting procedure
must be repeated right from pt. 9.1.
74
Adjust the male rotor in the same way

as described in points 9.1 to 9.9, but mount
the adjusting tools laterally reversed to the
arrangement in fig. 9.8. Tool no. 12 must be
mounted on the male rotor so that it gets the
same length as the female rotor.
Final adjustment
When both rotors have been adjusted and
the exact measures noted, we are ready for
the final adjustment of the rotors.
First check that the two adjusting screws,
pos. 44, are loose.
9.10 The final adjusting measure must be
0,02 mm less than the exact measure.
If, for inst., the exact measure is 0,171
mm for the female rotor as indicated in
example pt. 9.4, the final adjusting
measure must be:
0,171 0,02 = 0,151 mm
With the adjusting tools mounted on
the female rotor as shown in fig. 9.8
and the dial meter set on 0, tighten
adjusting screw pos. 44, while reading
the dial meter. The indicator of the dial
meter must move the final adjusting
measure.
9.11 After the final adjustment lock the adjusting screw pos. 44 with pointed
screws pos. 45, and the adjustment of
the female rotor has been completed.
9.12 Next mount adjusting tools at the male
rotor as indicated in pt. 9.9.The
adjustment described in sections 9.10
and 9.11 is now repeated for the male
rotor.
9.13 Check that the rotors are easy to turn
by hand.
0178-250-EN
Function:
On moving the capacity slide pos. 200 the
spindle, pos. 210, is turned by means of the
helical key groove in the spindle. The spindle
turns the transmitter, pos. 350, via the
magnetic coupling, pos. 216, which is completely tight so that neither oil nor refrigerant
can pass through it.
10. Capacity indicator

The SAB 202 compressor is equipped with a
standard position transmitter which registers
the compressor capacity and transmits it to
the regulating system.
Fig. 10.1 Magnetic coupling pos. 216
50
70
71
216
221
210
218
217
61
Dismantling
After cover, pos. 60, has been dismantled
from cylinder, pos. 50, remove the following
parts:
S By removing screws, pos. 73, the
following parts are dismantled:
Flange pos. 72
Sight glass, pos. 75
60
219
223
224
350
75
74
72
73
S Remove screws, pos. 71, and indicator

housing, pos. 70, can be taken down.
S Dismantle indicator dial, pos. 221, by

loosening screw, pos. 223.
S By removing screws, pos. 219, the entire
O-ring pos. 74
magnetic coupling, pos. 216, can be

pressed out of the flange, pos. 60, by
Supporting ring pos. 224
hand.
0178-250-EN
75
Fig. 10.2 Magnetic coupling for capacity indication pos. 216

60
217
210
A
AA
1
S
218
NS
SN
N
S
N
S
N
S
N
S
N
S
N
S
SN
NS
S By dismantling circlip no. 1, as illustrated

by fig. 10.2, the inner magnet retainer no.
2 and spindle, pos. 210, can be pulled out
against the magnetic force.
219
from T4161067_2
S Before fastening indicator dial, pos. 221,

with screw, pos. 223, it should be positioned so that the slot points to the left and
40 below horizontal. See sketch.
S Dismantle spindle, pos. 210, by loosening

screw, pos. 218.
A further dismantling of the magnetic coupling is usually not necessary. Reference is
made to section 7, however.
Note:
We recommend not to insert magnet retainer no. 2 in the coupling until spindle,
pos. 390, has been fitted as the magnetic
force makes it very difficult to dismantle
the parts again.
Assembly
Assembly of the complete unit is carried out
in reverse order to the dismantling.
Pay attention to the following, however:
S On mounting of the magnetic coupling in
cover, pos. 60, O-ring, pos. 217, must be
fitted.
76
40
S On mounting of sight glass, pos. 75, it

should be positioned so that the 0 mark
is right above the slot in the indicator dial,
pos. 221.
S Transmitter, pos. 350, must be fitted on
the sight glass, pos. 75, so that the
electric socket faces downwards when the
0 mark of the sight glass stands right
above the slot in the indicator dial as
described above.
S The retaining pin no. 3 of the transmitter
must engage in the slot in indicator
washer, pos. 221, on mounting sight
glass, pos. 75.
0178-250-EN
Transmitter
Usage:
Assembly
The following drawing shows a position
transmitter for capacity signalling and
indication. The transmitter is fitted in the sight
glass with the plug facing vertically down.
The transmitter arm is turned by the indicator
dial by means of pin no. 3 engaging in the
slot of the dial, pos. 221.
The position transmitter is used for remote

indication of compressor capacity. By
integrating electronic limit switches into the
control, max. and min. compressor capacity
can be signalled, for instance.
Slide position
4.5 4.
3.5
Volume ratio
3.
100%
2.5
SPAN + ZERO
No. 3
2.
0%
T0177063_0
Connect the position transmitter to the

control system according to the following
table:
Terminal
1
2
3
Used for
Signal 020 mA
Power supply
24 V DC +/20%
Earth connection 0V
Not used
Adjustment:
S Turn the transmitter shaft until the output
signal is approx. 4mA. On UNISAB II the
display shows 0%. Secure the arm opposite the 0% mark on the sight glass. Fit
sight glass with transmitter on the compressor. Make sure that the pin no. 3
catches the slot in the indicator dial!
0178-250-EN
S Turn the sight glass until the 0% mark

aligns with the indicator dial with the
capacity slide in its minimum position.
S With the Zero screw adjust to the desired
minimum signal. With controls supplied by
SABROE, adjust to 4mA signal. One turn
with the ZERO screw changes the signal
to 2mA.
S With the capacity slide in maximum
position, adjust the output signal to 20mA
on the SPAN screw. One turn changes the
signal to 1mA.
Note:
The adjustment of the slide will affect the
max. position of the capacity slide. The
max. signal of the position transmitter
must therefore be adjusted on the SPAN
screw after adjustment of the Vi slide.
77
Notes:
78
0178-250-EN
System for regulating the capacity

and the Viratio of SAB 202
This chapter comprises the following three
systems:
1. Regulating of compressor capacity.
2. Automatic regulation of the Vi-slide.
3. Manual regulation of the Vi-slide.
0178-258-EN
98.05
Please, refer to page 1 to see the system of

your compressor.
1. Regulating of compressor
capacity
The regulating system is a complete
assembly as shown in fig. 1. It regulates the
compressor capacity by supplying or draining
oil from the capacity cylinder pos. 50 (see
spare parts drawing).
The system is connected to the oil pressure
at connecting branch B and the oil returns
0178-250-EN
from the capacity cylinder through branch A.

Branch C is connected to the capacity cylinder.
The system has built in two throttle valves
pos. 72, by which the oil flow and thus the
velocity of the capacity slide can be regulated. The throttle valves are meant to create
a regular movement of the capacity slide,
adapted according to the operating conditions.
Turning the spindle clockwise reduces the
oil flow.
Solenoid valves:
Pos. 70 is a normal closed valve.
Pos. 71 is normal open meaning that with a
dead coil it is open for passage.
79
Fig. 1
C
A
72
72
NO
71
74
NC
70
73
Function
1. At a constant capacity both solenoid
valves are closed so that pos. 70 is dead
whereas pos. 71 is supplied with current.
2. On regulating to a higher capacity power
is supplied to coil pos. 70 so that both
coils are now supplied with current. Hereby, pos. 70 opens and puts oil pressure on
the capacity cylinder, and pos. 71 remains
closed.
80
3. On regulating to a lower capacity the current is cut to both coils. Hereby, pos. 70
closes and cuts the oil pressure to the capacity cylinder. Pos. 71 opens and lets oil
flow away from the capacity cylinder
through the force of spring pos. 191.
4. By standstill of the compressor the current
to both solenoid valve coils is interrupted.
Hereby, the capacity piston is moved to its
0% position as described in pt. 3, and
the compressor is unloaded at the next
start-up.
0178-250-EN
2. Automatic regulation of the

Vi-slide
For regulation of the Vi-slide position use the
same type of regulating system that is used
for regulating the compressor capacity.
70 and pos. 71 will receive opening and

closing signals without it leading to
changes in the compressor capacity.
2.2 At reduced compressor

capacity
This system has been described in the previous section.
When compressor capacity is reduced from

100%, the following happens:
In the following functional description the solenoid valve in the Vi-regulating system designated as indicated in the dash-and-dot line
frames on drawing in fig. 1.
S With the UNISAB II regulating system the

capacity slide is moved away from the
Vi-slide, creating a gap between the two
slides.
The solenoid valves in question are hereafter controlled by UNISAB II so that the
capacity requirement and the Vi-slide position are controlled by the pressure ratio
above the compressor.
Pos. 73 is a normal closed solenoid valve.

Pos. 74 is a normal open solenoid valve.
The regulating systems can be controlled by
a UNISAB II, and they work as follows:
2.1 At 100% compressor capacity:

S Pos. 73 is open and maintains the oil
pressure on the Vi-slide piston so that the
Vi-slide pos. 190 is permanently pressed
against capacity slide pos. 200. (See
spare parts dwg.). Pos. 74 remains
closed.
S The Vi-regulating is controlled by the capacity regulating system which, by minor
corrections of pos. 200, adapts the Vi-ratio
to the suction- and discharge pressures
on the compressor. By this regulation pos.
0178-250-EN
When the compressor capacity increases to

100% and pos. 200 reaches pos.190, the
regulating systems will return to the function
described in section 2.1.
2.3 When the compressor stops

When the compressor stops, the current is
cut to all four solenoid valves.
Hereby, pos. 74 and pos. 71 open and allow
the two regulating slides to move to their
minimum position as the slides are pressed
away from each other by the force of spring
pos. 191.
81
3. Manual regulation of the Vi-slide

Instead of the automatic regulation of the
Vi-slide, as described in section 2, regulation
may be done manually.
However, both systems are not found in the
compressor at the same time.
Function
The Vi-slide pos. 190 works as a movable
stop for the capacity slide, thus regulating the
size of the discharge port (pos. 140/141) and
consequently the built-in Vi volume ratio of
the compressor.
The Vi-slide is moved by turning the spindle
pos. 180 a predetermined number of revolutions.
S By turning the spindle clockwise a lower
Vi is obtained.
S By turning the spindle anti-clockwise a
higher Vi is obtained
Important
S Adjustment must only take place while the
compressor is at standstill.
S On regulating the Vi-slide to max. or min.
position it must not be tightened against
the end stops. This could impede the
movement of the capacity slide.
82
If, therefore, the Vi-slide is adjusted to

max. or min. position, the spindle must be
loosened by turning it 1/2 to 1 turn in the
opposite direction from its extreme position.
For correct adjustment of the Vi-slide position
use the shown diagrams which are applied
as follows:
For the current refrigerant, type of compressor and the evaporating temperature TE follow the horizontal line to the intersection with
with the curve for the current condensing
temperature TC. From this intersection two
readings can be made by following the line
up or down:
S Vertically up, reading of the Vi-ratio referring to the scale on the compressor capacity indicator. Note, whether or not your
compressor is connected to an economizer.
S Vertically down, reading of the number of
revolutions the spindle pos. 180 must be
turned anti-clockwise from its extreme
position in order to obtain the optimum
efficiency at the given temperature conditions TE and TC. Note, whether or not
your compressor is connected to an economizer.
0178-250-EN
Adjustment of the
Vi-slide position
SAB 202S
R22
R134a
R404A/R507
R407C
2 2.5
Volume
ratio Vi
3 3.5
Vi
4.5
Vi
ECONOMIZER
SAB 202S
R22
R134a
R404A/R507
R407C
0
10
TC
C
20
30
55
50
40
30
20
10
40
50
Adjustment
of Vi
ECONOMIZER
40
2 2.5
Volume
ratio Vi
60
3 3.5
3.5
4
62
4.5
Vi
Single stage
4.5
TE
20
Vi
ECONOMIZER
SAB 202L
R22
R134a
R404A/R507
R407C
10
Single stage
60 62 Turns on the adjusting screw
40
0 20
T250824
Adjustment of the
Vi-slide position
SAB 202L
R22
R134a
R404A/R507
R407C
10
25 20
0
10
TC
C
20
30
55
50
40
30
20
10
40
50
60
C
25 20
0
Adjustment
of Vi
40
60
10
10
TE
20
0178-250-EN
4.5
Single stage
60
T250825
3.5
Single stage
67 Turns on the adjusting screw
ECONOMIZER
0 20
40
60
67
83
Adjustment of the
Vi-slide position
SAB 202S
R717
Volume
ratio Vi
2 2.5
3.5
4.5 Vi
ECONOMIZER
2 2.5 3
3.5
4.5 Vi
Single stage
SAB 202S
TE
20
0
TC
C
10
20
55
50
40
30
20
10
0
30
40
50
60
C
25
020
Adjusting
of Vi
T250826
Adjustment of the
Vi-slide position
SAB 202L
R717
Volume
ratio Vi
40
2 2.5
10
Single stage
60 62 Turns on the adjusting screw
40
0 20
20
R717
10
2 2.5 3
60
3.5
3.5
4.5 Vi
ECONOMIZER
4
4
ECONOMIZER
62
4.5 Vi
Single stage
SAB 202L
TE
20
0
TC
C
10
20
55
50
40
30
20
10
0
30
40
50
60
C
25
0 20 40
Adjustment
of Vi
T250827
84
0 20
40
20
R717
10
10
Single stage
67 Turns of the adjusting screw
60
60
ECONOMIZER
67
0178-250-EN
Torque moments for screws and bolts
Metric thread (ISO 8.8)

M
94.12
Kpm
10
12
14
16
18
20
22
24
27
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
Metric thread (ISO 12.9)
0171-465-EN
M
Kpm
10
12
14
16
18
20
22
24
27
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
85
Bolt on discharge valve

HPC/SMC 100
SMC 180
Kpm
3.2
10.2
35
ft.lbf.
23
75
255
Nm
32
101
344
A
Compressor type
Coupling
type
HPO/CMO/TCMO
AMR225
NORMEX
Nm
5/16
3.5
25
34
104-108 AMR312S
7/16
5.6
40
55
112-116 AMR350S
1/2
13
95
128
186-188 AMR450S
11/16
28
200
275
H148
M8
2.2
16
22
H168
M8
2.2
16
22
225
5/16
3.5
25
34
262
3/8
4.2
30
41
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
312
7/16
5.6
40
55
350
1/2
13
95
128
375
9/16
18
130
177
425
5/8
25
175
245
450
11/16
28
200
275
128
163
SAB
128
Series 52
163
86
depending
on the
motor size
Series 52
202
VMY
Torque (A)
ft.lbf.
NORMEX
HPC/
SMC/
TSMC
Thread
Kpm.
Series 52
AMR
HPO/CMO
0172-133-EN
Oil separator
Fig. 1
27A
27B
31
30
98.05
30
0178-259-EN
34
Design and operating mode

As illustrated in fig. 1 the oil separator system
consists of two vessels, of which the upper
one is the oil separator. Here the oil is separated from the discharge gas and led down
into the bottom vessel which serves as the oil
reservoir.
Both vessels are firmly connected to pipes
that cannot be cut off one from the other.
Oil separator
As illustrated in fig. 2, the discharge gas and
the oil from the compressor first pass the
demisters in which the main part of the oil is
separated from the discharge gas and
drained into the oil vessel.
Fig. 2
From the compressor
Demister
27B
27A
To oil vessel
Fine oil separator elements, pos. 55
However, the discharge gas still contains a

certain amount of fine oil drops that are separated as the discharge gas passes the fine
oil separator elements (the fine filters)
This oil is returned to the compressor in separate pipe systems as described further on in
this section.
As the velocity and specific weight of the gas
influences the efficiency of the fine oil separator elements, the units are available in two
executions according to the following guidelines:
0178-250-EN
87
1: Refrigerants HFC and HCFC

All units types SM-LM-SFand LF are delivered with two built-in fine filters and both
connecting branches, 27A and 27B, are
connected to the refrigeration plant.
Normally, the fine oil separator elements

need not be inspected, but if it is considered
necessary e.g. in case an increasing oil
consumption has been observed in the unit
they can be removed through the ends of the
oil separator.
2: Refrigerant R717
S All units types LM-SF og LF are delivered with two built-in fine filters and both
connecting branches, 27A and 27B, are
connected to the refrigeration plant.
S Unit type SM is delivered with one fine
filter and only the open connecting
branch, 27A/27B, is connected to the
refrigeration plant.
Fig. 1
to condenser
In the case of units with two fine filters it is

essential that the pressure loss through the
oil separator and the piping system is the
same in both passes. This requires that the
pipe connections from the oil separator to the
refrigeration plant are of equal length and as
symmetrical as possible as shown in fig. 1
and 2, whereas the asymmetrical principle
sketch shown in fig. 3 should be avoided.
Fig. 2
to condenser
Fig. 3
Oil return system for fine filter

element
Whether the unit is delivered with one or two
discharge stop valves, thus with one or two
fine oil separator elements, two oil return
pipes will be fitted on the unit. This may be
seen from the piping diagram at the end of
this book.
88
Throttle valves pos. 52 are used for adjustment of the oil flow through the oil return systems. Their adjustment is just enough to
make the pipelines feel warm during operation. In general, it is recommended not to
open the throttle valves more than 4 turns.
At the same time gas bubbles should be
visible in sight glass pos. 53.
0178-250-EN
Oil vessel
As already mentioned, the lubricating oil is
collected in the oil vessel. The oil level in
the vessel must always be visible in sight
glasses pos. 31. The correct amount of oil in
the unit is stated in a table in a previous
chapter of this book.
The oil vessel contains 2 heating elements,
pos. 30, which must be on whenever the unit
0178-250-EN
is not operating, and off when the compressor is started. Remember to switch off the
heating elements when oil is drained off the
oil vessel before an oil renewal.
Also remember that if the unit has been idle
for a lenghty period without the heating elements being switched on, these must be connected at least 8 hours before the unit is set
into operation.
89
Watercooled oil cooler type OWSG/OWRG for

screw compressors type
SAB 110, SAB128/163 Mk3, SAB 202
Used for
Hot oil inlet
Cooled oil outlet
Water inlet
Water outlet
Type plate
Air purging from water side
For cooling of the oil with water a welded

shell and tube heat exchanger can be delivered of the OWSG/OWRG type.
Design
The oil cooler consists, in principle, of a cylindrical jacket with a steel tube insert.
The cooler has oil inlet and outlet sockets in
the jacket, whereas the inlet and outlet for
water are placed in one of the end covers.
The covers are made of cast iron. The tube
insert consists of two tube plates, each with a
number of tubes welded in.
Baffle plates are placed between the tubes to
extend the oils passage through the cooler,
thus causing the oil to flow across the tubes,
90
0171-561-EN
No
1
2
3
4
5
6
95.10
T0177037_0
which significantly improves the heat transmission from the oil to the cooling water.
The end covers on the cooler are formed to
guide the water back and forth a number of
times in order to ensure an adequate water
velocity.
Oil cooler type OWRG is made of stainless
steel in two versions for fresh water and sea
water, respectively. The type is indicated on
the type plate of the cooler.
Futher, the oil cooler can be manufactured
with corrosion plugs on the end covers. To
maintain the corrosion resistance of the two
types of oil cooler, it is a condition that the
pipes never become overheated. Consequently, they must not be uncovered.
To avoid this, it is important that:
0178-268
S there are no air pockets on the water side

of the oil cooler. Therefore, the oil cooler
must be supplied with a purge valve on
top of the cover without connections. This
valve may be left out if the water discharge pipe points upwards, so that air can
escape together with the water.
S the water velocity through the oil cooler
should never be below 1.5 m/sec. Furthermore, this high water velocity prevents
fouling in the oil cooler.
In the fresh water versions, the content of
chloride (Cl-) in the water must not exceed
400 ppm.
In the case of a chlorine treatment, if any, of
water for the sea water version, the amount
of chlorine must not exceed 0.5 mg Cl2 per
litre water for 30 min. once every 24 hrs.
Besides, the oil cooler must be drained of
water for longer standstill periods (more than
1 - 2 weeks).
Application
The OWSG type oil cooler is designed for
connection to a fresh-water system incorporating anti-corrosion and anti-scaling measures.
0178-268
When operating with a cooling tower, rust inhibitors, algicides and anti-fouling must be
added to the water according to normal practice in connection with cooling tower systems.
The OWRG oil cooler type is used where the
quality of the water cannot be guaranteed
satisfactory and constant.
Cleaning
Fouling or soiling of the water side of the
cooler will reduce the heat transfer, and hence the capacity of the cooler.
The cooler must therefore be checked and
cleaned at regular intervals, depending on
the degree of purity of the cooling water. The
internal pipe diameter is 8 mm.
The OWSG/OWRG oil cooler can be cleaned
by removing the end cover with no connection branches and scrubbing the piping clean
with a bronze brush.
Give the tubing a final rinse with fresh water.
Alternatively, ready-mixed inhibitive scouring
acids can be used, with subsequent neutralization. Such agents must be designed for
untreated steel tube heat exchangers. The
chemical manufacturers instructions should
be followed precisely.
91
Regulating the oil temperature

Open system:
If the oil cooler is connected in an open system, i.e. it cools by means of cooling tower
water, other fresh water or sea water, the oil
temperature must not be regulated by altering the water flow through the cooler.
A decreasing water flow will result in fouling
and perhaps in clogged-up tubes which
would lead to corrosion on the tubes.
Instead, the following is prescribed:
S If necessary, use a temperature-regulated
three-way valve to regulate the oil flow
through the cooler.
On SAB 202 the oil temperatur regulation
is based on a two-way valve incl. pilot
valve. See piping diagram.
92
S Or use a temperature-regulated three-way

valve on the water side in connection with
a water pump to maintain the prescribed
water flow through the oil cooler.
Closed system:
OWSG
If this oil cooler is connected in a closed
system, such as a heat recovery system, the
water flow can still be regulated.
OWRG
Only use the mentioned oil coolers for the
prescribed water flow in order to minimize the
risk of corrosion as a result of the combination of high temperature and ClB content in
the cooling water.
Therefore, we recommend the use of the
same regulating system as prescribed under
Open system.
0178-268
Refrigerantcooled Oil Cooler type OOSI

SAB 202
4
5
1 pass
1
6
3
4
5
2
2 pass
1
6
0178-261-EN
97.03
T0177101_0/1
1
2
3
Oil inlet
Oil outlet
Refrigerant inlet
For cooling of the oil with refrigerant a closed, welded tubular heat exchanger of the
OOSI type can be used.
Description
The OOSI oil cooler is an all-welded tubular
heat exchanger manufactured in steel. On
the inside the pipes are equipped with a special insert in order to improve the heat transfer.
The oil flows through the pipes, while the refrigerant evaporates outside the pipes. It is a
flooded system, which is to say that the refrigerant leaves the oil cooler as partly evaporated (mixture of liquid and vapour). This
ensures that, under normal conditions, no oil
is accumulated on the refrigerant side.
Mounting
In order for the condenser to function correctly it has to be mounted higher than the oil
cooler to ensure a natural circulation of the
0178-268
4 Refrigerant outlet
5 Oil draining (oil side)
6 Oil draining (refrigerant side R717)
refrigerant. The draft on the following page is

an example of a common pipe layout.
Ex. 1: The receiver is placed above the oil
cooler.
Ex. 2: In case the inlet height (H1) is insufficient a small priority vessel can be
placed between condenser and receiver as shown in the example.
If it proves quite impossible to obtain
a satisfying inlet height, a pump
could possibly be mounted for the
refrigerant supply.
Normally, the inlet height (H1) will be
sufficient when constituting min. 75%
of the return height (H2), provided
that the horizontal length of the return pipe is less than 50% of the vertical pipe length or if executed min. 1
pipe dimension larger.
For detailed calculations and choice
of velocity, please see Capacities.
93
Ex. 1
Ex. 2
From the compressor
Condenser
Alternative
arrangement
From the condenser
C
Receiver
H1
E
to the evaporator
or main receiver
H2
Decrease 1:300
to the receiver
A
A
Oil cooler
R
Oil cooler
R
Increase 1:300
The oil temperature, typically within the range

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

Most units are fitted with an oil temperature
regulating system as described in the following section. This system is of special importance if, f.inst. during cold periods, the
condensing temperature at times drops below 20C during operation or below 10C
during standstill.
Should this oil temperature regulating system
not be fitted and the condensing temperature
drops below 10C at standstill, the liquid
supply line to the oil cooler must be closed.
For this purpose, a solenoid valve with a low
pressure drop, closing whenever the compressor stops, can be mounted. The valve
reopens once the compressor is working
94
again and the oil temperature has reached

min. 20C.
Before the compressor is started, the oil in
the pipe system must have a temperature of
at least 10C. In machine rooms without any
heating it may be necessary to mount a heating rod. Normally, oil separators are standard
mounted with heating rods in order to ensure
a sufficiently high oil temperature in the oil
separator.
In case several oil coolers are mounted in
parallel with a considerably different flow resistance due to the pipe lengths etc, a throttle
valve (R) (see Ex. 1) can be fitted in the
liquid supply line (A), so that the flow can be
equalized between the oil coolers and thus
ensure the full function of all oil coolers. Do
not throttle so much that the oil cooler does
not remain flooded.
Do not throttle the oil temperature by throttling on the liquid supply line (A) or the return
line (B). In that case the oil cooler does not
remain flooded, and the return line will only
contain refrigerant gas.
Hereby, oil will accumulate on the refrigerant
side in the oil cooler, causing malfunction and
a heavy thermal loading of the oil cooler. This
increases the risk of its break-down.
0178-268
0171-562EN
95.10
Watercooled oil cooler, type B

SAB 110, SAB 128/163 Mk3, SAB 202
No.
1
2
3
4
Used for
Hot oil inlet
Cooled oil outlet
Water inlet
Water outlet
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 assembled 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 connecting branches and the first heat- exchanger
plate, a row of channels is visible. By means
of a welding rod, for instance, check that the
V-pattern faces up-wards, preventing water
from accumulating here. Owing to the principle of its design, the heat exchanger cannot
be stripped down and must not be used in
R717 plants.
Application
The B-type oil cooler can only be used with
freshwater as cooling agent.
0178-250-EN
For water-cooling of oil in units with HFC/

HCFC a B-type soldered plate heat exchanger can be used. Refer to page 1 to see the
type of oil cooler used for this unit.
Cleaning
Since the oil cooler cannot be dismantled,
mechanical cleaning is not possible. It is therefore recommended that the water filter be
fitted before the oil cooler. Cleaning can only
be done with a cleaning fluid. The cleaning
intervals for the cooling water side of the heat
exchanger should be determined on the basis of the waters hardness and tendency to
deposit scale.
For cleaning purposes a weak acid can be
used as e.g. a 5% phosphoric acid or, if the
heat exchanger is cleaned often, a 5% oxalic
acid solution. Rinsing with plenty of pure water is then required to remove any remaining
acid and dirt.
95
Oil temperature regulation

Open system
If the oil cooler is connected in an open system, ie that it is cooled by means of water
from a cooling tower, other fresh water or sea
water, the oil temperature must not be regulated by altering the water flow through the
cooler.
A decreasing water flow could lead to fouling
and perhaps clogged-up cooling pipes which
would lead to corrosion on the pipes.
Instead, the following is prescribed:
S Adjust the oil flow through the cooler by
means of the temperature regulated threeway valve.
96
S Or use a temperature-regulated three-way

valve on the water side in connection with
a water pump to maintain the prescribed
water flow through the oil cooler.
Closed system
Only use the B-type oil coolers for the prescribed water flow in order to minimize the
risk of corrosion as a result of the combination of high temperature and ClB content in
the cooling water.
Therefore, we recommend the use of the
same regulation system as prescribed under
Open system.
0178-250-EN
Oil temperature regulating system

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

nameplate on the valve cover.
Function
Valve pos. 46 is fitted in a bypass piping system as shown in fig. 2:
Fig.1
Fig. 2
To the compressor
Oil cooler
0178-277-EN
98.05
Three-way
valve
This thermostatic three-way valve is used in

the following dimensions for above-mentioned compressor units:
Compressor unit
Valve
dimension
Welded
connection
SAB 110
RT3
DN 25
SAB 128
RT3
DN 25
SAB 163
RT5
DN 40
SAB 202
RT6
DN 50
SAB 330
RT6
DN 50
VMY 536
RT6
DN 50
0178-085-EN
From oil receiver
As shown in fig. 3 and 4, it works by letting a

built-in thermo element, pos. 1, regulate a
cone, pos. 2, so that cold and warm oil is
mixed to the set temperature.
In fig. 3 the thermo element is shown in its
cold position, i.e. the flow of cold oil has been
shut off whereas the flow of warm oil is completely unobstructed. Fig. 4 illustrates the opposite situation in which the thermo element
is in its warm position, hereby shutting off the
flow of warm oil.
97
During operation the thermo element will adjust the regulating cone modulatingly so that
the two oil flows are mixed to the set oil temFig. 3
perature, leaving the valve through connecting branch A.
Fig. 4
B
Varm oil
from oil
separator
B
Varm oil
from oil
receiver
Cooled
oil from
oil cooler
C
Cooled
oil from
oil cooler
2
1
A
Thermo element in cold 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:
Oil with
correct
mixed temp.
Thermo element in warm position
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.
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.
Assembling:
Dismantling:
S The O-ring, fitted in the cover, should be

replaced by a new one. See section Spare
Parts Survey in this manual.
During dismantling, if any, apply the following

procedure:
S After the pressure in the piping system
has been equalized to atmospheric, unscrew the four Allen screws that keep the
cover fixed to the valve housing.
S The cover which reaches down into the
valve housing in order to keep the thermo
element in a fixed position, is most easily
dismantlled by turning it slightly and then
98
Assembling the valve is done in the reverse

order and attention should be paid to the following:
S No sealing ring should be fitted between

the inner guideway of the cover and the
valve cone.
S In case the three-way valve does not regulate the oil temperature correctly, the
thermo element and cone can be replaced
as one entire unit. See section Spare
Parts Survey in this manual.
0178-085-EN
Notes:
0178-085-EN
99
Heating rods, pos. 30
For screw compressors starting with much

refrigerant dissolved in the oil, there is a risk
of the compressor being stopped by the Flow
Switch as the oil will be foaming owing to the
fall in pressure through oil pipe and oil filter.
Note:
The heating rod must not be energized if
the oil level in the reservoir is below the
minimum mark in the sight glass, and it
should generally be switched off during
compressor operation. Remember to turn
off the heating rod whenever the crankcase of the reciprocating compressor is
opened for inspection.
The following table indicates which heating
rods are used for the various compressor
types. In the spare parts lists for compressor
or unit you will find the current part numbers.
Marking:
NV 50
50
30
30
G 1 1/4
Prod. nr.
Watt
Volt
Manu. date
L1
L2
80
Heating rods
Power
Watt
Voltage
V
270
270
270
250
230
115*
460
460
460
250
230
115*
L1
mm
L2
mm
Used for:
CMO - TCMO - SMC 100 - TSMC 100
158
175
HPO - HPC, SMC 180 - TSMC 180

VMY 347 /447 536
SAB 110 128 163 202 330
* Can be delivered with a UL approval.

All heating rods are executed in Degree of Protection IP54.
100
0178-085-EN
98.05
In reciprocating compressors there is a

serious danger of vigorous oil foaming when
the compressor starts as a result of a falling
suction pressure.
As illustrated on the drawing the heating rod

consists of an electric heating element, incorporated in a dia. 30 mm pipe. The entire heating cartridge is screwed on tight at the
G 1 1/4 thread.
0170-017-EN
In order to keep the lubricating oil in the compressor warm during a period of standstill,
the oil reservoir has one or two heating rods
built in. Before start-up, the heating rod (s)
must have been activated for 6-8 hours in
order to ensure that there is only a minimum
of refrigerant in the oil. When containing
much refrigerant, the oil will lose its lubricating property and the following operational interruptions may occur:
External oil filter

The compressor unit may be executed with
an external oil filter, pos. 106, mounted in
the oil pipe between the oil separator/the oil
cooler and the compressor. In case of an external oil filter, no oil filter will be mounted in
the compressor block.
Concerning the construction of the compressor unit, please see page 1.
The filter housing may be either cast or

welded, but the filter insert is the same for
both.
0178-266-EN
97.12
The external oil filter may be designed with

either one or two parallel filters.
Stopping the compressor at too high a differential pressure happens with a 30 second
delay as the pressure difference may momentarily exceed 1.0 bar if the compressor is
started up with cold oil.
Opening the oil filter

Before the filter is opened, new O-rings pos.
2 and 5 should be available in case the existing ones cannot be reused. The filter cartridge pos. 6 cannot be cleaned and reused
but has to be replaced.
1. Stop the compressor after regulating it
down to minimum capacity.
2. Close the valves on both sides of the oil
filter.
3. Open the ventilating valve/plug at the top
of the oil filter carefully in order to equalize
the pressure in the oil filter to atmospheric
pressure.
4. Take off the cover at the top of the oil filter.
The filter insert can now be removed without the use of tools. The oil charge in the
filter housing may be drained through the
drain valve/plug at the bottom of the filter
housing and the filter housing can be
wiped clean.
Replacement of the filter cartridge

The filter is a vertical filter in which the oil
must pass the filter cartridge from the inside
and out. In this way dirt will accumulate on
the inside of the filter cartridge and thus not
fall into the filter housing during a replacement of the filter cartridge. The filter is protected against bursting because UNISAB ll
stops the compressor if the pressure drop
across the filter exceeds 1 bar.
0178-250-EN
When the filter insert has been removed, it is

dismounted by dismantling the hexagon nut
at the end of the filter.
Throw away the filter cartridge (it cannot be
reused).
Clean the magnetic rod with compressed air.
Position the new filter cartridge by fastening it
in the fixture.
101
Top up the filter housing with clean refrigerant oil after positioning the whole filter cartridge.
The interval for changing the filter cartridge

very much depends on how carefully the refrigerating plant has been cleaned at the assembly.
Unit with double oil filter

If the unit has two parallel filters only, one filter should be used at a time. The filter which
is not being used can be cleaned while the
compressor is working.
The first replacement of the filter cartridge

can be expected after a few hours operation.
By cleaning the oil filter while the compressor

is working it is important to be aware of the
higher pressure when the ventilating valve/
plug is opened. There may be a lot of oil
foam, especially in the case of (H)CFC
plants.
Note:
Remember to open the stop valves before
and after the oil filter before restarting the
compressor.
Note:
While the compressor is working, both
discharge valves should be open to avoid
that a hydraulic pressure arises in the filter
housing.
102
0178-250-EN
Oil pump pos. 63
0178-265-EN
97.12
The pump principle
Description
The oil pump, pos. 63, is an internally
toothed gear pump with built-in pressure
relief valve and slide ring shaft sealing. The
pump is fitted with suction inlet facing downwards and discharge connection and outlet
from pressure relief valve facing upwards.
The pump is fitted on an intermediate piece
which again is mounted on the electric motor.
The electric motor is fastened to the oil separator by means of a small frame.
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.
In consideration of bearings and shaft sealing, the pump may only run without an oil
flow for brief periods. On charging of oil to a
completely empty oil separator it must be
made sure that the pump is filled with oil in
accordance with the instruction: Preparations
before Start-up.
2. Dismantle the screws between the intermediate piece and the oil pump.
Dismantle the screws that keep the motor
fixed to the oil separator, at the same time
supporting the motor. The motor with the
intermediate piece can now be pulled
away from the oil pump. It may be necessary to dismantle the wires leading to the
electric motor in order to remove it sufficiently. Now carry out the replacement of
the shaft seal with the pump still mounted
in the pipe system.
Service
Replacement of shaft seal
The oil pump is designed as one unit and

should not be separated. However, the shaft
seal is regarded as a wearing part which can
be replaced in case of leakage.
The easiest way to replace the shaft seal is

to follow below procedure:
If the shaft seal is going to be replaced, you

can do one of two things:
S Dismantle the 3 screws keeping the shaft

seal housing fixed to the oil pump.
Start-up
0178-015-EN
S Remove the half section of coupling and

the key fitted in the oil pump shaft.
103
S Screw in the 3 threaded rods no. 3 in the

threaded holes in the shaft seal housing.
Fasten puller no. 1 with thrust screw no. 2

on the threaded rods with nuts no. 4.
3
S Pull off the shaft seal housing by turning
thrust screw no. 2. Replace the O-ring
pos. 6, which seals the shaft seal housing,
if damaged.
S Loosen the 3 pointed screws in the rotating part of the shaft seal pos. 9, and pull if
off the pump shaft. In order to remove the
fixed part of the shaft seal, bearing pos.
10 must first be pressed out with punch
no. 5.
Remember to dismantle locking ring pos.
11. The fixed part of the shaft seal can
now be pushed into the shaft seal housing.
S Tape over the key way in order to protect
the O-ring of the shaft seal and lubricate
the shaft in refrigerating machine oil. Take
care not to damage the lapped surfaces
on the shaft seal parts.
S Press the rotating part of the shaft seal
over the shaft. On mounting of the shaft
seal, press it against the oil pump housing
with a 0.05 mm feeler gauge in between.
Tighten the 3 pointed screws in turns.
S Mount the fixed part of the shaft seal inside the shaft seal housing. Make sure
104
that the retaining pin in the shaft seal

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

the motor
Before the initial start-up of the oil pump remember to check that the oil pump has the
correct rotating direction. This is done by
looking through the fan shield mounted at
the end of the motor away from the oil pump.
Seen through this shield the motor must
rotate clockwise.
0178-015-EN
Spare Parts drawings
Pos.
1
2
3
4
5.
6
8
9
10
11
12
13
14
Designation
Pump cover
Pump shaft
O-ring
Pump wheel
Housing
O-ring
Shaft seal housing
Shaft seal
Bearing
Circlip
Rotor shaft
Shim
Shim
0178-015-EN
Tools
4
1
3
No.
1
2
3
4
5
6
Designation
Puller
Screw M10 x 75
Threaded rod M8 x 150
Nut M8
Punch, solid
Punch, hollow
105
The oil pump filter
94.05
0178-264-EN
The filter consists of a filter housing, pos. 1,

a flange for the end cover, pos. 2, an insert
for the end cover, pos. 3, a filter element,
pos. 4, an O-ring for the cover, pos. 5,
O-rings for the filter element, pos. 6, and
screws for the cover, pos. 7.
The purpose of the filter is to protect the oil
pump against dirt in the oil.
In order to clean the filter element, close the
valves pos. 60 and 65. Hereafter, open the
filter and take out the filter element.
106
Note:
Some oil will be present in both the filter
and the oil pump. This oil may be drained
off through valve pos. 62.
The filter element can be cleaned in a cleaning fluid by means of a stiff brush and pressurized air. Hereafter, refit the filter element
and close valves pos. 62 and 64. At the
same time open valves pos. 60 and 65.
0178-250-EN
Safety and monitoring devices

SAB 110, SAB 128/163 Mk3, SAB 202
Compressor units with relay control or terminal strip for remote control are normally
equipped with the following instruments for
safety and operating control, depending on
the specific order.
Safety devices
95.10
Pos. 28
Safety valve on oil separator

with exhaust to the atmosphere.
The exhaust line must be routed
from the engine room out into
the open air.
0171-566-EN
The SAB 110 compressor has a

built-in by-pass safety valve
which, in case of too high differential pressure across compressor, will lead gas from the oil
separator to the compressor
suction chamber. The opening
pressure the of safety valve is
indicated on its name plate.
Pos. 43
Flow control in the oil distributor

pipe. A spherical float with a
permanent built-in magnet is
able to actuate a reed switch in
the float guide. The switch is wired up to a timing relay which
will stop the compressor if the
flow control chamber is not filled
with oil within max. 50+10 sec.
after start-up, or after 10 sec.
without oil during normal operation.
Pos. 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 discharge pressure.
Pos. PDAZ 11 Differential oil pressure cutout MP55. This pressure cut-out
is designed to ensure sufficient
lubricating pressure and oil
pressure for capacity regulation.
The pressure cut-out is equipped with a time lag of 45 secs.
If the preset differential pressure
has not been obtained by that
time, the compressor will stop.
The MP55 is equipped with
manual reset.
Pos. 0376-A12
Differential pressure cut-out for
control of pressure drop across
oil filter. If pressure drop across
oil filter becomes excenssive
107
due to impurities, the pressure

cut-out will stop the compressor
and a pilot lamp will light. Futher, the differential pressure cutout contains a visual indication
of presure drop represented by
a green field for permissible
pressure drop and a red field indicating excenssive a pressure
drop across oil filter in which
case the pressure cut-out will
stop the compressor.
Pos. TAZ12 Thermostat KP79 with sensor in
oil flow control. Designed to safeguard against excessive oil
temperature.
Pos. TAZ13 Thermostat KP79 or KP81 with
sensor in oil separator.
Designed to safeguard against
excessive discharge gas temperature.
Pos. TC14
108
Thermostat KP77 with sensor in

oil separator. Designed to safeguard against too low discharge
pipe temperature and hence too

low oil temperature in connection with HLI oil cooling.
Please see section on setting of safety devices for various values.
Monitoring devices
Pos. PI15
Suction pressure gauge

(evaporator pressure)
Pos. PI16
Discharge pressure gauge (condenser/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 temperature read off the suction pressure 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.
3. Start up the compressor. Adjust regulating system to lower suction pressure.
2. Moisture in the plant.
4. Keep a close eye on the suction pressure gauge! When the suction pressure is
equal to atmospheric, stop the compressor and quickly shut off the discharge stop
valve. Shut off any stop valve in the oil return line.
3. Air in the plant.
94.05
4. Anti-freezing liquid is missing.
0171-464-EN
bled of refrigerant. Adjust any constantpressure valves to bring evaporator pressure down to atmospheric.
5. Congestion due to metal shavings and

dirt.
6. Congestion due to iron oxides.
7. Congestion due to copper oxides.
8. Inadequate refrigerant charge.
Below, some information is given about ways
of keeping contaminants out of the refrigerating system and at the same time facilitating
day-to-day supervision of the refrigeration
plant.
Pumping down the refrigeration

plant
Before dismantling any parts of the refrigeration plant for inspection or repair, pump-down
must be carried out.
1. Open suction and discharge stop valves
on compressor.
2. Close liquid stop valve after condenser or
receiver so that liquid refrigerant can be
collected in the tank. Any solenoid valves
in the liquid line should be opened by
force, adjusting the thermostat to its lowest position so that the liquid line can be
0171-702-EN
If the receiver has an extra stop valve in

the feed line, this can be closed; practically the entire refrigerant charge will then
remain shut off in the receiver.
Note:
The receiver must not be overfilled! There
should be a minimum gas volume of 5%.
5. A slight overpressure should normally remain in the piping system - this safeguards the system against the penetration
of air and moisture.
6. Before dismantling parts, the operator
should put a gas mask on.
Dismantling plant
In order to prevent moisture penetrating into
the refrigeration plant during any repair work,
it is advisable to follow the rules below:
1. No component should be opened unnecessarily.
2. When dismantling the system, the pressure in the system should be a little higher
than atmospheric.
109
3. Note:
If the piping system is colder than the surroundings, there is a considerable risk of
damp precipitation (condensation) on cold
plant parts. Plant components to be dismantled must be warmer than the ambient temperature.
Tightness testing and pump-down

of refrigeration plant
4. No two points in the system should be

opened at the same time.
Afterwards, pump down in order to eliminate

air and moisture. In this regard, consult the
section on Evacuation.
Otherwise, follow the instructions given in the
separate instruction manual on plant components.
5. Plug, close or at least cover opening with

oiled paper or suchlike.
6. Be aware of the possibility of filters
being very moist.
110
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.
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 temperature variations in a refrigerant system can
provide information about the operating condition of the refrigeration plant.
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.
0171-627EN
95.01
In particular, suction and condenser pressures as well as the temperatures of suction

and discharge gases may provide important
information as to the operating conditions of
the plant.
Considerable changes in operating conditions can often be produced by only very
slight modifications to variable pressures and
temperatures.
Using the following troubleshooting chart, it is
possible to ascertain the cause of and remedy for any operating disturbance.
Fault
Code
The code numbers refer to the subsequent

chart. The section entitled Remedying malfunctions states how to remedy the observed
error. See the following example for the correct procedure.
Example
Observed error: excessive suction
pressure - error code 5.
Cause codes: 2. (compressor lacks capacity) and 48. (safety valve leaky or opens prematurely).The entry keys to the subsequent
section are therefore (5,2) and (5,48).
Observed Fault
Probable causes
1
2
3
Excessive suction pressure

Suction temperature is too low
Suction pressure is too low
Compressor starts and stops too frequently, at

low-pressure cut-out
Excessive suction pressure
Compressor starts and stops too frequently, at
high-pressure cut-out
38, 41, 43, 44.
Excessive condensing pressure

Condensing pressure too low
Oil pressure too low
22, 23, 24, 26, 38, 41, 43, 44.

2, 22, 23, 24, 26.
5, 11, 25, 31, 32.
10
11
12
Oil temperature too high

Oil temperature too low
Excessive pressure drop across oil filter
13, 18, 19, 20, 37, 48.

21, 50.
19.
13
14
15
Excessive capacity aut. controls out of order

Insufficient capacity aut. controls out of order
Oil level in the reservoir falls
3, 4, 12.
3, 4.
15, 16, 17.
16
17
18
Oil foams vigorously during standstill

Oil reservoir sweating during standstill
Abnormal noise from compressor
31, 32.
47, 50.
5, 7,
19
20
21
Compressor motor will not start

Compressor runs continuously
Liquid in the suction line
5
6
7
8
9
0178-012-EN
2, 28, 48, 49.

31, 32.
1, 14, 27, 28, 29, 30, 33, 40, 42.
1, 14, 27, 28, 29, 30, 33, 39, 42, 49.
2, 48.
8,
9, 10, 31, 32, 48, 52.
6, 12, 13, 19, 34, 35, 36, 40, 41, 45, 46,
2, 3, 4, 42, 48, 49.
1, 31, 32.
47
111
Code
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
112
Cause
Code
Cause
Compressor has excessive capacity

Compressor lacks capacity
Solenoid valve in regulating system
fails to open
Timer or other automatic control out
of order
Excessive capacity during
decrease in temperature
26
27
Water filter clogged

Filter before valve in liquid or
suction line clogged
Excessive suction gas superheating
Freezing-up of thermostatic
expansion valve
Thermostatic expansion valve has
lost its charge
Capacity regulation not set to 0%

Loose foundation bolts
Misalignment of motor and
compressor
Friction between rotors and housing
or defective bearings
Loose bolts in coupling
Oil pressure regulating valve set too
low
Oil pump out of order
Oil too hot - oil thermostat cut out
Too much oil circulating in system
(evaporators)
Filter in solenoid valve in oil-return
line clogged
Solenoid valve in oil return out of
order
During initial start-up, some of the
oil will be led out into the plant
A valve in the oil line is being
throttled
Oil filter clogged
Insufficient water through oil cooler
Excessive oil cooling - oil too cold
Insufficient water or air through
condenser
Condenser tubing clogged by
sludge or scale
Cooling water too hot
Too much water through condenser
28
29
30
31
32
33
34
35
Excess flow through expansion

valve (liquid in suction line)
Loose or misplaced sensor
Solenoid valve in liquid or suction
line not opening
Oil filter needs cleaning - pressure
cut-out has cut
Oil pressure too low - pressure
cut-out has cut
36
37
38
39
40
Oil too hot - oil thermostat has cut

Oil thermostat set too high
High-pressure cut-out set too low
Low-pressure cut-out set too high
Low-pressure cut-out shut off
41
42
43
44
High-pressure cut-out shut off

Insufficient charge in plant
Too much charge in plant
Air or non-condensable gases in
system
Fuses blown
45
46
47
48
49
50
52
Thermal relay reset

Main switch interrupted
Safety valve leaky or opening
prematurely
Evaporator soiled or iced up
Heating element blown
Liquid in suction line
0178-012-EN
Remedying Malfunctions
1. Excessive suction temperature
1.2
Inadequate capacity
Increase capacity
1.28
Excessive superheating of suction

gas
Check and regulate thermostatic valves on evaporators
1.48
Safety valve leaky or opening prematurely
Check condenser pressure and adjust or repair

safety valve
2. Suction temperature too low

2.31
Regulate expansion valves or float valves
2.32
Check whether sensors are making good contact

with suction pipe and whether correctly positioned
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

gas
Regulate expansion valves
3.29
Freezing in thermostatic expansion valve
De-ice thermostatic expansion valve with hot wet

cloths and run the liquid from the receiver
through the drying filter
Note:
Never add methanol to the system to avoid
freezing, as this will give rise to corrosion and
chemical attacks in compressor, etc.
3.30
Thermostatic expansion valve has

lost its charge
Valve fails to open - change the valve
3.33
Solenoid valve in liquid or suction

line not opening
Coil may have blown - change the coil
3.42
Insufficient charge
Charge more refrigerant into the plant
0178-012-EN
113
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
4.42
See point 3.42
4.49
Adjust pressure cut-out
Clean or defrost evaporator
5. Excessive suction pressure

5.2
Regulate compressor capacity
5.48
Adjust or repair valve
6. Compressor starts and stops too frequently at high-pressure cut-out

See point 7
7. Excessive condensing pressure
114
7.22
Insufficient water or air through

condenser
Regulate water supply or clean condenser
7.23
Condenser tubing clogged by

sludge or scale
Clean condenser tubing
7.24
Cooling water too hot
Procure colder cooling water or reduce compressor capacity
0178-012-EN
7.26
Water filter clogged
Clean water filter
7.38
High-pressure cut-out set too low
Adjust pressure cut-out
7.43
Too much charge in plant
Draw fluid off into empty vessel
7.44
Air or non-condensable gases in

system
Blow air out at condenser
8. Condensing pressure too low

8.2
Check whether compressor capacity corresponds to load on plant. Regulate water supply to
condenser.
8.25
Too much water through condenser
Adjust water supply
9. Oil pressure too low

9.5

decrease in temperature
Excessive capacity during temperature decrase

(run-down) may result in liquid being sucked
along in suction line. This liquid may cause the
oil in the oil reservoir to foam vigorously so that
the oil pressure drops, thus stopping the machine. Before restarting, check whether there is
liquid in the oil reservoir.
This liquid must be boiled off using a heating
element or by heating the oil reservoir with hot
water or steam. The plant must therefore be rundown at reduced capacity.
9.11
Oil pressure regulator set too low
The regulator is set to the 2.5 kp/cm prescribed

by the manufacturer, but must be checked during
operations.
9.31

See comments under point 9.5
9.32
Loose sensor on expansion valve may cause

liquid throughflow to suction line - see also comments under point 9.5.
0178-012-EN
115
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

throttled
Check whether all valves are open
10.20
Insufficient water or refrigerant

through oil cooler
Check whether valves are open or whether

water filter or oil cooler need cleaning
10.48
Adjust or repair valve
11. Oil temperature too low

11.21
Excessive cooling of oil
Regulate oil cooling
11.50
Heating element in oil reservoir

out of order
Change heating element
12. Excessive pressure drop across oil filter

12.19
Oil filter clogged
Change filter element
13. Excessive capacity - automatic controls out of order

13.3
Solenoid valve in regulating system fails to open
Change valve or coil
13.4
Timer or other automatic control

out of order
Change or fix
13.12
Auxiliary pump out of order
When the compressor stops, the auxiliary pump

must ensure capacity regulation is set to 0% capacity so that the compressor is ready for restarting.
Check whether the pump is being energized or
whether pump or motor is out of order.
14. Insufficient capacity - automatic controls out of order
116
14.3
See point 13.3
14.4
See point 13.4
0178-012-EN
15. Oil level in the reservoir falls

15.15
Filter for solenoid valve in oil-return line clogged
Clean filter
15.16
Solenoid valve in oil return out of

order
The oil return line must be hot during operation.
15.17
During initial start-up, some of the

oil will be let out into the plant
On HCFC plants, particularly, some of the oil will

circulate in the plant.
When the system is balanced, top up with oil, if
necessary.
16. Oil foaming vigorously during standstill

16.31

Check expansion valve
16.32
Check sensor positioning
17. Oil reservoir sweating during standstill

17.47
If the compressor is stopped and the current interrupted at the main switch, any refrigerant in
the oil reservoir will evaporate. As the heating
element in the oil reservoir has also been cut off,
the heat needed for evaporation must be taken
from the surroundings. The oil will therefore go
very cold and will require heating up before restarting.
17.50
Heating element blown
See point 17.47
0178-012-EN
117
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

run-down
Excessive capacity during run-down may result

in liquid being sucked along into the compressor
suction line. Therefore, operate at reduced capacity during run-down.
18.7
Loose foundation bolts
Tighten bolts
18.8
Misalignment of motor and compressor
Adjust alignment
18.9
Friction between rotors.

Friction between rotors and
defective bearings
Do not start the compressor. Open and repair.
18.10
Loose bolts in coupling
Stop compressor and tighten bolts
18.31
Check and adjust the valves with excess

throughflow
18.32
Check sensor positioning
18.48
Safety valve opens
Check opening pressure of safety valve
19. Compressor motor will not start
118
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

has cut
Clean oil filter. Reset pressure cut-out
19.35
Oil pressure too low
See under point 9
19.36
Oil too hot
See under point 10
19.40
Low-pressure cut-out interrupted
The compressor will restart after a rise in 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
Switch power on
0178-012-EN
20. Compressor runs continuously

20.2
See under point 14
20.3
Solenoid valve in capacity regulating system fails to open
20.4
Timer or other automatic control

out of order
20.42
Insufficient charge on plant
Top plant up with refrigerant
20.48
See point 10.48
20.49
Clean or defrost evaporators
21. Liquid in suction line

21.1
Compressor has excessive capacity
Reduce capacity
21.31

valve
Adjust expansion valve
21.32
Loose or misplaced sensor for expansion valve
Check sensor positioning and rectify
0178-012-EN
119
Selecting lubricating oil for SABROE compressors
The problems have been seen with several

mineral oil brands, often occuring within a
few operating hours and resulting in severe
consequences for both compressor and
plants.
Following the careful investigation undertaken by YORK Refrigeration during the past
few years, it has been decided to introduce a
range of synthetic oils which can fulfil the demands of modern refrigeration plants.
Mineral oils may continue to be used in refrigeration plants, providing the lubricating
quality is carefully monitored. For modern,
high capacity refrigeration plants, where long
lifetime for both lubricants and moving parts
is expected, YORK Refrigeration recommends the choice of synthetic lubricating oils.
The application areas and specifications for
these synthetic oils can be found in the following pages. Installers and/or users are at
liberty to choose either YORK Refrigerations
own or alternative oil brands which fulfil the
necessary specifications.
General
This recommendation only deals with the lubrication of the compressor. The performance of the lubricant in the plant (receiver,
evaporator, etc.) must, however, also be taken into consideration.
120
To obtain the best lubrication, the oil must:

S Provide the required fluidity at the lowest
evaporating temperature encountered in
the plant and at the highest permissible
temperatures in the compressors.
S Provide acceptable fluidity at start-up.
S Provide sufficient oxidation stability (the oil
must be moisture-free when added to the
system).
S Provide sufficient chemical stability when
used together with the particular refrigerant.
In addition, the extent to which different refrigerants dissolve in the oil must be determined, so that the oil return systems, etc. can
be designed to function properly.
Stratification
It should be noted that in certain plants, particularly with HFC and HCFC refrigerants, the
oil may stratify into layers in the refrigerant
receivers and evaporators at certain operating conditions and at particular oil concentrations.
The Oil recommendation diagrams for
SABROE compressors for HFC and HCFC
will indicate the limits for Sabroe oils at which
this stratification occurs. The oil concentrations stated in these diagrams must not be
exceeded. This will enable suitable oil rectification/return systems to be designed to balance with the compressor oil carry-over so
that the maximum concentration is not exceeded.
For area A in the diagrams, the max oil concentration in liquid phase must not exceed
0170-151-EN
99.02
a: The oil changes viscosity

b: The oil decomposes (becomes very black)
Lubricating oils with relatively high viscosities

must be used to ensure satisfactory lubrication of refrigeration compressors.
0170-151-EN
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:
2%. For the other area, the max. oil concentration must not exceed 5%. For area B:
please contact YORK Refrigeration.
Plants with several different compressor
types/makes
In plants comprising several different interconnected compressor types and makes, it is
strongly recommended that all compressors
should use the same type of oil. This is essential where automatic oil return systems
are employed.
If it is intended to change the oil from one
type to another, please refer to the Oil changing on SABROE compressors later in this
publication.
Selecting the lubricating oil
There are a number of operating diagrams
for the selection of lubricating oils for Sabroe
compressors operating with various refrigerants. Once the general conditions concerning the lubrication of the compressor and oil
type in the plant have been considered, the
specific plant conditions must be taken
into consideration.
Use the Oil recommendation diagrams to select the appropriate oil code number.
The oil code number consists of letters designating the oil type together with the Sabroe
viscosity grade number.
Code
design
Oil types
Mineral oil
Synthetic oil based on

Alkylbenzene
PAO
Synthetic oils based on

Polyalphaolefin
AP
Mixture of A and PAO-oils
Synthetic ester-based lubricants
0170-151-EN
In the oil recommendation diagrams for each

refrigerant and compressor type, it is possible to determine the code number for the
oil best suited to the operating conditions.
With this code number, it is possible to select the correct Sabroe oil for the application.
The marked area on each side of the separating line in the diagram shows the zone
where both oils are useable.
Oil types and oil companies
As a result of the large number of oil companies world-wide that deals in oil for refrigeration plants, it is impossible for YORK
Refrigeration to test the many different
brands of oil on the market. It is our experience, however, that some oil brands during
use can change character and thus no longer
fit the specifications given by the companies
at delivery. We have thus experienced
changes in the specifications as well as in
the formula and performance without having
had any information about this from the oil
company. This makes it very difficult for
YORK Refrigeration to give a general approval of the various oil brands.
For this reason YORK Refrigeration has, in

cooperation with a large recognised oil company, developed a series of three oils which
cover most purposes. YORK Refrigeration
has however, also listed a limited number of
oils which can be supplied through YORK
Refrigeration. The typical data of these oils
can be found in the Data Sheet for Sabroe
Oils. We suggest you to use these Sabroe
oils, which are delivered in 20 litre pails and
208 litre drums and can be ordered using the
parts no. listed in the List of Oils.
It is of course possible to use similar oils from

other oil companies, and in this connection,
121
the Data Sheet for Sabroe Oils may be helpful.

Please note, however, that YORK
Refrigeration has not tested any other oils
than our own brand, and hence we cannot
answer for the quality, the stability or the suitability of other oils for any purposes. The oil
company in question is thus solely responsible for the quality and suitability of the oil delivered, and if any problems are experienced
with these oils in the compressors or in the
refrigeration plant, the oil supplier should be
contacted directly.
When choosing oils from other oil companies, please pay particular attention to the
oils effectiveness in the compressor and the
refrigeration plant as a whole.
Pay particular attention to the following aspects:
S Oil type
S Refrigerant type
S Compressor type
S Miscibility between refrigerant and oil
S Operating data for the compressor
Discharge gas temperature
Oil temperatures:
Reciprocating compressors:
Normal oil temp. in the crankcase
50-60 C
Max. permitted oil temperature = Setting point for alarm
Min. permitted oil temperatures = setting point for alarm - if fitted
122
Screw compressors:
The oil temperature before injection in
the compressor, but after the oil cooler
Max. permitted oil temperature = setting point for alarm
Min. permitted oil temperature = setting point for alarm
Condensing pressure
Evaporating pressure
S Oil viscosity in the compressor during
operation and under the influence of:
Refrigerant type and solubility of refrigerant in the oil
Operating temperatures
Vapour pressure in the oil reservoir
Reciprocating compressor: Suction
pressure and oil temperature in the
crankcase.
Screw compressor: Discharge pressure
and gas temperature.
S Compatibility with the neoprene O-rings:
the aniline point gives an indication of how
the O-ring material reacts to the oil.
At an aniline point less than approximately
100C the material tends to swell, and at
an aniline point higher than approximately
120C it tends to shrink.
For this reason it is not recommended to
change oil type from M oil to PAO oil as a
leakage may occur if the O-rings are not
changed. YORK Refrigeration therefore
recommends using the Sabroe AP68 oil
as it reduces the risk of leaks considerably
in this case.
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.
YORK Refrigeration is aware, however, that

several customers have been using mineral
oils for many years without problems. Those
customers who wish to continue using mineral oils in existing, as well as new, compressors can do so, providing the compressor
type and operating conditions are similar to
the existing ones (excepting the HPC and
HPO series compressors).
YORK Refrigeration has therefore decided to

market a brand of mineral oil which has been
tested and found to be suitable for most general refrigerating purposes.
If another brand of mineral oil is chosen, the

specifications in the data sheet in this recommendation should be followed as a guideline.
Use of mineral oil

Lately we have experienced a number of
problems with mineral oil, particularly in R717
plants. The problems can be divided into two
groups:
a: The oil changes viscosity within a few
operating hours.
b: The oil decomposes (becomes very
black) within a few operating hours.
The problems have been seen with several
oil brands and have resulted in severe consequences for both compressors and plants.
When using mineral oil, it is thus important
that the plant is monitored very closely, that
oil samples are taken regularly (every
1-2,000 hours) and that the condition/colour
of the oil is checked on a weekly basis.
YORK Refrigeration therefore recommends only to use M oil at moderate operating conditions - cf. the attached oil recommendation diagrams.
0170-151-EN
Mineral oil can be used in refrigerating

plants, providing the lubricating quality is
carefully monitored. For modern, high capacity refrigeration plants, in which a long lifetime for both lubricant and moving parts is
expected, YORK Refrigeration recommends
using synthetic lubricating oils.
A benefit of using the synthetic lubricant oil is

a much lower oil carry-over to the plant and
longer intervals between oil changes.
A better fluidity at lower temperatures also
gives an easier drainage at the cold parts of
the plant.
How to use the oil recommendation diagrams:

To determine the code number, first refer to
the Oil recommendation diagram for the refrigerant and compressor type and then plot
the proposed operating conditions.
123
the example above, a oil code number E5

can be selected.
Example (recip. compressors):

Refrigerant:
R134a
Condensing temp. TC +35C
Evaporating temp. TE
3C
Code no
Area no
1
Please observe !
Plants may operate at different conditions
from time to time, for example at different
evaporating temperatures due to plant
variations or at different condensing temperatures due to seasonal changes.
By plotting TC and TE in the oil recommendation diagram, this example would
require a No 1 oil. If, however, TE
changes at certain times, e.g. from 3 to
+7C, a No 2 oil should be utilised. But, as
+7C is inside the marked area, the No 1
oil can be utilised also at this TE.
R134a
TC
F
C
158 70
140 60
122 50
104 40
86 30
68 20
50 10
32
E5
E9
Y
Y
In plants which incorporate both screw and

reciprocating compressors and where the
recommendations indicate the use of different oil types, please contact YORK
Refrigeration for advice.
Changing oil on Sabroe compressors
The oil should never be changed to another
type without consulting the oil supplier. Nor is
it advisable to top up compressors with an
other oil than the one already used for the
particular plant and compressor.
Mixing different oils may result in operating
problems in the refrigerant plant and damage
to the compressors. Incompatibility between
the different oil types may degrade the lubricating properties or may cause oil residues to
form in the compressor or oil separator or in
the plant. These oil residues can block filters
and damage the moving parts in the compressor.
14 -10
-4 -20
-22 -30
-60 -50 -40 -30 -20 -10 0 10 20 30 C
-76 -58 -40 -22 -4 14 32 50 68 86 F
TE
By referring to the Oil recommendation table

placed at the bottom of each oil recommendation diagram, it is possible to select the
code number for the appropriate oil type. In
124
Furthermore, changing the oil from one type

or make to another should only be undertaken in connection with a careful procedure involving the drainage and thorough evacuation of the refrigeration plant. Information on
a suitable procedure can be obtained from
YORK Refrigeration as well as from a number of oil companies.
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.
Oil drums should, ideally, be racked and

mounted with a proper barrel tap to ensure
an effective airtight seal.
Oil changing intervals
Ensure that the original container is sealed

during storage to prevent moisture from the
air being absorbed into the oil - many oils,
particulary the polyolester oils, are extremely
hygroscopic. Consequently, it is recommended that the oil is only purchased in containers corresponding to the amount to be
used on each occasion.
If the oil is only partially used, make sure that
it is effectively re-sealed in the original container and that it is stored in a warm, dry
place. Ideally with nitrogen blanking of the oil
to keep the water content below 50 ppm.
A list of the recommended intervals for

changing the oil can be found in the compressor instruction manual. These are provided for guidance only. The actual interval
between oil changes will often be determined
by a variety of operating parameters within
the plant.
It is strongly recommended to monitor the
quality of the oil by carrying out oil analyses
with regular intervals. This will also give a
good indication of the condition of the plant.
The service can be supplied by YORK
Refrigeration or the oil suppliers.
Oil recommendation diagram symbols:

Y :
In case of a new plant. Very suitable.
l :
In case you wish to change from mineral oil
A :
B :
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 :
Max oil concentration in liquid phase: contact YORK Refrigeration
Suction gas superheat, K (Kelvin)
Zone in which both oils are useable
Calculation must be performed using COMP1
0170-151-EN
125
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
40C
cSt
100C
Index
grav. at
15C
COC
C
C
point
mg
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
E5
E9
E11
Due to the big difference between polyolester-based lubricants from various suppliers, it is
not possible to present typical data for these oils. When using another oil brand than the one
recommended by YORK Refrigeration, please contact the oil supplier to select the correct
oil type.
The listed data are typical values and are intended as a guideline only when selecting a similar
oil from a different oil company. Data equivalence alone does not necessarily qualify the oil for
use in YORK Refrigerations Sabroe compressors.
126
0170-151-EN
List of part numbers for available Sabroe oils

Oil brand
Oil code no.
Part 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
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)
Sabroe H oil
E11 (E370)
1)
1231-279
3914 1512 954 1)
9415 0008 000
18.9 litre pail (5 US gallons)
The oils recommended by the former Stal Refrigeration correspond to the following oils:
Stal Refrigeration oil type
0170-151-EN
Sabroe oil
Mobil Gargoyle Arctic 300
M1 (M68)
Sabroe Oil PAO 68
PAO 3 (PAO 68)
PAO 9 (PAO 220)
Sabroe H oil
E 11 (E 370)
127
R717
TC
one-stage
reciprocating
compressors
Area no
122 50
Code no
104 40
86
30
68
20
50
10
32
14 -10
1
PAO 3
AP 1
M1
Y
l/Y
-4 -20
-22 -30
See note
-60
-50
-40
-30
-20
-10
10
20
-76
-58
-40
-22
-4
14
32
50
68
TE
Note: YORK Refrigeration recommends that the use of M oils is restricted to moderately loaded compressors and
that the oil quality is monitored carefully via regular oil analyses.
Y
l :
128
: In case of a new plant. Very suitable.

0170-151-EN
R717
TC
two-stage
reciprocating
compressors
122 50
Code no
Area no
104 40
86 30
68
20
50
10
32
14 -10
1
Y
PAO 3
AP 1
l/Y
M1
See note
-4 -20
-22 -30
-60
-50
-40
-30
-20
-10
10
20
-76
-58
-40
-22
-4
14
32
50
68
TE
Y
l :

0170-151-EN
129
R717
TC
HPO and HPC

reciprocating
compressors
176 80
158 70
140 60
122 50
104 40
86 30
68 20
50 10
Code no
Area no
1
PAO 5
32
0
-30
-20
-10
10
20
30
40
50
-22
-4
14
32
50
68
86
104
122
TE
Please observe: PAO 5 oil is the only oil which can be used in the HPO and HPC compressors.
Y
130
0170-151-EN
R22
Contact YORK Refrigeration
TC
one-stage
reciprocating
compressors
Code no Area no
122
50
104
40
86
30
68
20
50
10
32
14 -10
-4 -20
1
A3
-22 -30
-60
-50
-40
-30
-20
-10
-76
-58
-40
-22
-4
14
10
20 C
32
50
68 F
TE
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
131
R22
TC
two-stage
reciprocating
compressors
122 50
104 40
Code no Area no
86
30
68 20
50 10
32
14 -10
-4 -20
1
A3
-22 -30
-60
-50
-40
-30
-20
-10
10
20
-76
-58
-40
-22
-4
14
32
50
68
TE
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.
132
0170-151-EN
R134a
TC
140 60
Code no
122 50
104 40
E5
E9
86
30
68
20
50
10
32
14 -10
Area no
1
C
158 70
F
one-stage
reciprocating
compressors
-4 -20
2
-22 -30
Y
-60 -50 -40 -30 -20 -10
10
20
30 C
-76 -58 -40 -22
32
50
68
86 F
-4
14
TE
Y:

0170-151-EN
133
R134a
TC
two-stage
reciprocating
compressors
C
158 70
140 60
122 50
86
30
68
20
50
10
32
14 -10
-4
Code no Area no
1
E5
104 40
-20
-22 -30
-40 -40
-70 -60 -50 -40 -30 -20 -10
-94 -76 -58 -40 -22
-4
10
20
30 C
14 32
50
68
86 F
TE
134
0170-151-EN
R407C
TC
one-stage
reciprocating
compressors
122 50
104 40
Code no Area no
86
30
68 20
50 10
32
14 -10
-4 -20
1
E3
-22 -30
-60
-50
-40
-30
-20
-10
10
20
-76
-58
-40
-22
-4
14
32
50
68
TE
Y:
B :
C :

0170-151-EN
135
R407C
TC
two-stage
reciprocating
compressors
122 50
104 40
Code no Area no
86
30
1
B
68 20
50 10
32
14 -10
-4 -20
1
E3
-22 -30
-60
-50
-40
-30
-20
-10
10
20
-76
-58
-40
-22
-4
14
32
50
68
Y:
B :
C :
136
TE
0170-151-EN
R404A
TC
one-stage
reciprocating
compressors
122 50
Code no
Area no
1
E3
104 40
86
30
68 20
50 10
32
14 -10
-4 -20
Y
-22 -30
Y
E5
-60
-50
-40
-30
-20
-10
10
20
-76
-58
-40
-22
-4
14
32
50
68
TE
Y:
C :
:

Zone in which both oils are useble
0170-151-EN
137
R404A
TC
two-stage
reciprocating
compressors
122 50
104 40
Code no Area no
86
30
68
20
50 10
32
14 -10
-4 -20
1
E3
-22 -30
-60
-50
-40
-30
-20
-10
10
20
-76
-58
-40
-22
-4
14
32
50
68
Y:
C :
138
TE
0170-151-EN
R410A
TC
HPO og HPC
reciprocating
compressors
122
60
104
50
40
Code no Area no
86
30
68
20
50
10
32
0
A
-10
14
-20
-4
-30
1
E5
-22 -40
-60 -50 -40 -30 -20 -10
10
20
30
40
50
TE
-76 -58 -40 -22
-4
14 32
50
68
Y:
A :

Max oil concentration in liquid phase at: TE: 2%
0170-151-EN
139
R507
TC
one-stage
reciprocating
compressors
122 50
104 40
Code no Area no
86
30
68 20
50 10
32
14 -10
-4 -20
1
E5
-22 -30
-60
-50
-40
-30
-20
-10
10
20
-76
-58
-40
-22
-4
14
32
50
68
Y:
C :
must be introduced.
Min suction temperature 50C: at TE< 50C superheating most
140
TE
0170-151-EN
R507
TC
two-stage
reciprocating
compressors
122 50
104 40
Code no Area no
86
30
1
68 20
50 10
32
14 -10
-4 -20
1
E5
-22 -30
-60
-50
-40
-30
-20
-10
10
20
-76
-58
C
-40
-22
-4
14
32
50
68
Y:
C :
0170-151-EN
TE
141
R717
TC
Screw compressors
Code no Area no
1
PAO 3
AP 1
l/Y
M1
See note
122
50
104
40
86
30
68
20
50
10
32
14 -10
-4
-20
-22 -30
-60
-50
-40
-30
-20
-10
10
20
-76
-58
-40
-22
-4
14
32
50
68
TE
HLI:
Y :
l :
C :
142

Calculation must be performed using COMP1.
0170-151-EN
R22
TC
Screw compressors
122 50
SH25
Code no
Area no
1
2*
A3
PAO 5
104 40
SH5
86 30
SH10
68 20
50 10
32
14 -10
SH20
-4 -20
-22 -30
SH20
-60
-50
-40
-30
-20
-10
10
20
-76
-58
-40
-22
-4
14
32
50
68
TE
Using the calculating programme COMP1 it is possible to optimize the requirement for suction superheat values
(SH) as stated in the diagram. See Oil types and oil companies in this section. Due to the ongoing development of
lubrication oils, please contact YORK Refrigeration for an update on the requirement for superheat.
HLI: Calculation must be performed using COMP1.
Y :
A :

Max oil concentration in liquid phase at: TE: 2% W
C :
* :
Dry expansion systems only. Flooded systems to be considered individually: contact YORK Refrigeration
SH :
:

0170-151-EN
143
R134a
TC
Screw compressors
158 70
140 60
Code no
104 40
86
30
68
20
50
10
32
Area no
(See note)
1
E5
E9
122 50
14 -10
SH30
SH20
SH10
SH5
SH20
-4
Y
-20
-50
-58
-40
-30
-20
-10
10
20
30 C
-40
-22
-4
14
32
50
68
86 F
TE
Note: For the compressors type S, Rotatune, SAB 81, SAB 83, and SAB 85 only Sabroe oil H is approved.
(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.
Y :
SH :
144
0170-151-EN
R404A
TC
Screw compressors
SH15
Area no
(See note)
1
2
3
Code no
E3
E5
E9
104 40
86
30
68
20
50
10
32
SH10
2 (3)
(2)
14 -10
-4 -20
SH15
-22 -30
-70
-60
-50
-40
-30
-20
-10
-94
-76
-58
C
-40
-22
-4
14
10
32
50
TE
Y :
B :
C :
SH :
0170-151-EN
145
R407C
TC
Screw compressors
122
50
40
104
Code no
Area no
(See note)
1
2
E3
E9
86
30
68
20
50
10
32
-4
-20
SH5
-22 -30
SH5
14 -10
SH10
-70
-60
-50
-40
-30
-20
-10
-94
-76
-58
-40
-22
-4
14
10
20 C
32
50
68 F
TE
Y :
B :
C :
SH :

146
0170-151-EN
R507
TC
Screw compressors
104 40
Code no
E5
E9
Area no
(See note)
1
2
Y
86
30
68
20
50
10
32
SH5
SH5
SH15
14 -10
-4 -20
SH30
-22 -30
-70
-60
-50
-40
-94
-76
-58
C
-40
-30
-22
-20
-10
-4
14
10
32
50
TE
Y :
C :
SH :
0170-151-EN
147
List of major oil companies

The oil from the companies listed below are NOT tested by YORK Refrigeration and are therefore NOT approved by YORK Refrigeration either. The following list reflects the information provided by the companies themselves. The assessment of durability and suitability of specific oils
for specific purposes are entirely at the companies own discretion. Oils tested and approved by
YORK Refrigeration can be found in the List of part numbers for available Sabroe oils.
Oil
Oil Types
Company
Aral
Avia
BP
Castrol
Chevron (UK: Gulf Oil)
CPI Engineering Services
DEA
Elf / Lub Marine 1
Esso/Exxon
Fina
Fuchs
Hydro-Texaco
PAO
AP
ICI
Kuwait Petroleum (Q8)
Mobil
Petro-Canada
Shell
Statoil
Sun Oil
148
0170-151-EN
Notes:
0170-151-EN
149
Alignment of VMY/SAB 202 unit and coupling
Note:
Before work on the coupling can proceed,
it must be ensured that the compressor
cannot be started inadvertently. If need
be, remove the motor protection devices.
Vibrations may be caused by the following:
a) Distortion between compressor unit and
foundation.
b) Distortion between compressor and base
frame.
c) Distortion between motor and base frame.
d) Strains from pipe connections between
compressor and plant.
e) Incorrect alignment of coupling between
compressor and motor.
f) Untruth in compressor or motor shafts.
g) Untruth in coupling.
h) Imperfect balancing of coupling.
i) Imbalance in compressor and motor.
The fitter who sets up the unit is responsible
for points a-b-c-d-e. The other points must be
checked by the compressor or motor manufacturer prior to delivery.
The following sections will deal with the individual points concerning the fitter.
150
When installing the unit straight onto a foundation, the foundation should be cast in accordance with the foundation drawing
forwarded.
When the foundation has been cast, with the
holes marked out as shown, and has set, the
unit should be positioned, allowing it to rest
on sleepers, laid with a spirit level, at a
suitable height so that the foundation plate is
slightly recessed into the foundation.
Check that the foundation plates are hard on
the base frame - this is best done by tying
them up to the base frame with steel wire.
The concrete which is cast down around the
foundation bolts should have only minimal
water content to allow it to be rammed well
down around the bolts and up under the
foundation plates. Low water content does
not cause the hardening concrete to shrink.
10-14 days should pass before tightening the
foundation bolts. Remove the steel wire beforehand and check that there is no air space
between the footplate of the base frame and
the foundation plate. Otherwise, shims must
be inserted between the plates before
lashing them down.
Point a-2 Mounting vibration

dampers
The units are invariably delivered without vibration dampers mounted.
The vibration dampers supplied are marked
with a code.
0178-250-EN
95.01
Misalignment of compressor unit or coupling

may produce stresses and vibrations which
can be transmitted to the compressor
bearings and thus cause major damages.
Point a-1 Mounting unit straight

onto foundation
0171-669-EN
In order to ensure a long life for compressor

and motor, the compressor unit and coupling
need to be set up with care.
Matching codes are indicated in the drawing

forwarded to the customer or dealer; these
are valid for the unit in question only.
fitted correctly, as shown in the drawing forwarded, since the load on the foot-plates
varies.
It is important that the vibration dampers be
Standard type
A 1 to 2 mm.
Marine type
A
A 3 to 5 mm.
T0177040_0
Standard type
The machine room or ship floor on which the
unit is to be placed must possess the
necessary bearing strength and be level
enough for the difference in height between
the foundation plates not to exceed the
scope for adjustment on the vibration
dampers, as stated in the positioning
drawing.
The vibration dampers are installed on the
unit in their unstressed state while it is suspended from the crane; the unit is then
placed in its final position.
The unit is aligned with the aid of wedges
placed in the vicinity of the vibration
dampers.
When the unit is horizontal, both longitudinally and laterally, the vibration dampers are
tightened exactly enough to release the
wedge.
0178-250-EN
The vibration dampers are intended to compress between 1.0 and 2.0 mm under the expected load at the corresponding point of
support.
To check that the vibration dampers are
adjusted for the correct load, make a note of
measurement A in the unloaded state for
each individual damper. After mounting and
adjustment, A should be reduced by 1 to 2
mm.
When the adjustment is correct, tighten down
the lock nut.
Alignment of the unit against the foundation
is now complete.
Marine type
Always fit the vibration dampers directly
under the feet of the base frame.
Measure the A-measure of the vibration
dampers while unit is still suspended in the
crane. Measure it again once the unit is back
151
in its position. The difference (compression)

must be between 3 and 5 mm for all vibration dampers.
In case this is not observed liner plates must
be inserted under the vibration dampers until
above compression is reached.
Point b) Alignment of compressor

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

base frame
Check the resting surfaces of the motor
against the base frame in the same way as
mentioned for the compressor.
Point d) Stress from pipe

connections
To prevent transmission of stresses from pipe
connections between unit and plant, care
must be taken that the pipes are laid so as
not to cause tensile or compression strains
during expansion or contraction due to temperature changes. Steel pipes will expand
approx. 1 mm per metre per 100C.
152
We recommend laying the piping as shown in

the sketch with a free length of min. 1.5 m in
two directions which are at right angles to
each other.
Here a nonreturn valve may
be fitted in the
discharge pipe
min. 1.5 m.
min. 1.5 m.
Connection to
compressor unit
Do not mount pipe hangers close to the compressor unit.

On some elevated point on the compressor
unit discharge pipe mount a non-return valve
to prevent condensed refrigerant from
returning to the oil separator.
Note:
Pipe systems that connect the compressor
unit with the remaining refrigeration plant
must be executed in a flexible way in order to prevent tensions in pipes and their
connections.
Point e) Mounting and alignment

of coupling
hen all piping has been connected up to the
unit, final alignment between compressor and
motor can be undertaken. See the following
section.
0178-250-EN
Auxiliary tools for coupling

alignment
Four sets of liner plates are supplied, each
consisting of one 3 mm, two 1 mm, three
0.25 mm, two 0.15 mm and two 0.1 mm
plates to be placed under the motor feet.
Four clamps are supplied with each unit, as
shown in the sketch. These clamps can be
used either to shift the motor sideways or to
lift the motor with a view to inserting liners.
In addition, an alignment gauge is supplied
for the coupling, as shown in the drawing,
together with a set of feeler gauges.
Before mounting of coupling carefully clean
motor and compressor shafts, half-sections
of coupling, and bushing, if any.
Then lubricate all parts in refrigerant machine
oil. Do not use products containing any
grease or molybdenumdisulfide.
0178-250-EN
T0177059_0
153
Mounting and alignment

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

set must be replaced at a time.
Note:
When being dismantled, the coupling
discs must be kept together in exactly the
same position in which they are received.
1
Z
2
X
a
C
T0177120_0/V1
Coupling alignment
The principle of the alignment procedure is to
move the motor so that its shaft forms a continuation of the compressor shaft, but with
the motor shaft 0.05 mm higher than the
compressor shaft. In operation, the compressor shaft is lifted, owing to the fact that it
rests in slide bearings.
Mounting
1) Dismantle the coupling. Note the placing
of bolts, washers and nuts, as these must
be mounted in the same order again. Tie a
string or a piece of thread through one of
the bolt holes in the coupling discs in order to avoid the plates being turned rela-
154
tive to each other and relative to the

flange.
2) Examine both compressor and motor shaft
journals as well as the bores of the hubs
to ensure that they are free of burrs.
Check that the key fits the shaft and hub
exactly.
3) Mount the hubs on the shafts. It is recommended to heat the hub in water, oil or
over a gentle flame. Do not heat the hub
in spots, as this may cause adverse
stresses. When heated, the hub must immediately be placed on the shaft.
On SAB 202 compressors a bushing must
be applied between compressor shaft and
coupling hub. On mounting adopt the following procedure:
0178-250-EN
Position the coupling hub with the bushing

on top of the shaft as shown in the
following drawing.
4) Position motor and compressor, and

check the distance between the coupling
flanges C. This distance is given in the
table below. Motors with slide bearings or
other equipment with end play in the shaft
must be in neutral centre position.
Compressor
Bushing
and shaft
must be
flush
with each
other
Tighten the screws on the bushing crosswise, first to 18 Nm and then to the final
torque of 35 Nm. The screws must be
tightened cross-wise and a torque wrench
must be used.
5) Insert the intermediate piece of the

coupling and the coupling discs and
tighten the bolts. At the same time, fit the
alignment gauge to the coupling flange of
the compressor. The torque moment is
given in the following table.
Avoid mounting the bolts between the
coupling flange on the motor and the coupling discs until alignment has been completed.
The following table indicates the dimensional
tolerances and torques to be observed.
Max. Variation at 180
Coupling
No.
Diam.
A
mm
Distance
C
mm
Torque
200
225
138
145
127
127
34
34
262
168
127
41
312
198
140
55
350
221
152
128
375
246
178
177
425
267
178
245
450
287
203
275
Nm
Obtaining parallel shafts on the

horizontal plane
1. Turn the coupling so that the alignment
gauge is in the upper position.
2. Guide the measuring pin (pos. 2) towards
the coupling part using a 1 mm feeler
gauge and fix the pin.
0178-250-EN
rotation
Pos. 1
Horizontal
mm
0 0.05
Pos. 2
Vertical
mm
mm
0.10 0.15
0 0.05
3. Turn the coupling 180. Measure by feeler

gauges how much the distance from the
measuring pin to the coupling part has
changed. This change is called X.
4. Insert shims of thickness y either under
both front feet or both rear feet, tilting the
motor at the end desired.
155
The shim thickness is calculated using the

following formula:
y =X
Z = double the distance between the

centreline of the two shafts in the horizontal plane.
b
2a
see the drawings
4. Lift the motor by placing shims with thickness Z / 2 + 0.05 mm underneath all four
feet.
5. After securing the motor, repeat the measurement and compare the results with the
values in the table.
Obtaining parallel shafts on the

vertical plane
y
b
2a = the diameter described by the measuring pin when rotated 180.

b = length between the fastening bolts on
the motor.
The motor can be lifted using the abovementioned tools.
5. After fixing the motor bolts, repeat the
measurement and compare the result with
the values in the table.
Obtaining parallel displacement for

correct centre height
Remember that the centreline of the motor
shaft must be 0.05 mm higher than the
centreline of the compressor, as the rotors
will lift during operations.
gauge faces down.
It only remains to push and turn the motor at

the level on which it is now shimmed up.
gauge faces horizontally out to one side.
2. guide both measuring pins towards the
coupling using a 1 mm feeler gauge.
3. Turn the coupling 180 and measure the
deviations using the feeler gauge.
4. Moving and turning the motor sideways
with the adjusting screws, set the motor so
that the deviations are in accordance with
the values in the table. Remember that the
motor must be secured during each measurement.
Final check and assembly

1. Tighten the foundation bolts on the motor.
2. Check flange distance C.
3. Check the alignment of the coupling on
the horizontal and vertical planes for pos.
1 and 2.
2. Guide measuring pin (pos. 1) towards the

coupling part using a 1 mm feeler gauge
and fix the pin.
4. Fit the bolts between the coupling flange

and coupling discs on the motor and
check the tightening torque for all the
bolts.
3. Turn the coupling 180 and measure the

increase in distance by feeler gauges.
This increase is called Z.
5. Fit the outer shell of the coupling guard on

the adaptor plate which is secured on the
compressor shaft seal cover.
156
0178-250-EN
Push the inner shell, placed in-side the

outer shell, so far towards the driving motor that access to the rotating parts is
made impossible. See below drawing.
6. Check the coupling alignment once more

while still warm from operating and with
pressure on the plant.
It is strongly recommended that the alignment method described be used, as it measures the relative position of the shafts directly
and eliminates all possible faults in the coupling flanges.
T0177045_0
0178-250-EN
157
Pressure transducer
(suction pressure)
PDAZ10
Oil pressure difference cut-out

(oil pressure - discharge pressure)
PT2
Pressure transducer
(discharge pressure)
PDAZ11
PT3
Pressure transducer
(oil pressure after oil filter)
Oil pressure difference cut-out

(oil pressure - suction pressure) for classified systems only
TAZ12
Pressure transducer
(oil pressure before oil filter)
Thermostat
(oil temperature in manifold)
TAZ13
PT5
Pressure transducer
(oil pressure after oil pump)
Thermostat
TC14
Thermostat
(pilots solenoid valve pos. 82)
TT5
Temperature transducer
PI15
Suction pressure manometer
TT6
(oil temperature in flow control)
PI16
High-pressure manometer
PDI17
Oil difference manometer
(suction gas temperature)
FT18
Level switch
19
Compressor safety valve
Position transmitter (capacity

slide)
20
Suction stop valve
21
Non-return valve
GT9
Position transmitter (Vi slide)
22
PAZ10
Safety pressure cut-out

(for TV, SDM and SA only)
Flanged joint discharge pipe compressor
23
Suction filter built into compressor
Low-pressure cut-out
(only for classified systems)
24
Service valve - air purge valve
25
Oil separator
PAZ2
High-pressure cut-out
26
PDAZ3
Differential pressure cut-out

(pressure drop across oil filter)
Non-return valve in outlet pipe

from oil separator
27
Thermometer
Stop and non-return valve in outlet pipe from oil separator
28
Safety valve - the unit
TI6
Thermometer (oil temperature)
29
TI7
Thermometer (suction gas temperature) - only if specially ordered
Change-over valve for double

safety valve
30
Immersion heater in oil separator
31
Oil level indicators (2 pieces)
32
Oil cooler OOSI (refrigerantcooled)
PT4
TT7
GT8
PAZ1
TI5
GT8
158
Position transmitter
(capacity slide)
0178-085-EN
0171-575-EN
PT1
99.11
Key to Piping Diagrams
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

(refrigerant side)
62
Oil charging valve
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
40
Oil inlet from pump
Solenoid valve (NC) - open during

prelubrication
41
Non-return valve built into oil filter
68
Stop valve
42
Stop valve after oil filter
69
Non-return valve
43
Combined flow control and

oil distributing manifold
70
Solenoid valve (NC) - capacity

regulation min. > 100%
44
Check valve, rotor lubrication
71
Solenoid valve (NO) - capacity

regulation 100 -> min.%
45
Nozzle in injection pipe
72
46
Thermostatically-controlled 3-way
valve for oil temperature
regulation
Throttle valve for regulation of

slide velocity
73
Solenoid valve (NC) - capacity

regulation min. > 100%
74
Solenoid valve (NO)
75
Non-return valve
76
Three-way non-return valve
80
Stop valve
81
Liquid refrigerant filter
82
Solenoid valve (NC)
TC83
Liquid injection valve TEAT
84
Stop valve
90
Oil supply to bearings at

discharge end
91
Oil supply to shaft seal and bearings at suction end
47
Service valve for oil drainage
48
Oil purge valve on oil filter
49
Thermostatic water valve for

water-cooled oil cooler
50
Stop valve
51
Oil filter
52
Nozzle/throttle valve
53
Oil level indicator
54
Stop valve
55
Oil separation element

(fine separation)
56
Non-return valve
57
Hand-regulated valve
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
159
95
Liquid supply for HLI cooling

Vi 4.0
127
Stop valve
128
Stop valve
96
Liquid supply for HLI cooling

Vi 2.6
129
Solenoid valve (NC)
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

(only by auto-Vi)
140
Stop- and non-return valve
100
Oil return from fine oil separator
141
Main valve
142
Pilot valve
101
Bypass throttle valve at suction

stop valve
143
Solenoid valve
144
Stop valve
145
Float valve
147
Liquid filter
148
Stop valve for oil purge
149
Non-return valve
150
Stop valve
151
Safety valve
152
Solenoid valve
153
Stop valve
154
Stop valve
160
Stop valve
200
Gas-powered stop valve
201
Solenoid valve (NC)
202
Stop/non-return valve
203
Non-return valve in discharge pipe
204
Stop valve after oil separator
102
Non-return valve
103
Stop valve
104
Nozzle
105
Flow switch
106
External oil filter
107
Oil filter for units with full flow

oil pump
108
Oil regulating valve
110
Stop valve
TC111
Thermostatic valve
112
Solenoid valve (NC)
113
Liquid filter
114
Stop valve
115
Stop valve for oil purge
116
Economizer vessel
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
160
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

(main valve)
221
Compressor protecting valve

(pilot valve for pos. 220)
222
Filter in economizer pipe

connection
Note:
On units supplied without valves the
bracketed figures near the branches refer
to the component numbers in this list.
These components are to be fitted by the
customer.
0178-085-EN
161
Ordering Spare Parts

When placing an order for spare parts,
please state the following:
ber. If you are in any doubt, add the spare

part no. too.
1.
3.
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-
162
When ordering spares, please advise the forwarding address, and the address to which
the invoice should be sent. If appropriate,
please state the name of your local bank, the
way in which you want the goods transported
and required delivery date.
4.
Classification certificate
If you require a certificate from a Classification authority, please mark the order
appropriately, as the inspection and issuing
procedures take extra time and incur extra
expenses.
5.
Quotation No.
If a quotation no. has been given during earlier correspondence, please refer to this when
placing your order it will help us to identify
and execute your order quickly.
0178-925-EN
94.05
All compressors are fitted with an identification plate, which states the type and shop no.
of the compressor and indicates what refrigerant is to be used.
Forwarding instructions
0171-466-EN
Shop No.
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 replacements without wasting time while waiting for new spare parts to arrive.
On contacting SABROES local representative you may receive specifications for the following spare part sets for compressor and unit.
Compressor block:
0171-945-EN
98.03
S Standard set of spares

This set contains a representative selection of O-rings and gaskets.
S Certificate set of spares
Besides the parts from the standard set
of spares this set further includes all
bearings as well as shaft seal.
Basic Unit:
S Standard set of spares:
This set includes the following spare parts
for the below-mentioned components:
Oil separator:
O-rings, gasket
Service valves:
Gaskets, O-rings
Capacity regulating system:
Gaskets, O-rings
Pressure outlet stop valve:
Gaskets
Suction Inlet stop valve:
O-rings, sealings rings, gaskets,
teflon ring
0178-085-EN
Safety valve:
Gaskets, cone, O-rings
Oil by-pass system:
Gaskets, teflon ring
Oil pump:
O-rings
S Certificate set of spares:
Further to the parts contained in the standard set of spares this set also includes
spare parts for the below-mentioned components:
Coupling:
Screws and discs
Oil separator:
Sight glass, oil separator element,
heating element
Capacity regulating system:
Solenoid valve
Safety valve:
Spring
Solenoid valves:
Coils
Oil pump:
Shaft seal, filter
163

SAB - 202 - EN Instruction Manual

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SAB - 202 - EN Instruction Manual

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Instruction Manual

0178-251-EN Rev. 00.03

Christian Xs Vej 201, P.O. Box 1810, DK-8270 Hjbjerg, Denmark

The screw compressor and the unit may

Part of these variants are treated in this

instruction manual although they may not be

UNISAB II and manual regulation of Vi slide

Water-cooled oil cooler

Water-cooled oil cooler

Refrigerant oil cooler

With 1 discharge valve

Thermostatisc oil valve

Both compressor and unit are

To prevent accidents during dismantling and

SABROE REFRIGERATION A/S

S the function and maintenance of the

this instruction manual to ensure reliable and

The aim of this instruction manual is to

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

Handling of the compressor, areas of application,

First Aid for accidents with Ammonia . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

First aid for accidents with HFC/HCFC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Protecting the operator as well as the environment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Sound data for reciprocating and screw

Vibration data for compressors - all types . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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

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

Compressor and unit operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Service Schedules for screw compressors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Major Service Intervals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Oil charging, weight and shipping volume . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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

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

Maintenance of compressor SAB 202 Dismantling and assembly . . . . . . . . . . . . . . . . .

Magnetic coupling for Vi-indication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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

Water-cooled oil cooler type OWSG/OWRG for screw compressors . . . . . . . . . . . . . . . . .

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

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

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

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

Oil pump pos. 63 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

The oil pump filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Safety and monitoring devices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Refrigeration Plant Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Troubleshooting on the Screw Compressor Plant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Selecting lubricating oil for SABROE compressors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Alignment of VMY/SAB 202 unit and coupling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Key to Piping diagrams for screw compressors type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Ordering Spare Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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

Spare parts drawing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

List of parts for SAB 202 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Spare parts survey for SAB 202 unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Tools for compressor SAB 202 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Placing the vibration dampers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Instructions for control and regulating equipment . . . . . . . . . . . . . . . . . . . . . . . . .

Description of SAB 202

pressor from running backwards whenever

The two rotors are equipped with 4 lobes

The driving shaft is fitted with a shaft seal of

As indicated on the spare parts drawing at

S Manual regulation of the Vi slide: