Instruction Manual SAB 163 HM/HF Screw Compressor Unit
0178-202-EN Rev. 00.03
Christian X´s Vej 201, P.O. Box 1810, DK-8270 Højbjerg, Denmark .
Phone +45 86 27 12 66 Fax +45 86 27 44 08
99.06
The screw compressor and unit can be fitted with different equipment, depending on their functions and requirements.
instruction manual, even though they are not fitted on your particular unit. A cross (x) in the following table indicates which variants that are fitted on your unit – with the shop no. stated below.
Some of these variants are described in this
Type of drive Refrigerant
Male drive
Female drive
R717
R22
Other
Shop no. UNISAB II and manual regulation of the Vi slide Instrumentation UNISAB II and automatic regulation of the Vi slide Water-cooled oil cooler
Oil cooling Economizer system (ECO-system) Ex-execution
0178-050-EN
OWSG/OWRG
Water-cooled oil cooler
Type B
Refrigerant-cooled oil cooler
OOSI
Refrigerant injection in compressor
HLI
Vessel type
HE S S
Closed system and vessel type
EOSE
Open system and vessel type
SVER
Both compressor and unit are
safeguarded
1
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: the function and maintenance of the individual components; service schedules; 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 familiarize themselves thoroughly with the contents of
this instruction manual to ensure reliable and efficient operation of the plant as SABROE is unable to provide a guarantee against damage occurring during the warranty period where this is attributable to incorrect operation. To prevent accidents during dismantling and assembly of compressors and components, these should only be carried out by authorized personnel. The contents of this instruction manual must not be copied or passed on to any unauthorized person without Sabroe’s permission.
In the space below you can enter the name and address of your local SABROE REPRESENTATIVE REPRESENTATIVE :
SABROE REFRIGERATION A/S P.O. Box 1810, DK –8270 Hø jbjerg Chr. X’s Vej 201, Århus, Denmark
2
Phone: Telefax:
+45 86 27 12 66 +45 86 27 44 74
0171-702-EN
6 0 . 6 9
N E 0 0 5 1 7 1 0
Instruction Manual for SAB 163 Mk3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1
Preface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2
Table of Contents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3
Description of compressor SAB 163 Mk3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6
Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Screw compressors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . General safety instructions and considerations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Handling of the compressor, areas of application, safety equipment and symbols, safety at servicing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Safety equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Safety symbols . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . First Aid for accidents with Ammonia . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . First aid for accidents with HFC/HCFC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Protecting the operator as well as the environment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8 8 8 12 13 14 16 17 18
Sound data for reciprocating and screw compressor units – all types of compressors . .
21
Vibration data for compressors - all types . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
25
Compressor Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Operating limits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Compressor Unit Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Type of compressor unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Compressor and unit operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1. Preparations before starting up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2. Initial start-up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3. Current control at normal operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4. Normal stop . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5. Preparations before a lenghty standstill period . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6. Pressure testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7. Evacuation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8. Operating log . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Service Schedules for screw compressors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Preparations before compressor inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Cleansing of oil in the unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Checking the oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Assessing the oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Visual assessment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Analytical evaluation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . The analysis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Major Service Intervals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
26 26 30 32 33 33 33 34 34 34 34 35 36 37 37 38 39 42 42 42 43 45
Oil charging, weight and shipping volume . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
46
Servicing the refrigeration plant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
47
0178-050-EN
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Maintenance of Compressor SAB 128/163 Mk3 - Dismantling and Assembly . . . . . . . . . 1. Oil filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2. Suction filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3. Shaft seal type 680 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4. Regulating cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5. Regulating slide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6. Slide stop for Vi-regulation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Magnetic coupling for Vi-indication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7. Suction cover and bearing in compressor shaft end . . . . . . . . . . . . . . . . . . . . . . . . . . 8. Rotors and bearings in compressor discharge end . . . . . . . . . . . . . . . . . . . . . . . . . . . 9. Capacity indicator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Magnetic coupling for capacity indication type A and B . . . . . . . . . . . . . . . . . . . . . . . . . Transmitter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Limiting the minimum capacity of the screw compressor . . . . . . . . . . . . . . . . . . . . . . . . 10. Compressor Protection System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Systems for regulation of compressor capacity and Vi ratios SAB 128/163 Mk3 . . . . . . . 1. Regulation of compressor capacity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2. Automatic regulation of the Vi-slide - For SAB 163 Mk3 only . . . . . . . . . . . . . . . . . . 3. Manual regulation of the Vi slide - For SAB 128/163 Mk3 . . . . . . . . . . . . . . . . . . . . . Adjusting the position of the Vi-slide SAB 128 Mk3 R22, R134a, R404A/R507, R407C . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Adjusting the position of the Vi-slide SAB 163 Mk3R22, R134a, R404A/R507, R407C . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Adjusting the position of the Vi-slide R717 - SAB 128 Mk3 . . . . . . . . . . . . . . . . . . . . . . Adjusting the position of the Vi-slide R717 - SAB 163 Mk3 . . . . . . . . . . . . . . . . . . . . . . Torque moments for screws and bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
49 51 52 55 57 58 59 61 63 65 73 73 74 76 77 81 81 82 83
Component description SAB 128/163 Mk3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fine separator element . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Oil level glass, pos. 31 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Stop valve, pos. 34 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Discharge stop valve and non-return valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Heating rods for heating the oil in reciprocating and screw compressors . . . . . . . . . . . . .
89 90 91 91 91 92
Water-cooled oil cooler type OWSG/OWRG . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
93
Water-cooled oil cooler, type B . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
96
Refrigerant-cooled oil cooler type OOSI . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
98
Oil temperature regulating system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
99
Refrigerant injection in compressor HLI (High-stage Liquid Injection R717) . . . . . . . . . . .
85 85 86 86 87
102
Throttle Valve pos. 52 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104 Oil pump pos. 63 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105 Spare Parts Drawings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107 Flow security . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108 Safety and monitoring devices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109
4
0178-050-EN
Refrigeration Plant Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Operational reliability . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Pumping down the refrigeration plant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Dismantling plant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Tightness testing and pump-down of refrigeration plant . . . . . . . . . . . . . . . . . . . . . . . . . Troubleshooting on the Screw Compressor Plant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
111 111 111 111 112 113
Selecting lubricating oil for SABROE compressors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
122
Alignment of compressor unit and coupling - Coupling series 52 . . . . . . . . . . . . . . . . . . . . 151 Mounting of Series 52 coupling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 154 Key to Piping diagrams for screw compressors type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 161 Ordering Spare Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 165 Spare Part Sets for screw compressor and unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
166
Tools for compressor SAB 163 Mk3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
0661-816
List of parts for SAB 163 Mk3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
0661-885
Spare parts survey for SAB 163 Mk3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
0661-883
Spare Parts drawing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
0661-884
Piping diagramm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .order specific Wiring diagramm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .order specific Dimension sketch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .order specific Placing of vibration dampers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . order specific Other instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .order specific
0178-050-EN
5
Compressor SAB 163 Mk3 is a capacity adjustable screw compressor equipped with oil injection. The two rotors are provided with 4 and 6 grooves (male and female rotors, respectively) in an asymmetric profile under SRM licence. At the suction end, the rotors are provided with roller bearings, while the bearings at the discharge end consist of a combined set of roller bearings, assimilating the radial load, and ball-bearings, assimilating the axial load. The axial forces are partly equalized by rotating balance pistons mounted on the rotors. The rotors are available in either hardened or non-hardened design. If the compressor is fitted with hardened rotors, the motor can be connected to either male or female rotor. The idle shaft end is blanked off with a cover. For non-hardened rotors, the motor can only be connected to the male rotor. On the shaft to which the motor is connected, a shaft seal of the slide ring type which effectively seals between the interior volume of the compressor and the atmosphere, has been fitted. The compressor is provided with a large built-in oil filter, which effectively prevents dirt particles in the refrigerating plant from penetrating into the compressor together with the suction gas. The compressor is also equipped with a nonreturn valve, preventing the rotors from rotating in reverse whenever the electricity to the motor is cut off. The non-return valve is controlled by the internal suction pressure of
6
the compressor. In this way it is kept open during operation without causing unnecessary loss of pressure in the suction gas. The SAB 163 Mk3 compressor block is very compact in its construction. It has both oil filter and electrical flow switch built in, hereby reducing the number of connecting pipes. The compressor can be capacity regulated continuously from approx.10% to 100% by means of a slide system fitted under the rotors. A piston moves the slide system. This piston is influenced by the gas pressure on the compressor discharge side and the lubricating oil pressure controlled by solenoid valves. As a rule, Sabroe’s microelectronic control system is used to control the solenoid valves. The SAB 163 Mk3 screw compressor has one more control system, by which the builtin Vi volume ratio of the compressor can be controlled. This means that the compressor always works at its highest efficiency, even at variable operating pressures in the refrigeration plant. The Vi control is particularly effective with the compressor working at 100% capacity and acts as a mechanical stop to the capacity slide already mentioned. In this way the capacity slide adapts the size of the discharge gas outlet opening, maintaining the same compression ratio in the compressor as the pressure ratio from discharge to suction side in the refrigeration plant. At a reduced compressor capacity the Vi control system is of little effect.
0178-050-EN
2 1 . 6 9
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The built-in Vi volume ratio can be adjusted in the following two ways: (Please check your type of compressor on page 1). Manual adjustment of the Vi slide This is done by turning the spindle under the rotor shaft in accordance with the curves in the instruction manual. Automatic adjustment of Vi slide This is done by means of the oil pressure and two solenoid valves, controlled by UNISAB II.
The type of screw compressor can be determined by reading the name plate placed on the end surface of the compressor, just above the capacity cylinder.
0178-050-EN
As shown in fig. 1 this name plate contains the compressor shop number, which should be used whenever you contact Sabroe concerning the compressor.
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
7
Screw compressors WARNING Read related safety precautions before operating this machine. Failure to follow safety instructions may result in serious personal injury or death.
Important The safety precautions for this Sabroe Refrigeration machine have been set down to assist the operator, programmer and maintenance personnel in practicing good shop safety procedures. The operator and maintenance personnel must read and understand these precautions completely before operating, setting up, running, or performing maintenance on the machine.
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
8
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.
0178-015-EN
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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.
0178-015-EN
When the compressor is installed, be sure that the motors rotate in the right indicated direction.
9
WARNING Failure to follow the safety instructions outlined on this page may result in serious personal injury or death.
Setup and operation safety Read and understand all the safety instructions before setting up, operating or servicing this compressor. Assign only qualified personnel, instructed in safety and all machine functions, to operate or service this compressor. Operators and maintenance personnel must carefully read, understand, and fully comply with all machine mounted warning and instruction plates. Do not paint over, alter, or deface these plates or remove them from the compressor/unit. Replace all plates which become illegible. Replacement plates can be purchased from Sabroe Refrigeration. Safety guards, shields, barriers, covers, and protective devices must not be removed while the compressor/unit is operating. All safety features, disengagements, and interlocks must be in place and functioning
10
correctly prior to operation of this equipment. Never bypass or wire around any safety device. Keep all parts of your body off the compressor/motor/unit during operation. Never lean on or reach over the compressor. During operation, be attentive to the compressor unit process. Excessive vibration, unusual sounds, etc., can indicate problems requiring your immediate attention. Maintenance safety Do not attempt to perform maintenance on the compressor unit until you read and understand all the safety instructions. Assign only qualified service or maintenance personnel trained by Sabroe Refrigeration to perform maintenance and repair work on the unit. They should consult the service manual before attempting any service or repair work and when in doubt contact Sabroe Refrigeration. Use only Sabroe Refrigeration replacement parts; others may impair the safety of the machine. Before removing or opening any electrical enclosure, cover, plate, or door, be sure that the Main Disconnect Switch is in the OFF position and the main fuses are dismantled.
0178-015-EN
If any tool is required to remove a guard, cover, bracket, or any basic part of this compressor, place the Main Disconnect Switch in the OFF position, lock it in the OFF
position. If possible, post a sign at the
disconnect switch indicating that maintenance is being performed. Dismantle main fuses to the unit.
DANGER: HIGH VOLTAGE Before working on any electrical circuits, turn the machine Main Disconnect Device ”OFF” and lock it. Dismantle the main fuses to the compressor unit. Unless expressly stated in applicable Sabroe Refrigeration documentation or by appropriate Sabroe Refrigeration Field Service Representative, do NOT work with electrical power ”ON”. If such 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:
First aid for accidents with Ammonia. First aid for accidents with HFC/HCFC.
Whenever maintenance is to be performed in an area away from the disconnect and the
0178-015-EN
Protecting the operator as well as the environment.
11
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.
12
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: 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. With the following refrigerants: R717 – R22 – R134a – R404A – R507 – R600 – R600A – R290 – LPG Other HFC refrigerants in accordance with SABROE’s instructions. All other types of gas may only be used following a written approval from SABROE.
0178-015-EN
In an explosion-prone environment, provided the compressor is fitted with approved explosion-proof equipment.
WARNING The compressor must NOT be used: For evacuating the refrigeration plant of air and moisture, For putting the refrigeration plant under air pressure in view of a pressure testing, 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: 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
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.
0178-015-EN
13
Safety symbols
DANGER: The high voltage sign
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.
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 Re-
CAUTION
frigeration Field Service Representative. The customer and subsequent transferees must determine that any other person performing work with electrical power ”ON” is trained and technically qualified.
Before handling, installing, operating or servicing the compressor and unit, read the Safety Precautions section in the Instruction Manual. It is the responsibility of the operator or his employer that the instruction manual 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 sección Precauciones de seguridad en el Libro de Instrucciones. Es respondabilidad del operarío o de su patrón, que el libro de instrucciones permanezca siempre al alcance de la mano. Esta señal no debe de ninguna manera suprimirse o dañarse . 2516-297
14
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.
0178-015-EN
In such cases a yellow label like the one shown below are stuck on the compressor surface.
Påfyldt beskyttelsesgas Charged with inert gas Enthält Schutzgas Chargé 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 70°C 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 second’s 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: Read related Safety Precautions section in this manual before opening the compressor and other parts of the refrigeration plant. Make sure that the motor cannot start up inadvertently. It is recommended to remove all main fuses. Switch off all electric components on the compressor/unit before the dismantling. 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.
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.
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
0178-015-EN
15
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 1. Call a doctor immediately. 2. Be prepared: Keep an irrigation bottle available, containing a sterile isotonic (0.9%) NaCl-solution (salt water). 3. A shower bath or water tank should be available near all bulk installations with ammonia. 4. When applying first aid, the persons assisting should be duly protected to avoid further injury.
16
Skin burns from liquid splashes or concentrated vapour 1. Wash immediately with large quantities of water and continue for at least 15 minutes, removing contaminated clothing carefully while washing. 2. Call a doctor immediately. 3. After washing, apply wet compresses (wetted with a sterile isotonic (0.9%) NaCl-solution (salt water)) to affected areas until medical advice is available.
0178-015-EN
WARNING No plant can ever be said to be too safe. Safety is a way of life.
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. 300°C 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.
0178-015-EN
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.
17
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 No plant can ever be said to be too safe. Safety is a way of life.
When halogenated gasses come into contact with open flame or hot surfaces (over approx. 300°C) 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, industry, including refrigeration, and must be complied with.
Oil vapour in the t he 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: refrigerants
Usually the strong smell of ammonia will give ample warning of its presence before concentrations become dangerous.
cooling media (brines etc) lubricating oils.
Refrigerants usually Refrigerants usually have a natural boiling point which lies a good deal below 0 °C. 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
18
vol.%
0.2
0 . 00 2
0178-015-EN
Furthermore, it can be said about refrigerants: 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 Halogenated refrigerants must, therefore, never be never be released to the atmosphere. Use a separate compressor to draw the refrigerant into the plant’s condenser/receiver condenser/receiver or into separate refrigerant cylinders. 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. Ammonia is easily absorbed by water: At 15°C, 1 litre of water can absorb approx. 0,5 kg liquid ammonia (or approx. 700 litres ammonia vapour). 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. As ammonia is alkaline it will damage plant life if released to the atmosphere in large quantities.
Halogenated Halogenated refrigerants must never be mixed. Nor must R717 ever be mixed with halogenated halogenated refrigerants. Purging a refrigeration plant If it is necessary to purge air purge air from a refrigeration plant, make sure you observe the following: Refrigerants must not be released to the atmosphere. 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. Halogenated refrigerants can not be 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.
Refrigerant evacuated from a refrigerant plant shall be charged into refrigerant cylinders intended for this specific refrigerant.
Never empty brines down a sewer or into the environment.
If the refrigerant is not to be reused, return it return it to the supplier or to an authorized incineratincinerating plant.
The brine must be collected in suitable containers, clearly marked with the contents, and sent to an approved incinerating incinerating plant.
0178-015-EN
19
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 – polyalphaolefine-based
– mineral oil – semi-synthetic oil
– glycol-based glycol-based synthetic oil. When you change the oil in the compressor or drain oil from the refrigeration plant’s 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.
20
0178-015-EN
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.
In the following tables the noise data of the compressors is stated in:
– A-weighted sound power level LW (Sound Power Level)
– A-weighted sound pressure level LP (Sound Pressure level) The values for LW constitute an average of a large number of measurings on various units. The measurings have been carried out in accordance with ISO 9614-2. 6 0 . 9 9
N E 4 1 1 0 7 1 0
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.
SAB 128 HR and SAB 163 HR: Compressor block at max. number of revolutions + IP23 special motor + oil separator 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
0170-114-EN
1 meter
Reflecting plane
21
Note the following, however: 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. 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. as already mentioned, the stated sound pressures are only average values above a fictional frame around the noise source. Thus, it is sometimes possible to measure higher values in local areas than the ones stated – for inst. near the compressor and motor.
22
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. 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.
0170-114-EN
RECIPROCATING COMPRESSORS One-stage Evaporating temperature = –15°C Condensing temperature =+35°C Refrigerant = R22/R717 Number of revolutions =1450 rpm.
Two-stage Evaporating temperature Condensing temperature Refrigerant Number of revolutions 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
= –15°C = +35°C = R22/R717 = 900 rpm.
Evaporating temperature Condensing temperature Refrigerant Number of revolutions Compressor block
LW
LP
= –35°C = +35°C = 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
= –35°C = +35°C = R22/R717 = 900 rpm.
Evaporating temperature Condensing temperature Refrigerant Number of revolutions Compressor block
LW
LP
TSMC 188
100
82
Heat pump Evaporating temperature Condensing temperature Refrigerant Number of revolutions Compressor block
= +20°C = +70°C = 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
0170-114-EN
23
SCREW COMPRESSORS Evaporating temperature Condensing temperature Refrigerant Number of revolutions
= –15°C = +35°C = R22/R717 = 2950 rpm.
*Number of revolutions
= 6000 rpm.
Compressor block SAB 110 SM SAB 110 SF SAB 110 LM SAB 110 LF
LW
Evaporating temperature
= –35°C
Condensing temperature
= –5°C
Refrigerant
= R22/R717
Number of revolutions
= 2950 rpm.
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
105 109 103 106
86 90 86 87
SAB 163 HR*
103
85
SAB 202 SM SAB 202 SF
104 105
85 86
SAB 202 LM SAB 202 LF
104 105
85 86
SAB 330 S SAB 330 L
106 106
87 87
SAB 330 E
106
87
SV 17 SV 19
100 101
83 84
FV 19*
101
86
SV 24
103
85
FV 24*
104
86
Refrigerant
= R22/R717
SV 26
103
85
Number of revolutions
= 2950 rpm.
FV 26*
107
85
SAB 81 SAB 83 SAB 85 SAB 87
101 102 103 105
86 85 86 86
SAB 89
108
85
Compressor unit
LW
LP
SAB 163 BM
106
88
SAB 163 BF
110
92
Evaporating temperature
= –15°C
Condensing temperature
=+35°C
Refrigerant
= R22/R717
Number of revolutions
= 2950 rpm.
Compressor block
LW
LP
VMY 347 H
97
82
VMY 447 H
100
85
VMY 536 H
104
88
Evaporating temperature
= 0°C
Condensing temperature
=+35°C
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
24
0170-114-EN
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 Range 6 0 . 5 9
N E 5 1 1 0 7 1 0
0.28 0.45 0.71 1.12 1.8 2.8 4.5 7.1
ms-velocity V (in mm/s) at the range limits 0.28 0.45 0.71 1.12 1.8 2.8 4.5
11.2
7.1 11.2
18 28
18
45
Class I
Class II
Class III
Class IV
A A B
A A
B C
B C
B C
D
C
D D
D
28 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: 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 However, a higher vibration level may occur if:
0178-250-EN
– 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.
25
Compressor Rotor Intern. Rotor L/D ∆P Motor at 2950 Motor at 3550 type drive volume dia. max. male rotor swept vol. male rotor swept vol. ratio bar 1 2 3 Vi mm rpm m3/h rpm m3/h SAB 128 H-M SAB 128 H-F
male
127.5
female 2.0-4.5 127.5 1.7
20
2950
303
3550
364
4425
454
5325
547
SAB 163 H-M
male
163.2
2950
635
3550
764
SAB 163 H-F
female
163.2
4425
952
5325
1145
1) The female drive design can be changed to male drive 3) Discharge pressure minus suction pressure
2) Rotor length divided by rotor diametre
See permissible operating l imits, however, in the following Operating Limits Diagrams
Block weight Kg 290
200
SAB 163 H-M
460
245
The enclosed diagrams for R717, R22, R134a, R404A/R507 and R407C indicate the limits within which the compressor is permitted to work. Please, observe the following: The upper operating limits are for Male Drive and Female Drive, respectively (see compressor type on p.1).
26
Centre height mm
SAB 128 H-M
Operating limits
4 0 . 8 9
N E 3 5 0 8 7 1 0
Further, note the additional operating limits provided the compressors have the following extra equipment:
– HLI (High Stage Liquid Injection) – HLI + Economizer, simultaneously The use of an economizer is allowed within the entire permissible operating area of the compressor.
0178-050-EN
Operating limits
SAB128H SAB163H MK3
°
R717
e r u t a r e p m e t g n i s n e d n o C
R717
°
Evaporating temperature
(T250835_0)
Operating limits
°
R22
60
C
50
SAB 128 H, SAB 163 H Mk3 MALE DRIVE
FEMALE DRIVE
40 e r u t a r e p m e t g n i s n e d n o C
30
HLI + ECO
HLI
20 10 0
–10
R22 –20 –30 –60 –50 –40 –30 –20 –10 (T250834_0)
0178-050-EN
0 Evaporating temperature
10
20
°
C
27
Operating limits
°
SAB 128 H, SAB 163 H Mk3
C
MALE DRIVE
R134a
70 FEMALE DRIVE
60 HLI+ ECO
50
e r u t a r e p m e t g n i s n e d n o C
HLI
40 30 20 10 0
R134a
–10 –20 –50 –40 –30 –20 –10
0
10
20
30
°
C
Evaporating temperature
(T250836_0)
Operating limits R404A - R507
°
SAB 110S/L, SAB 128H, SAB 163H Mk3
e r u t a r e p m e t g n i s n e d n o C
R404A-R507 (T250829_2)
28
°
Evaporating temperature
0178-050-EN
Operating limits R407C
SAB 110S/L, SAB 128H, SAB 163H Mk3 TC ° C 60
LIMIT FOR MODEL S/H, SAB110L LIMIT FOR MODEL M, SAB202L
MALE DRIVE
50 HLI
40 e r u t a r e p m e t g n i s n e d n o C
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 –20
VMY 447: Below curve full flow oil pump required
R407C
–30 –60 –50 –40 –30 –20 –10
0
10
20
TE °C
Evaporating temperature (T250133_1)
0178-050-EN
29
SAB 128 Mk3
t h g i e H
r e p m a d n o i t a r b i V
Z
Width 2 0 . 6 9
EXTRACTION OF FINE SEPARATOR ELEMENT
600
Length
N E 4 5 0 8 7 1 0
1500 CLEANING OF OIL COOLER OWSG
Table SAB 128 COMPRESSOR TYPE
REFRIGERANT
SAB128H
R717
MK3
1)
OIL COOLING SYSTEM 1)
R22 R134a R404A/ R507
OWSG,OOSI HLI,BLI
WIDTH
MAX. DIMENSIONS LENGTH
Z
MM
MM
HEIGHT MM
1364
2200
1378
68
1419
2200
1403
68
MM
MAX. NET WEIGHT KG 2)
1150
OWSG = HEAT EXCHANGER WITH SHELL (WATER)
2)
EXCL. MOTOR, OIL AND WATER
OOSI = HEAT EXCHANGER WITH SHELL (REFRIGERANT) HLI = REFRIGERANT INJECTION INTO THE COMPRESSOR BLI = REFRIGERANT INJECTION INTO DISCHARGE PIPE
30
0178-050-EN
SAB 163 Mk3
t h g i e H
Z
Width
EXTRACTION OF FINE SEPARATOR ELEMENT
800 IEC 315 L
Length
1900 CLEANING OF OIL COOLER OWSG
Table SAB 163 COMPRESSOR
REFRIGERANT
SYSTEM 1)
TYPE SAB163H MK3
1)
OIL COOLING
R717 R22 R134a R404A/ R507
OWSG,OOSI HLI,BLI
WIDTH
MAX. DIMENSIONS LENGTH HEIGHT
Z
MM
MM
MM
MM
1576
2628
1670
68
1739
2628
1725
68
MAX. NET WEIGHT KG 2)
1800
OWSG = HEAT EXCHANGER WITH SHELL (WATER)
2) EXCL. MOTOR, OIL AND WATER
OOSI = HEAT EXCHANGER WITH SHELL (REFRIGERANT) HLI = REFRIGERANT INJECTION INTO THE COMPRESSOR BLI = REFRIGERANT INJECTION INTO DISCHARGE PIPE
0178-050-EN
31
Type of compressor unit On the base frame of the compressor unit a name plate has been fitted as shown in fig 1. This name plate provides you with all relevant information in accordance with CE labelling.
32
0178-050-EN
During operation of the compressor, the below points should be observed. These are described in detail in the following sections. 1. Preparations before starting up. 2. Initial start. 3. Current control requirements at normal operation. 4. Normal stop. 2 0 . 7 9
5. Preparations before a lengthy standstill period. 6. Pressure testing.
N E 5 5 2 8 7 1 0
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.
0178-250-EN
4-5 mm Hg. If necessary, use a thermostatic vacuum gauge for measuring of pressure and fill up with dry air or nitrogen until the pressure reaches 1 bar. Then empty again to 4-5 mm Hg. e) 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 or- der to avoid cavitation in the oil pump. f) Open all internal valves. g) Slowly open the suction and discharge stop valves and fill up the plant with 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.
33
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 run- ning down of the evaporating pressure as indicated in the instruction on refrigeration plants. i) Do not leave the compressor for the first 60 mins.
34
3. Current control at normal operation The following should be noted daily: •
Suction pressure (bar).
•
Suction temperature (°C).
•
Discharge pressure (bar).
•
Discharge pipe temperature ( °C)
•
Oil temperature (°C).
•
Power consumption (amp.).
•
Number of hours
•
The position of the Vi slide
4. Normal stop Regulate the compressor down to min. 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: Dry air - Pressurized cylinders containing dry atmospheric air may be used - never use oxygen cylinders. Air compressor for high pressure. Nitrogen.
0178-250-EN
Important Do not use the plant compressors for pressurizing the plant. Water or any other liquid must not be used in connection with pressure testing. In case nitrogen is used it is important to place a reduction valve with pressure gauge between the nitrogen cylinder and the plant. During pressure testing it is important that pressure transducers and other control equipment are not exposed to the test 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 com- ponents or in the vicinity of the plant out- side the rooms. The entire plant is strength tested according to the local rules for pressure testing. Usually, the test pressure must not be allowed to exceed the design pressure. However, also in this case the local rules and regulation apply. 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. 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.
0178-250-EN
During leak testing, it is permitted to enter the rooms and approach the plant. 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 100°C. If the pressure is lowered, so is the boiling point of water. The following table indicates the boiling point of water at very low pressures: Boiling point of water °C
At pressure mm HG
5
6,63
10
9,14
15
12,73
20
17,80
35
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.
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.
Evacuate again to a pressure below 5 mm Hg. 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 10 °C. 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:
Time
Power consump. Electric motor Fact.: No.: CV/kW: COS Ø: n: rpm
A
36
V
kW
Compressor . n a m . t c u S
. n a m . h c s i D
C° C°
f s o n o r i e t u b l m o u v e N r
Condenser
e e p r . e p i u p t g r m n a r a e o e t i h p c e t c s p u m i i e D p S t
rpm C°
C°
Cooling water Inlet C°
Outlet C°
lh
Temperature e n i h m c o a o M r
C°
1 Air Inlet C°
Outlet C°
2 Suction pipe Pres. C°
Air
Suction pipe
Temp. Inlet Outlet Pres. C ° C ° C° C°
Temp. C°
Temp. of ambient air C°
0178-250-EN
Good and careful servicing of the compressor and the unit is of great importance for their proper functioning and service life.
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.
Preparations before compressor inspection 5 0 . 9 9
N E 8 2 0 8 7 1 0
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: Regulate the compressor down to its lowest capacity stage and stop it. 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 non- return valve. Close suction stop valve pos. 20. 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 Envi- ronment . The heating element in the oil separator must remain connected until the pressure is completely equalized, thus boiling the refrigerant out of the oil.
0178-028-EN
Replacement of oil filter In case only the oil filter has to be replaced, follow below procedure depending on the the type of your compressor: SAB 110, SAB/163 and SAB 202 Above-mentioned compressors all have builtin oil filters. Follow the procedure described in the previous passage: Preparations before com- pressor inspection. Remove oil filter as described in section: Maintenance of the compressor . VMY with external oil filter As the units may be fitted with one or two oil filters (mounted in parallel) apply procedures A or B. A: Units with one oil filter only • Bring compressor to minimum 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 .
37
B: Units with two parallel oil filters • While the compressor is operating, the stop valves before and after one of the oil filters must be closed. •
•
Over pressure in filter housing is equalized to atmospheric pressure through evacuation valve on filter housing. Cover on filter housing can now be dismantled, as described in section Oil filter.
Cleaning of oil in the unit The most critical time for an oil filter is, 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-
38
en to the lubricating system of the unit and absorbed by the oil filter. These impurities may result in a need to change the oil filter cartridge shortly after initial start-up. It is equally important to check the oil at regular intervals as specified in the sections Checking the oil and Assessing the oil. Purification of the oil may be done by means of a 3 micron filter in a closed system. During this process, the oil must not come into contact with the oxygen and moisture in the air. In addition, it is important that all pressures and temperatures be kept within the specified values and that filters be kept clean; provided inspection is carried out to the schedules prescribed below, compressor and unit will work efficiently and achieve a long service life. The following charts indicate the schedules for checking the oil in the compressor unit and a more detailed description of the operations to be performed during scheduled service inspections.
0178-028-EN
Checking the oil Service schedules
Operating hours between main inspections See chart for main inspections 20000h HCFC
•
•
30000h
R717
HCFC
40000h
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 start-up of compressor. ætning Serviceterminer efter føinitial rste igangs af kompressoren. Serviceterminer efter hvert hovedeftersyn. Service schedules after each main inspection.
NB: It is not advisable to reuse oil drawn from compressor or plant. This oil has absorbed the moisture in the air and is likely to cause operating problems. Always turn off the power to the heating rod before draining off the oil.
0178-028-EN
39
Activities during a service inspection Periodic service 1
Daily
Activity 1.1 External inspection and leak check. 1.2 Check the oil level in the oil separator. 1.3 Check pressures and temperatures. 1.4 Check for unusual vibrations or noise. 1.5 Record operating data in the log book.
2
After 50 hours’ operation
2.1 Clean the suction filter.
3
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.
4
5
After 1000 hours’ operation
4.1 Clean the compressor suction filter.
After 2500 hours’ operation
5.1 Clean the compressor suction filter.
4.2 Take an oil sample from the oil separator and appraise it visually, or send the sample to a laboratory for analysis. Both methods are described in the section entitled Assessing the oil .
5.2 Take an oil sample from the oil separator and send it to a laboratory for analysis, as described in Assessing the oil . 5.3 Fit a new oil filter cartridge. 5.4 Clean all other oil filters and connections to and from the compressor. 5.5 Check the coupling and its alignment (SAB 110*) 5.6 Check that the pressure switches and thermostats function correctly (refer to the set values in the instruction book). If UNISAB II computerized control is fitted, check the transducers (see the instruction manual for UNISAB II )
*
40
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
Periodic service 6
Activity
After 5000 hours. operation
6.1 Clean the compressor suction filter.
This service should be repeated after every 5000 hours of operation
6.3 Clean all other oil filters and connections to and from the compressor.
6.2 Fit a new oil filter cartridge.
6.4 Check the coupling and its alignment (SAB 110*) 6.5 Check that the pressure switches and thermostats function correctly (refer to the set values in the instruction manual). If UNISAB II computerized control is fitted, check the transducers (see the instruction manual for UNISAB II) 6.6 Take an oil sample from the oil separator and send the sample to a laboratory for analysis, as descri bed in the section entitled Assessing the oil . Please also refer to the table entitled Checking the oil.
7
Major service Carried out as specified for the individual screw compressor type. (See the diagram for major service)
7.1 Total overhaul of the compressor, including fitting new gaskets. As the compressor is already open, inspect the bearings and, if necessary, fit new ones. Check the regulating system. 7.2 Overhaul and clean the compressor motor. N.B. Follow the service schedule specified by the motor manufacturer. 7.3 Fit a new oil filter cartridge. 7.4 Drain off the compressor oil and charge with new, fresh oil. 7.5 Check the coupling and its alignment (SAB 110*) 7.6 Check that the pressure switches and thermostats function correctly (refer to the set values in the instruction book). If UNISAB II computerized control is fitted, check the transducers (see the instruction manual for UNISAB II)
*
Check the elastic intermediate part to see whether there are any visible oblique cracks in the rubber part. If such cracks are observed, replace the intermediate part.
0178-028-EN
41
Assessing the oil Refrigeration machine oil is a vital part of the compressor, as it not only lubricates and cools the movable parts of the compressor, it also prevents abrasive particles from 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
bottle with subsequent risks of explosion. Never fill a bottle up completely. Do not send glass bottles through the postal ser- vice – use purpose-made plastic bottles. Please, see below.
Analytical evaluation Naturally, the oil sample can be analysed by the oil company which supplies the oil. As a special offer to our customers SABROE has developed an analytical concept, in cooperation with Mobil Oil, which is able to analyse all oil makes. This will mean a uniform reporting of the results. The analysis allows the following to be determined: Whether or not the oil is still usable - after filtering, if necessary - or whether it should be replaced.
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.
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.
An oil which you approve on the grounds of a visual assessment must:
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.
•
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 don’t feel that you can approve the oil by visual assessment, charge with new oil or send a sample to a laboratory for analysis. Note: If the oil sample is poured into a glass bottle, this must not be hermetically sealed until all the refrigerant in the oil sample has evaporated. Refrigerant in the oil may produce excess pressure in the
42
Procedure A form set with a plastic sampling bottle and a dispatching envelope can be requested from the local Sabroe Refrigeration representation. The oil sample must be drained from the cleaned oil drain valve into the sample bottle. Screw the lid loosely on and let the bottle stand for a few hours to enable re-
0178-028-EN
frigerant contained in the oil sample to evaporate before sending it to the laboratory. 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 analysis The following table states some average values that can be applied in practice. However, you should be on the alert whenever the results of the analyses approach these values. In some cases the water content of 100 ppm in HCFC plants may be too much and thus lead to Cu –plating in the shaft seal.
Limiting values Parameter
Unit
Method
Sabroe Oil PAO 68
Sabroe Oil AP 68
Target Spec.
Target Spec.
Max.
Min.
Sabroe Oil A 100
Max.
Min.
Target Spec.
Max.
Min.
Viscosity @ 40 °C
cSt
ASTM D 445
66
76
53
64
74
51
100
115
80
TAN *1)
mg KOH/g
ASTM D 664
0.03
0.2
–
0.01
0.2
–
0.05
0.2
–
SAN * 2)
mg KOH/g
ASTM D 665
–
0
–
–
0
–
–
0
–
Water
ppm
Karl Fisher
–
100
–
–
100
–
–
100
–
Appearance
–
–
report
report
report
Colour
–
ASTM D 1500
report
report
report
Pentane Insolubles
W%
MM 490 (5m)
–
0.05
Oxidation
abs/cm
IR,1700-1720 /cm
–
5
Nitration
abs/cm
IR,1627-1637 /cm
–
Nitro Compounds
abs/cm
IR,1547-1557 /cm
–
0.05
–
–
0.05
–
–
–
5
–
–
5
–
5
–
–
5
–
–
5
–
–
0.5
–
–
0.5
–
–
0.5
–
Maximum values for metal content in the oil Lead
ppm
ICP
–
10
–
–
10
–
–
10
–
Copper
ppm
ICP
–
10
–
–
10
–
–
10
–
Silicium
ppm
ICP
–
25
–
–
25
–
–
25
–
Iron
ppm
ICP
–
100
–
–
100
–
–
100
–
Chromium
ppm
ICP
–
5
–
–
5
–
–
5
–
Aluminium
ppm
ICP
–
10
–
–
10
–
–
10
–
Tin
ppm
ICP
–
10
–
–
10
–
–
10
–
1): TAN (Total Acid Number) is only reported for non-ammoniaapplications
0178-028-EN
2): SAN (Strong Acid Number) is only reported for non-ammonia-applications
43
A report is drawn up for every sample received. This report concludes: Whether the oil can still be used – without taking any further action. Whether the oil can be used after it has been filtered through a very fine filter. If this is necessary, the oil must be pumped directly from the compressor unit through a 3 micron filter and back to the unit. The
44
system must be completely closed, to 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.
0178-028-EN
Condensing temp.
”Extreme” operating conditions
TC (°C)
Normal operat. cond. 30000 hour interval
20000 hour interval
55 55 50 50 45
0 1 . 5 9
45
40
40
35
35
30
30 25
25 N E 0 3 0 8 7 1 0
20
20
15
15
10
10
5 0 –5 –10 –15 –20 –30
5 0 –5 –10
–20 –30 –50
“Booster” conditions 40000 hour interval
–50 R22 R717
–50 –30 –20
–10 –5
0
5
10
15
20
25
Evaporating temp.
–50 –30 –20
–10 –5
0
5
10
15
20
25
TE (°C) T0177068_0
0178-250-EN
45
Oil charging (oil level at the middle of upper sight glass during operation) Oil cooler Type SAB 128 OOSI OOSI OOSI OOSI OOSI OWSG OWSG OWSG OWSG OWSG OWSG OWSG HLI
1614 2114 2714 3214 4114 1615 1619 2115 2119 2719 3219 4119
11 20
Litres SAB 163
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
25
103 112 123 140
216 225 236 253 291
117
230
131 155
244 278 283 324 205
87
39 39 63
0
Total, unit Litres SAB SAB SAB 128 163 202
0
60
80
180
9
12
25
39 63 78 119 0
97
69
92
2 0 . 6 9
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
120
1528 1580 1630 1665
3218 3270 3320 3355 3520
1580
3270
1660 1760
3350 3450 3580 3880 3160
1050
185 210 310
20
Total, unit Kg SAB SAB SAB 128 163 202
20
700
210 310 440 740 20
950
2100
230
500
1040
1115
950
1470
Shipping volume (excl. motor) Oil cooler Type
OOSI OOSI OOSI OWSG OWSG OWSG HLI
46
2114 3214 4114 2115 2719 4119
Compressor type m3 SAB SAB SAB 128 163 202 5 8 11 6 9 4
7
12 10
0178-250-EN
N E 6 5 2 8 7 1 0
During both start-up and operation it must be made sure that the plant is working correctly.
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:
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.
the desired temperatures are observed,
7 0 . 7 9
the oil pressure and discharge pipe temperature on the compressor are correct,
Check
N E 0 7 4 1 7 1 0
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
Condenser
Alignment of coupling V-belt drive
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 during the plant’s 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 supplier ’s instructions. At temperatures lower than -25°C, use special lubricant.
Periodically
Corrosion
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, receiver, etc. for oil accumulation. Exercise caution; use a gas mask.
0178-250-EN
Servicing work on the SAB 128/163 compressor must be carried out by professional, well-trained well-trained staff acquainted with the compressor. These instructions describe the complete dismantling and assembly of the compressor, although this will not always be required. When dismantling, parts should be marked to ensure that they can be remounted in the same position as before. 6 0 . 8 9
N E 1 6 0 8 7 1 0
Torque moments for screws and bolts as stated in the Torque moments table table must be strictly observed.
As O-ring gaskets have a tendency to expand beyond their size when exposed to oil and refrigerant, it is useful to have an extra set of gaskets ready before starting work. See the list of spare part sets in this instruction manual. Tools Apart from having the necessary tools at hand (see the tool list in the instruction manual), it is an advantage to place the compressor on an iron plate when dismantling completely. This will allow for easy removal of oil leaking from the compressor during disassembly.
Preparations before dismantling A description is given below of complete dismantling, inspection and reassembly of the compressor. Partial dismantling and inspection can be undertaken while the compressor is secured to the base frame. To allow a complete 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 these instructions in order to avoid damage when restarting the compressor. Therefore, read the instructions carefully, carefully, before commencing the work.
0178-050-EN
It is also recommended to position the compressor in a spot with plenty of space around and to ensure that the room is clean and dust-free. Elimination of refrigerant gas Shut off the suction and discharge stop valves and eliminate the refrigerant gas as described in the section Environmental Environmental pro- tection . Removal of various accessories When working on the compressor, the power to the compressor motor must be cut off and it must be ensured that the compressor cannot be inadvertently started (if necessary, remove the master switches).
49
Dismantle the following parts from the compressor: 1. Coupling between compressor and motor motor.. 2. Flanges Flanges connecti connecting ng the suction suction and disdischarge sides of the compressor to plant and oil separator (in the case of total dismantling). 3. Oil piping piping connecte connected d to the compressor compressor.. There may be oil in these pipes. They should therefore be loosened carefully to allow for collection of this oil. When the oil pipes have been removed, they must be stored without being neither bent nor damaged. 4. Electrica Electricall connection connections s to the compressor compressor block. The position numbers in the following sections refer to the spare parts drawing. Draining oil from the compressor Following dismantling of the oil pipes, quite some oil may still remain in the compressor. Most of it can be removed by unscrewing the threaded plug pos. 24 on the underside of the compressor while this is suspended, suspended, for example, in the crane.
50
Note: For cleaning and drying compressor parts, do not use use twist or any any other fluffy fluffy cloth. Dismantling the compressor Sequence for dismantling Sequence and Descrip. no.
Parts to be dismantled Oil filter Suction filter and non-return valve
1 2
Shaft seal, balance piston and shaft cover Regulating cylinder Regulating slide
3
Slide stop for Vi regulation Suction cover and bearings in compressor shaft end Rotors and bearings in compressor discharge end Capacity indicator
6 7
4 5
8 9
The individual points are described below. Reassembling the compressor Clean all parts carefully before reassembling. Examine the parts for damage and wear and replace with new parts, if necessary. Examine all gasket rings to see if they can be reused. If in doubt, replace with new parts. Before remounting, lubricate all parts, including screws, with clean fresh f resh refrigeration oil.
0178-050-EN
1. Oil filter
Fig. 1 B
The oil filter pos. 470 is a replaceable filter cartridge, fitted in the compressor block as shown on the spare parts drawing. Along with the consumption of the filtering capacity of the filter cartridge, the pressure loss across the filter increases, which is registered by the two pressure transducers pos. 752 and pos. 753.
A
•
C •
Make sure that a new filter cartridge is at hand as the replaced oil filter cannot be cleaned. Before removing the filter cartridge from the compressor block, stop the compressor and the pressure will be equalized to atmospheric pressure. Further, empty the oil filter housing of oil, which is done by using drainage valve pos. 48 – see piping diagram as well as fig. 1.1. This drainage is most easily carried out while there is still some excess pressure left in the compressor.
•
T4840165_0
1.1.1. Next, dismantle electrical coupling pos. 753 and temperature transmitter pos. 761. 1.1.2. By removing screws pos. 456, cover pos. 450 with oil cartridge pos. 470 and O-ring pos. 452 can be extracted from the oil filter housing. 1.1.3. By dismantling nut pos. 455 filter cartridge pos. 470 can be pulled out across spindle pos. 458. 1.1.4. Do not dismantle magnetic filter pos. 460, but wipe it with a clean piece of cloth.
Fig. 1.1
1.2. 48
Cutting ring connection Pipe dia.OD = 10 mm ID = 8 mm
Mounting of oil filter cartridge
1.2.1. After cleaning cover pos. 450 on the inside, mount filter cartridge pos. 470 and O-ring pos. 453. Fasten the parts with nut pos. 455. 1.2.2. Position the complete cover pos. 450 with O-ring pos. 452 in the compressor and tighten with screws pos. 456.
1.1.
Removal and cleaning After the pressure in the compres sor has been equalized to atmospheric, dismantle oil pipe pos. A at flanges B and C as illustrated in fig. 1.
0178-050-EN
1.2.3. Mount oil pipe pos. A and fasten it onto flanges B and C as illustrated in fig. 1. If considered necessary, replace O-ring in flange B and gasket in flange C. See part numbers in in Spare Parts Survey in the section on Oil system – Flange connection .
51
1.2.4. Next, fit the electrical coupling onto pressure transducer pos. 753 and temperature transmitter pos. 761.
2. Suction filter The suction filter is built into the compressor housing above the rotors. The purpose of the filter is to collect the impurities conveyed from the evaporator system with the suction gas. Experience shows that a good deal of impurities are collected in the filter during the initial period following start-up of a new refrigeration plant. Consequently, it is important to clean suction filter after 200 hours of operation from the initial start-up of the compressor. In case this is not done, there is a certain risk that the suction filter may burst due to an excessive differential pressure across the filter. 2.1.
Extraction of suction filter
2.1.1. Begin by removing the oil filter as described in section 1.1. 2.1.2. Next, dismantle the float switch as follows: Dismantle circlip pos. 511 by hand, hereby loosening washer pos. 508 and spring pos. 510. Normally, float ball pos. 507 cannot be removed before nipple pos. 505 has been unscrewed. Dismantle electrical coupling pos. 500 and unscrew nipple pos. 505.
52
Hereby, float ball pos. 507 is loosened; remember to support it by hand. 2.1.3. By removing screws pos. 280 it is possible to pull out flange pos. 279 together with oil filter housing pos. 480 and non-return valve pos. 260. But watch out, there may be a fair amount of oil behind the flange as mentioned in pt. 1.1.2. During the dismantling, apply the two supports no. 25 from the tools kit. These are mounted diagonally in the holes, in which screws pos. 280 were fitted. Pull out the flange pos. 279 by means of two of the screws pos. 280, which are fitted in the two threaded holes in the flange. Once the flange is loose, pull the whole unit straight out of the compressor block, guided by the two supports. 2.1.4. Now take out suction filter pos. 170 by hand, at the same time taking great care that no dirt falls out of the filter. As an extra safety measure it is recommended to check that in particular the oil chamber in the block between O-rings pos. 281 and 481 is completely clean before reassembly. 2.1.5. Clean the suction filter in an oil detergent and blow dry and clean it with compressed air.
0178-050-EN
2.2.
Mounting of suction filter After cleaning suction filter pos. 170, check that the filter mesh is undamaged. Mount suction filter as follows:
2.2.1. Place suction filter in the suction chamber by hand and press it firmly into flange pos. 253. In order to make the suction filter fit firmly onto the flange, you may press it into an oval shape before the mounting. Center the other end of the suction filter in the suction chamber.
2.2.5. Next, mount float switch as follows: Lead float ball pos. 507 through the oil filter housing and up into the float housing.
Note: The float ball must be positioned as shown in fig. 2 with the NO mark facing upwards. 1–31
Fig. 2
NO
2.2.2. Check that non-return valve pos. 260 is easy to move back and forth and check that the oil chamber in the compressor block is clean as described in pt. 2.1.4. 2.2.3. Using the supports no. 25 as guides, position the complete unit with flange pos. 279, oil filter housing pos. 480 and non-return valve pos. 260 in the compressor. Remember the two Orings pos. 281 and 481. Using these two supports guide the whole unit straight into the compressor, avoiding to push the suction filter out of its central position as indicated in pt. 2.2.1. Press the whole unit into place with your hands until flange pos. 279 touches the housing. 2.2.4. Mount and tighten screws pos. 280 with the prescribed torque.
0178-050-EN
C N
Position nipple pos. 505 with guide tube in the threaded hole of the housing and guide the float ball into place on the guide tube in which the electrical switch is situated. Screw nipple pos. 505 together with gasket pos. 506 firmly into place, at the same time making sure not to squeeze the float ball. Now mount spring pos. 510, washer pos. 508 and circlip pos. 511. Finally, mount the electrical coupling pos. 500.
2.2.6. Next, mount oil filter as described in section 1.2.
53
2.3.
Non-return valve
•
Once oil filter housing pos. 480 has been dismantled as described in section 2.1, check that non-return valve pos. 260 is easy to move back and forth. It is usually not necessary to dismantle the non –return valve. It can be dismantled in the following way, however: 2.3.1 Dismantling •
By removing screw pos. 262 the whole non-return valve comes loose.
•
Before dismantling the non-return valve, loosen locking screw pos. 266 by means of an Allen key.
•
Using two wrenches that engage in the holes of the valve cone pos. 260 and the locking device pos. 265 – as illustrated by fig. 3 – the two parts can be taken apart. Pay attention to the tense spring pos. 261.
If necessary, it is possible to replace tape bearings pos. 264 by new ones as they are easy to place in the grooves of the valve cone.
2.3.2 Assembly Assemble the non-return valve in the reverse order to the one described in pt. 2.3.1. Note the following, however: •
Assemble valve cone pos. 260 and locking device pos. 265 with the wrenches just mentioned and fix locking screw pos. 266. Remember to fit spring pos. 261.
•
Assemble the non-return valve completely before fixing it in oil filter housing pos. 480 with screw pos. 262.
Fig. 3
54
58 - 62
5
68 - 75
6
5
240
0178-050-EN
3. Shaft seal type 680 Fig. 1
81 D B C A 80
120 Oil out E w
•
w
w w
w w
w
w
O-ring pos. C seals against the shaft seal cover (80). The rotating part of the shaft seal, in which the carbon face pos. F is fitted, is fastened on the rotor shaft by means of the 3 pointed screws pos. E and tighten by means of the static O-ring pos. D.
w
w
Please be extremely careful with the lapped surfaces of the cast-iron seat and the carbon face. The slightest scratch will impair the sealing effect.
83 F
Oil in 3 to 4 mm T264106, rev. 0
Removing the shaft seal Designation Cast iron seat
Pos. No. A
Rotating part with carbon face
B
Outer O-ring
C
Inner O-ring
D
O-ring for cover
81
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 type 680 has a built-in metal bellow in its 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 seal is a slide ring type, consisting of a stationary cast-iron seat pos. A which is positioned in the shaft seal cover (80). Rotation is prevented by a pin pos. 83. The end face of the cast-iron seat is lapped to ensure that the slide face seals tightly. The
0178-050-EN
Take the pressure off the compressor - as described in the instruction manual - and dismantle the coupling. Remove all screws pos. 82. The shaft seal cover pos. 80 can then be pulled out over the shaft. If the cover sticks, so that it is not possible to remove it manually, use two cover screws fitted in the threaded holes of the flange to ease it off.
Note that the holes are not threaded all the way, so it is advisable to insert a steel pin dia. 8 x 40 before putting the screw into the hole. The oil splash ring pos. 113 and the castiron seat pos. A will come out together with the cover. The part, with carbon ring, can then be drawn out over the shaft. Normally tools are not required.
Fitting the shaft seal Clean the shaft seal cover pos. 80 and the rotor shaft thoroughly. Check the shaft for scratches and marks that might cause leaks.
55
Oil the shaft and shaft seal parts with the same type of refrigeration oil as the one used in the compressor. Press the rotating part carefully in over the rotor shaft until it touches the recess on the rotor shaft as shown on the drawing. Do not press the carbon ring but use two screw drivers as illustrated by fig. 2. In this way you avoid twisting the bellows in the shaft seal.
Fig. 2
Carefully ease the shaft seal cover in over the shaft until it meets resistance from the rotating part. Before screw pos. 82 has been tightened, there will be a gap of 3 to 4 mm between the two flanges, as shown in fig. 1. Check to ensure that O-ring pos. 81 is correctly placed. Insert screws pos. 82 and tighten them alternately - take care not to damage the shaft seal by tightening unevenly. Tighten the screws with the torque inidcated in the instruction manual. Fit the oil splash ring pos. 113. Fit the coupling as described in the Instruction Manual and turn the shaft (by hand) to check that it rotates freely.
Balance piston at suction end Attach balance piston pos. 120 to the rotor to be coupled to the motor so that the tubular pin pos. 118 slots into the milled recess.
Cap cover Then tighten the 3 pointed screws alternately with the supplied 3 mm Allen key. Mount the cast-iron seat pos. A and the O-ring pos. 6 in the shaft seal cover and make sure that the pin pos. 83 catches the slot in the seat pos. A.
56
After dismantling of screws pos. 92, dismantle cap cover pos. 90 by mounting two of the screws in the free threaded holes in the flange of cap cover. Hereby, the cap cover can be pushed out. Remounting of the cap cover is done in the same way as the shaft seal cover.
0178-050-EN
4. Regulating cylinder The purpose of the regulating cylinder pos. 50, the built-in piston system and the capacity slide pos. 200 is to adapt the capacity of the compressor to the actual cooling requirements of the plant. The system works by letting the piston pos. 201, 202, 203 and 204 move the capacity slide pos. 200 back and forth hydraulically. This opens modulatingly for an internal bypass channel which - when the position of the piston is to the extreme right on the drawing - is most open. Hereby, the compressor runs at its lowest capacity. Dismantling Dismantle capacity indicator as described in section 9. After dismantling of screws pos. 62, the cover pos. 60 can be pushed free of the cylinder by mounting two of the screws no. 21.2 in the threaded holes of the flange.
Watch out, there may be oil in the cylinder! Remove cover together with capacity indicator as an entire unit. Pull the whole thing straight out in order not to damage the
0178-050-EN
spindle pos. 210 and its catching in the piston. Dismantle cover and capacity indicator following the description in the section on Capacity indicator . At the piston first dismantle screws pos. 206, and next the whole unit pos. 202 and 201 can be pushed free of the piston rod and pulled out af the cylinder. For this purpose use screws No. 22.2 which are fitted diagonally in the piston and screwed completely through until they press against the piston rod pos. 207.
Watch out for oil behind the piston. Before dismantling regulating cylinder pos. 50, it is recommended to move Vi-slide pos. 190 to minimum position by turning the spindle pos. 180 clockwise.
Hereby, the spring pos. 191 is slackened as much as possible, but pay attention to the fact that a weaker spring force still remains which will press the regulating cylinder pos. 200 out against regulating cylinder pos. 50. Dismantle regulating cylinder pos. 50 after removing screws pos. 52.
57
5. Regulating slide The regulating slide pos. 200 can now carefully be pulled out of the compressor by hand. Two PTFE tape bearings are fitted in the regulating slide the purpose of which is to guide the slide on the guide tube pos. 192. Usually, the PTFE tape bearings are only replaced during an overhaul of the compressor. Any dismantling of piston rod pos. 207 and slide pos. 200 can be done by removing screw pos. 311 and locking plate pos. 310. Mounting The assembly is done in reverse order from the one described above, and attention must be paid to the following: When assembling piston rod pos. 207 and slide pos. 200, pay attention to O-ring pos. 209. Tighten the screw pos. 311 to the torque prescribed in the table. Also check that pin pos. 205 is in position and in good working order. The flat end of the pin must point down towards the spindle. When mounting the slide, spring pos. 191 must be in position as shown on the drawing.
58
Carefully guide the regulating slide onto the guide tube without damaging the two PTFE bearing tapes, pos. 208. When mounting the cylinder pos. 50, this must be pressed against spring pos. 191 while fitting the screws pos. 52. Pay attention to O-ring pos. 51. Tighten the screws pos. 52 with 75 Nm on SAB 128, and with 130 Nm on SAB 163. Assemble the piston, consisting of pos. 201, 202, 203 and 204, and insert it in the cylinder pos. 50 as one whole unit. Make sure that the sealing ring pos. 204 is positioned as shown on spare parts drawing with the open side facing inwards.
Pull the entire unit onto the piston rod pos. 207 by means of screws No. 22.2 until the screws pos. 206 can be fitted and tightened. When mounting cover pos. 60 the spindle pos. 210 must catch the piston rod pos. 207 and pin pos. 205. Pay attention to Oring pos. 61. Fasten the cover with screws pos. 62. Mount the capacity indicator as described in section 9.
0178-050-EN
6. Slide stop for Vi-regulation The purpose of the Vi-regulating system is to regulate the built-in volume ratio of the 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 dislocating slide stop pos. 190, hereby - via the regulating slide pos. 200 - changing the size of the discharge port of the compressor. This changing of the size of the discharge port increases or diminishes - the compression chamber and consequently the compression ratio. The Vi-regulation may be carried out either: A: manually on SAB 128 and 163 Mk3 or B: automatically on SAB 163 Mk3 only
A: Manual Vi adjustment Manual adjustment of the Vi slide stop position is described in a separate section in this instruction manual. Please refer to table of contents and fig 6.1. Adjustment of the system is described in a separate section of this instruction manual. Fig. 6.1
Dismantling After dismantling of screws pos. 102, screw out the whole unit with the slide stop cover pos. 100 and the bearing housing pos. 103 by turning the spindle pos. 180 anti-clockwise. When the spindle has been completely unscrewed from the thread in the slide guide pos. 192, the unit can be removed by hand. By dismantling screws pos. 104, the cover pos. 100 is dismantled from the bearing housing pos. 103, and the sealing rings pos. 182, 183 and 184 can be removed by hand. Spindle pos. 180 and ball bearings pos. 186 can now be pushed out of bearing housing, pos. 103. Slide stop pos. 190 and slide guide pos. 192 are squeezed together and should usually not be separated. Do not remove the unit from the compressor until suction cover pos. 20 has been dismantled. Please refer to section 7. Screw pos. 193 acts as a slide stop and should usually not be dismantled.
190 104
Mounting
184
When mounting - which is done in reverse order from the dismantling - attention must be paid to the following:
182 183 180 186 192 103 102 100 193
0178-050-EN
T0177135/V2
Insert the ball bearings, which must be well greased with ball-bearing grease in the bearing housing pos. 103 with the collar of the spindle pos. 180 in between. Avoid knocking on the bearings.
59
Before assembling of slide stop cover pos. 100 and bearing housing pos. 103, position the sealing rings pos. 182, 183 and 184 as shown on drawing. The open side of the sealing ring pos. 183 must face the ball bearing. Assembling is done by means of screws pos. 104.
Mount the whole unit in position by screwing the spindle into the slide guide pos. 192 until the slide stop cover pos. 100 bears against the suction cover pos. 20.
Pay attention to O-ring pos. 101. Secure with screws pos. 102
– Check that the spindle is easy to turn. B: Autom utoma atic tic Vi-regulation - only for SAB 163 Mk3 Fig. 6.2
Magnetic coupling pos. 405
40 0
405
407
406
3 72
37 4
390
190
370
191
401
403 402
• •
395 396
• •
•
410
•
• • • • •
• •
• •
•
•
•
•
• •
•
•
415
•
5
4
3
2
1
373
371
382
380
381
20
from T4161T01_2_4_JAN
By automatic Vi regulation, see fig. 6.2, the slide stop is moved by oil pressure controlled by solenoid valves and a position transmitter pos. 410. Dismantling First dismount the electrical connection to position transmitter pos. 410.
60
Dismount the pipe connection to the cover pos. 380. Having removed the screws pos. 382, the cylinder pos. 380 and appurtenant parts can be pulled out with care as one unit. unit. Be careful not to damage the spindle pos. 390 and the sealing ring pos. 371.
0178-050-EN
The entire unit including the magnetic coupling pos. 405 can be dismantled and assembled as described in the following section Magnetic coupling for Vi-indication Vi-indication . Dismantle piston pos. 372 by removing screws pos. 374, whereby the sealing ring pos. 371 can be taken out. Pay attention to the loose pin pos. 373. Slide guide pos. 190 and slide stop pos. 370 cannot be removed until suction cover pos. 20 has been removed. See section 7 in this respect.
Mounting When mounting – which is done in reverse order from dismantling – attention must be paid to the following: When mounting the piston, pos. 372, make sure: that the open side of the sealing ring pos. 371 faces the piston as shown on the drawing, that pin, pos. 373, is positioned in the groove of the piston, pos. 372, and fastened with screws, pos. 374. Now mount the entire unit with cover pos. 380, ensuring that spindle, pos. 390, catches the hole in piston, pos. 372, and pin, pos. 373.
Take care not to damage
– sealing ring pos. 371 – O-ring pos. 381 and remember that
– the unit must be pressed against spring pos. 191. Secure with screws, pos. 382. Mount pipe connection to cover, pos. 380.
0178-050-EN
Magnetic coupling for Vi-indication The rotating movement from spindle, pos. 390 - see fig. 6.2 - is transferred to the transmitter, mitter, pos. 410, through a magnetic coupling, pos. 405, which is completely tight to both oil and refrigerant. Dismantling Start by removing the four screws, pos. 403, whereby cover, pos. 402, and transmitter, pos. 410, can be removed as one complete unit. Cover, pos. 402, and transmitter, pos. 410, are dismantled by the removal of screws, pos. 415. Remove screw, pos. 396, while at the same time holding back driving disk, pos. 395, using a big screwdriver in the slot of the washer. On removing screws, pos. 401, parts pos. 380 and pos. 400 are dismantled, and the complete magnetic coupling, pos. 405, can be pulled out of pos. 400 by hand. On dismantling the inner circlip no. 1 it is possible to pull out the inner magnet retainer no. 2 and spindle, pos. 390, can be pulled out against the magnetic force. Dismantle spindle, pos. 390, by loosening screw, pos. 407.
Assembling Assembling of the complete unit is done in the reverse order to the dismantling. Pay attention to the following, however: On assembling parts, pos. 400 and pos. 380, fit O-ring, pos. 406. On reassembling the magnetic coupling, we advise you not to not to position magnet retainer no. 2 in the coupling until spindle, pos. 390, has been mounted as the magnetic force will make it very difficult to dismantle the parts again.
61
On mounting driving disk, pos. 395, the slot in the disk must be in a complete vertical position as illustrated on the following sketch.
395
On mounting the transmitter pin no. 3 must engage in the slot of the disk, pos. 395. If arm no. 4 has been dismounted from the transmitter, transmitter, it must be mounted correctly as follows: Find the 4mA point of the transmitter by turning the shaft as described in In- struction manual for UNISAB II. Mount arm no. no. 4 so that pin no. no. 3 is positioned as illustrated on the sketch. Tighten pointed screw no. 5. Mount transmitter, pos. 410, as shown in fig. 6.2 with the connection facing downwards.
62
0178-050-EN
7. Suction cover and bearing in compressor shaft end
– Shaft seal cover pos. 80 and shaft seal
Before suction cover pos. 20 can be dismantled, the following parts must be removed as described earlier:
– Cap cover pos. 90 – Slide stop cover pos. 100
Fig. 7.1
T0177135_0 V12
can be knocked out of the cover with a punch. They cannot be reused.
Dismantling With tools Nos. 55 and 56, knock out guide pins pos. 22 Carefully pull out suction cover above the shaft ends, the outer rings of the roller bearings pos. 111 emerging with it.
After dismantling of the retention pin pos. 118 pull the inner ring of the roller bearing out of the rotors as shown in fig 7.1. The numbers on the drawing refer to the tools list.
Hereafter, the outer rings with the rollers
Lock the rotors as shown in fig 8.1.
Dismantle screws pos. 23
Fig. 7.2
T0177135_0 V11
0178-050-EN
63
Mounting When mounting, pay attention to whether the motor is to be connected to the male or female rotor. First, mount locking tool No. 11 on the end of the rotor on which the inner ring of the roller bearing is to be squeezed on as shown in fig 7.3. Fig. 7.3
Press on the inner rings of the roller bearings with the tools as shown in fig 7.2. Remember to grease the shafts with Molykote grease. Tighten to 70 Nm.
Always mount new roller bearings. Mount driving pin pos. 118 on the rotor shaft in which the shaft seal is to be mounted. Mount suction cover pos. 20 with the guide pins pos. 22 and tighten the screws pos. 23. Pay attention to O-ring pos. 21.
Press the outer rings with rollers into position as shown in fig 7.4. Remember to use tool No. 4 as shown on the drawing.
Dismantle locking tool No. 11. Now mount the remaining parts as mentioned at the beginning of this section.
T0177135_0 V21
Fig. 7.4
T0177135_0 V20
64
0178-050-EN
8. Rotors and bearings in compressor discharge end
By dismantling the screws pos. 115 it is a good idea to lock the rotors in order to prevent them from rotating. For this purpose use arrangement fig 8.1 in the rotor shaft end.
Before the rotors can be removed from the compressor, the parts mentioned in section 7 must be disassembled. Next, proceed as follows: 8.1.
Fig. 8.1
Dismantling
8.1.1. Loosen the four locking screws pos. 45 and slacken the two adjusting screws pos. 44 by 3 to 4 turns.
8.1.2. Dismantle cover pos. 40 by removing screws pos. 43. 8.1.3. Pull out the two inner covers pos. 151 and 153 by means of screws No 22.3, which must be mounted in the threaded holes in the middle of the covers. Be careful not to lose the two locking pins pos. 119.
Remember to dismantle the tools again before pressing out the rotors. 8.1.5. It is now possible to push out the rotors - one at a time - by means of the tools shown in fig 8.2. Screw the four long threaded journals No. 20.1 from the tools set into the threaded holes used for securing cover pos. 40.
8.1.4. Now dismantle screws pos. 115, whereby clamps pos. 114 can be removed.
Fig. 8.2
T0177135_0 V14
0178-050-EN
65
By pressing the rotors - one at a time so far with screw No. 21.1 that they become loose and can be removed by hand, the inner rings of the bearings are loosened from the rotors at the same time as they cannot pass the discharge ports pos. 140 and 141. 8.1.6. Loosen discharge ports pos. 140 and 141 as follows: •
Remove screws pos. 142.
•
The first production series of SAB 163 Mk3 compressors are fitted with an adjusting screw pos. 144 and locking screw pos. 145 as shown in fig. 8.2.1. Using key no. 51.2 begin by dismantling locking screw pos. 145, next loosen adjusting screw pos. 144 with the same key. There is only one set of screws pos. 144/145 per discharge port. Note: It is essential to loosen screws pos. 144 before pressing out the dis- charge ports as described in the fol- lowing.
•
66
On the more recent production series of SAB 163 Mk3 and all SAB 128 Mk3 the discharge ports are adjusted by means of adjusting screw pos. 148 and locking screw pos. 147 as shown on the spare parts drawing.
Fig. 8.2.1
T4161T01_0_3
With this kind of construction start by dismantling the blank-off screw pos. 146 together with gasket pos. 149. Next, dismantle pos. 147 and loosen pos. 148 with key no. 51.2. There is only one set of screws pos. 146/147/148 per discharge port. Note: It is essential to loosen screws pos. 148 before pressing out the dis- charge ports as described in the fol- lowing. 8.1.7. Press out the outer rings of the main bearings and the discharge ports pos. 140 and 141 by means of the tools shown in fig 8.3. Normally, the bearings should not be reused. Notice, that O-rings pos. 152 and 154 are not mounted. 8.1.8. Remove balance pistons pos. 130 and 135 from the discharge port by hand.
0178-050-EN
Fig. 8.3
Female
141
130
131
Male
140
135
136
2
153
3
1
20.1
151
•
• • •
•
•
23.2
• 10
•
21.1
• • T0177135_0 V17
8.2.
Mounting
8.2.1. Before positioning the discharge ports pos. 140 and 141 in the rotor housing, check that they are free of burrs and marks, in particular on the surfaces which are going to abut on the rotor housing.
Likewise, check the rotor housing for similar defects on the corresponding contact surfaces. 8.2.2. Push the discharge ports into place in the rotor housing and tighten screws pos. 142 and steel gaskets pos. 143.
Begin by tightening screws pos. 142 with half the torque (see table on torque moments) in order to make sure that the discharge ports are in close contact with the end surface in the rotor housing. Next, loosen the screws and tighten them again slightly in order to facilitate the subsequent adjustment.
0178-050-EN
Next mount capacity slide pos. 200 and tighten adjusting screw pos. 148 (144) loosely in the two discharge ports. While pushing capacity slide pos. 200 back and forth, tighten screws pos. 148 (144) alternately until the capacity slide is just moving smoothly back and forth. Now fit locking screw pos. 147 (145) and tighten with 32 Nm. Mount and tighten blank-off screw pos. 146 as well as gasket pos. 149. Finally, tighten screws pos. 142 with the prescribed torque.
Remember that steel gaskets pos. 143 are not to be reused but must be replaced by new ones in order to obtain tightness. 8.2.3. Before inserting the rotors pos. 110 into the rotor housing, it is recommended that the Vi-slide pos. 190/192 is brought into position in the rotor housing to support the rotors.
67
Fig. 8.4
Thickness
Number of rings Male Dia.70/90 mm
Female Dia.80/100 mm
0.49
1
1
0.52
1
1
0.55
1
1
0.58
1
1
0.61
1
1
0.64 0.67
1 1
1 1
+0 –0.01 8
8
8 T0177141_0/V20
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 8.4. (The number ”8” is given as an example). It is also extremely important that the male and female rotors are positioned in the rotor housing as indicated on the spare parts drawing and cast on the end cover pos. 20. 8.2.4. The bearing systems at the discharge end of the compressor consist of the following parts for each rotor: Female rotor
Male rotor
a balance piston
Pos. 130
Pos. 135
a roller bearing
131
136
a special ball bearing
132
137
a set of adjustment ring
133
138
The adjustment sets consist of the following rings:
68
In case of replacement, all bearings must be replaced. 8.2.5. Start mounting of the bearings by greasing the shaft ends with Molykote grease. Then position balance pistons pos. 130 and 135 by hand. The balance pistons must turn in the direction indicated on the spare parts drawing. 8.2.6. With the tool arrangement as shown in fig 8.5, press the inner rings of the roller bearings into position. Mount the roller bearings with the bearing manufacturer ’s marking facing outwards. On the female rotor, turn tool No. 7 as shown in fig 8.5. On the male rotor, the conical end of the tool must be facing the bearing. Before mounting the bearings it is a good idea to lock the rotors at the opposite end, as shown in fig 8.1. Tighten nut No. 23.3 with torque wrench No. 40.2 to 70 Nm.
0178-050-EN
Fig. 8.5 Female
Male
T0177135_0 V19
Fig. 8.6
•
•
•
•
•
•
•
• •
8.2.7. Press the outer rings pos. 131/136 of the roller bearing in position with tools as shown in fig 8.6. The factory marking must face outwards. 8.2.8. Press the inmost inner ring of the ball bearing pos. 132/137 into position by
0178-050-EN
means of the same tool arrangement as shown in fig 8.5 incl. the description. Tighten nut No. 23.3 with 70 Nm. The factory marking must face inwards. Notice that the O-ring pos. 152/154 is not mounted when thrust covers pos. 151/153 are used as mounting tools.
69
Fig. 8.7
8.2.9. After removing above tool arrangement, mount the following, as shown in fig 8.7. a: The outer rings of the ball bearings pos. 132/137, which are inserted by hand, and placed in the same position in relation to the mounted inner ring as in the original packing. b: Tools No. 8.1 on the male rotor and 8.2 on the female rotor and tighten with screws pos. 115:
d: Secure cover pos. 40 with screws pos. 43. e: Mount adjusting screws pos. 44 but do not tighten. f: Dismantle locking tools. 8.3.
Adjustment of the axial clearance of the rotors
225 Nm for SAB 163 Mk2 and 3.
After mounting of the bearings as described in the previous section, the axial clearance of the rotors can be adjusted with tool arrangement fig 8.8, which is mounted on the rotor shaft ends.
c: Mount thrust covers pos. 151 and 153.
Start by adjusting the female rotor.
100 Nm for SAB 128 Mk2 and 3.
Fig. 8.8
Female rotor
Male rotor T0177135_0 V15
70
0178-050-EN
Adjustment 8.3.1 Screw screw No. 22.6 in by hand until tool No. 30 has the same distance to both shaft ends as shown in fig 8.8. Tighten screw No. 22.2 with 14 Nm, whereby the female rotor is pressed against the discharge port pos. 141. The adjusting screw pos. 44 must be loose. Set dial meter on ”0”. 8.3.2 Now screw in adjusting screw pos. 44 at the female rotor and tighten with 32 Nm. Read the dial meter and note the difference that indicates how much the rotor can be moved axially. a: This movement can be 0.630 mm, for instance. b: As the correct movement must be between 0.05 and 0.10 mm, the average figure is 0.075 mm, which is deducted as from the measured value, which in example a: is: 0.630-0.075 = 0.555 mm 8.3.3 From adjusting set pos. 133 select the adjusting ring, whose thickness comes closest to the calculated value. In this example it is 0.55 mm. The thickness is stamped on the rings. 8.3.4 By inserting the selected adjusting ring as shown in fig 8.7 (pos. 133) and repeating the adjustment mentioned in section 8.3.2 it is made sure that the movement remains within the mentioned tolerances (0.05 and 0.10 mm) mentioned in pt. 8.3.2, and the Exact measure is noted down for later application (see section 8.3.10). The exact measure for a female rotor can, for instance, be 0.061 mm after the adjustments in sections 8.3.3 and 8.3.4.
0178-050-EN
In order to be able to insert the adjusting rings, the following must be done:
– Loosen adjusting screw pos. 44 – Dismantle cover pos. 40 – Take out thrust cover pos. 153 – Take out by hand the outer ring of the ball bearing together with the balls. The remaining parts of the tool arrangement are not dismantled. 8.3.5 After the adjustment, loosen adjusting screw pos. 44 and dismantle cover pos. 40, thrust cover pos. 153 and tool No. 8.2 (see fig 8.7). 8.3.6 By means of the tools shown in fig 8.5, mount the outmost inner ring of the ball bearing and tighten thrust plate pos. 114 with screw pos. 115. Tighten the screw to : •
70 Nm for SAB 128 Mk2 and 3
•
225 Nm for SAB 163 Mk2 and 3
8.3.7 Insert the locking pin pos. 119 in the groove in the outer ring of the ball bearing, turning it so that the groove faces downwards. 8.3.8 Position O-ring pos. 154 on the thrust cover pos. 153 and fit the screw No. 22.3 on the thrust cover and lock with nut No. 23.1. Place thrust cover in position and turn the screw No. 22.3 until the groove in the thrust cover catches locking pin pos. 119. This can be registered by the cover being carefully pressed inwards during the turning, and hereby it can be pressed in a little further when the locking pin catches the groove in the thrust cover.
71
8.3.9 Mount cover pos. 40 and secure with screws pos. 43. Remember that the adjusting screws pos. 44 must be loose. Adjust the male rotor in the same way as described in sections 8.3.1 to 8.3.9 by mounting the adjusting tools as shown in fig. 8.9. Fig. 8.9
leaves a final adjustment measure of 0.05 mm.
Exact measures between mm
0,050-0,055 0,056-0,060 0,061-0,065 0,066-0,070 0,071-0,074 0,075-0,079 0,080-0,084 0,085-0,089 0,090-0,094 0,095-0,100
1
Final adjustment measures mm
2
0,040 0,045 0,050 0,055 0,060 0,065 0,070 0,075 0,080 0,085
Final adjustment After both rotors have been adjusted and the exact measures have been noted down, we are now ready for the final adjustment of the rotors. 8.3.10 Compare the exact measure for each of the rotors with the measures in column 1 of the following table. Column 2 thus indicates the final adjustment measure. For instance, the exact measure of 0,062 mm for the female rotor will be between 0.061 and 0,065, which
72
With the adjusting tools mounted as shown in fig 8.9 and the dial meter set at ”0”, tighten adjusting screw pos. 44 while reading the dial meter. The dial meter indicator must move the final adjustment measure. 8.3.11 After this final adjustment, lock adjusting screws pos. 44 with the pointed screws pos. 45, and the adjustment of the male rotor is now completed. 8.3.12 Then mount the adjusting tools as shown in fig 8.8 and described in section 8.3.1. Repeat the adjustment described in sections 8.3.10 and 8.3.11 on the female rotor. 8.3.13 Check that the rotors are easy to turn by hand.
0178-050-EN
9. Capacity indicator As it appears from the spare parts drawing, the following two types of standard systems for capacity indication can be mounted.
Fig. 9.1 Magnetic coupling pos. 216
A:
Visual capacity indicator
B:
Capacity indicator with position transmitter.
Look at page 1 to see which system your compressor is using.
1
50
2
3
70
71 216
•
221
••
223
• • •
•
350
• • •
•
74
•
•
75
• •
210
218
217
61
Magnetic coupling for capacity indication type A and B The rotating movement from spindle, pos. 210, see fig. 9.1, is transferred to the transmitter pos. 350 through a magnetic coupling, pos. 216, which is completely tight to both oil and refrigerant. Dismantling After cover, pos. 60, has been dismantled from slide, pos. 50, dismantle the following parts: By removing screws, pos. 73, the following parts are taken apart:
0178-050-EN
60
219
224
••
72
73
– Flange pos. 72 – Sight glass, pos. 75, available in two different designs, either for visual indication or for mounting of transmitter.
– O-ring pos. 74 – Supporting ring pos. 224 Remove screws, pos. 71, and indicator housing, pos. 70, can be taken down. Dismantle indicator dial, pos. 221, by loosening screw, pos. 223. By removing screws, pos. 219, the entire magnetic coupling, pos. 216, can be pressed out of the flange, pos. 60, by hand.
73
By dismantling circlip no. 1 the inner magnet retainer no. 2 and spindle, pos. 210, can be pulled out against the magnetic force. Dismantle spindle, pos. 210, by loosening screw, pos. 218.
Assembling Assembling of the complete unit is carried out in reverse order to the dismantling.
40°
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.
On mounting of the magnetic coupling in cover, pos. 60, O-ring, pos. 217, must be fitted.
A transmitter, if any, pos. 350, must be fitted on the sight glass, pos. 75, so that the electric socket faces downwards when the ”0” mark of the sight glass stands right above the slot in the indicator dial as described above.
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.
The retaining pin no. 3 of the transmitter must engage in the slot in indicator washer, pos. 221, on mounting sight glass, pos. 75.
Pay attention to the following, however:
Transmitter Usage: The position transmitter is used for remote indication of compressor capacity. By integrating electronic limit switches into the control, max. and min. compressor capacity can be signalled, for instance.
74
Assembling 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 GT8.1, fitted in the slot of the dial.
0178-050-EN
Slide position
4.5 4. 3.5
Volume ratio
2
3. 100% 2.5
SPAN + ZERO
1
3
GT8.1 2. 0%
T0177063_0
Connect the position transmitter to the control system according to the following diagram: Terminal
Used for
1 2
Signal 0 - 20 mA Voltage supply
3
–20% 24 V DC +/ Frame OV Not used
Adjustment: 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 GT8.1 catches the slot on the indicator dial!
0178-050-EN
Turn the sight glass until the 0% mark aligns with the indicator dial with the capacity slide in its minimum position. 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. 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 V i slide.
75
Limiting the minimum capacity of the screw compressor SAB 128H Mk3, SAB 163H Mk3 228
•
210,2
229
75,2
• •
•
The above mentioned screw compressors, which are used at evaporating temperatures below –20°C for refrigerant R717 or R22, are fitted with a spacer ring pos. 228 which changes the minimum capacity of the compressor from normally approx. 10% to: SAB 128 SAB 163
approx. 30%
The limitation eliminates undesirable noise in the compressor in the start and stop periods.
76
Each individual part in the system is shown on the above drawing. Reference is made to the List of Parts at the end of this instruction manual. Pos. Pos. Pos. Pos
228 229 210.2 75.2
Spacer ring O-ring Spindle Glass for indicator
Dismantling and assembly The system is dismantled and asembled as described in section 9 Capacity indicator , and the spacer ring pos. 228 can be removed by hand by catching the hole in the middle. When the spacer ring is mounted it can be positioned arbitrarily.
0178-050-EN
10. Compressor Protection System In order to protect the compressor against inadmissibly high pressures, it has a built –on protection valve type POV, pos. 704 which is
Fig. 10.1
Pilot valve, BSV8, pos. 700
controlled by the pilot valve type BSV8, pos. 700. The protection system is shown in fig. 10.1 and described in the following:
Main valve, POV, pos. 704
Evaporator Oil separator, condenser
Condensing pressure Evaporating pressure Compressor
Functional description
When the pressure P1 reaches the set pres-
The pilot valve, shown in fig. 10.1, is actuated by the high pressure P1. The valve is supplied with a stainless metal bellow ➀. The reference pressure in the bellow is the atmospheric pressure P0. The effective area of the bellow is exactly equivalent to the area of the valve seating, which means that the back pressure P2” does not affect the opening pressure of the valve.
sure of the pilot valve, it will start opening.
The main valve is a normal closed valve. The high pressure P1 is affecting the lower side of the valve cone ➁ propagating up through the piston rod ➂ to the upper chamber ➃ of the valve, producing a pressure on the piston ➄. The area of the piston is larger than the area of the valve seating. Together with the power of the spring this will keep the valve closed.
0178-050-EN
The pressure P2” of the pilot line and of the lower chamber ➅ of the main valve will increase. The pressure of the lower chamber is limited by flow through the nozzle ➆. When the flow through the pilot valve exceeds the capacity of the nozzle, the pressure of the chamber
➅ will
increase, providing the open-
ing of the main valve. When the pressure P1 is reduced, the pilot valve will close, and the pressure P2” is equalized through the nozzle ➆.
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.
77
10.2 Dismantling the Protection System By dismantling the screws pos. 702 and 721 as shown on fig. 10.2, the complete safety system can be lifted off the compressor. Take care not to damage the O-rings pos. 703 and 722.
Normally, any further dismantling of the system is not necessary, and we recommend not to disassemble the various component parts.
5 702 703
704
3 701
Nipple, see fig. 10.3
700
2 730 732 722
727 726 721 725 4
10.3 Controlling the Opening Pressure The control of the functioning and the opening pressure of the protection system should be carried out in accordance with the local regulations and can in practice be done as follows: 10.3.1 Isolate the compressor unit at the stop valves and evacuate the refrigerant. Make sure that the unit cannot be started unintentionally and that there is no excess pressure in the system. 10.3.2 Dismantle the complete protection system by means of the screws pos. 702 and pos. 721. Take care not to damage the O-rings pos. 703 and 722. 10.3.3 Dismantle the pilot valve pos. 700 by first loosening the nuts Nos. 1 and 2
78
1
and thereafter dismantling the nuts pos. 727 and pos. 730.
726
727 G 3/8”
10.4 Testing the Pilot Valve pos. 700 10.4.1 Normally, the pilot valve is tested in a test bench, however, it can instead be connected to a pressure source by means of a high-pressure hose. The connection nut shown as pos. 727 in
0178-050-EN
fig. 10.3 has a 3/8” thread. In connection with the pressure source, a pressure gauge should be used. 10.4.2 By slowly increasing the pressure, control the following: a: that the pilot valve stays tight until the opening pressure is reached. b: that the valve opens at the pressure indicated on the name plate. By opening now entirely for the air supply, check that the pilot valve is able to open to full lifting height.
10.5 Testing the complete Protection System 10.5.1 For testing of the complete system, mount the pilot valve as shown on fig. 10.2. keeping, however, still in place the pressure hose as described in section 10.4.1.
0178-050-EN
10.5.2 When opening now for the pressure source, the pilot valve will open at the pressure controlled in section 10.4.2. This will activate the main valve pos. 704, which can be checked at a glance through the flange No. 5 – fig. 10.2. 10.6 Remounting the Protection System 10.6.1 When remounting the pilot valve, it will be a good idea to use new pipe sections pos. 701 and No. 4 and we suggest also to use new fittings Nos. 1, 2, 3, and pos. 725. 10.6.2 When remounting the complete system on the compressor, place the O – rings pos. 703 and 722 and tighten the screws pos. 702 and 721 as prescribed. 10.6.3 After filling with refrigerant, control that the system is not leaking to the atmosphere.
79
Notes:
80
0178-050-EN
This section comprises the following three systems: 1. Regulation of compressor capacity. 2. Automatic regulation of the Vi slide. For SAB 163 Mk3 only. 3. Manual regulation of the Vi slide. For SAB 128 and 163 Mk3. Please see on page 1 as to which system your compressor uses 5 0 . 8 9
N E 7 5 0 8 7 1 0
The system is connected to the oil pressure at branch B and the oil flows back from the capacity cylinder through branch A. Branch C is connected to the capacity cylinder. Two throttle valves pos. 72 are built into the system, whereby the oil flow and, consequently, also the motion speed of the capacity piston can be regulated. The purpose of the throttle valves is to provide a regular movement of the capacity piston, adapted to the operating conditions.
1. Regulation of compressor capacity
When the spindles are turned clockwise the oil flow is reduced.
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).
Solenoid valves:
0178-085-EN
Pos. 70 is a normally closed valve. Pos. 71 is normally open meaning that with a non-energized coil it is open for passage.
81
Fig. 1
Function 1. At constant capacity both solenoid valves are closed, pos. 71 being energized whereas pos. 70 is not. 2. When regulating to higher capacity, power to coil pos. 70 is switched on. Thus both coils are energized. Pos. 70 now opens and puts oil pressure on the capacity cylinder. Pos. 71 remains closed. 3. When regulating to lower capacities, the current is shut off to both coils. Thereby, pos. 70 closes and cuts the oil pressure to the capacity cylinder. Pos. 71 opens and allows the oil to flow away from the capac-
82
ity cylinder by the power from the spring pos. 191. 4. When the compressor stops, the current it cut to both solenoid valves. The capacity piston is then moved to 0% position – as described under item 3, and the compressor is unloaded at the next start-up.
2. Automatic regulation of the Vi-slide For SAB 163 Mk3 only For regulation of the Vi slide position, the same type of regulating system is used as for the regulation of the compressor capacity.
0178-085-EN
This system is described in the preceding article. In the following function description, the solenoid valve in the Vi regulation system is designated as shown in the dotted frames in fig. 1. Pos. 73 is a normally closed solenoid valve Pos. 74 is a normally open solenoid valve The Vi-slide is controlled by either UNISAB II and works as follows:
2.1 At 100% compressor capacity Pos. 73 is open and maintains oil pressure on the piston of the Vi slide so that the Vi slide pos. 190 is permanently pressed against the capacity slide pos. 200. (See spare parts drawing). Pos. 74 is closed. The Vi regulation is managed by the capacity regulation system which by small ad justments of pos. 200 adapts the Vi ratio to the suction and discharge pressures on the compressor. In this adjustment pos. 70 and 71 will receive signals for opening and closing without this involving any change of the compressor capacity.
2.2 At reduced compressor capacity
and the Vi slide position are determined by the pressure ratio over the compressor. With the UNISAB II Control regulating system, the Vi slide is moved to minimum position, depending on the pressure ratio over the compressor. This is an integral function of the UNISAB II Control, ensuring that operation is as economical as possible. These settings are non-adjustable..
At the same time the position of the capacity slide will be adjusted to the capacity requirement at the actual Vi-ratio. When the compressor capacity has increased to 100%, and pos. 200 reaches pos. 190, the regulating systems return to the function described in paragraph 2.1.
2.3 When the compressor is stopped When the compressor is stopped, the current to all four solenoid valves is cut off. This will force pos. 74 and 71 open and allow the two regulating slides to move to minimum position, as they are forced away from each other by the spring power pos. 191.
When the compressor capacity is reduced from 100%, the following happens: With the UNISAB II regulating system, pos. 74 remains closed and pos. 73 closes, which causes the capacity slide to move away from the Vi slide leaving a gap between the two slides.
The solenoid valves are regulated by UNISAB II so that both capacity requirement
0178-085-EN
3. Manual regulation of the Vi slide For SAB 128/163 Mk3 Instead of automatic regulation of the Vi slide as described in section 2, regulation can be done manually. However, the two systems are not simultaneously contained in the compressor.
83
190
180
T0177135_0 V3
Note: Adjustment must only be made when the compressor is either stopped or working at reduced capacity. On adjusting the V i -slide to its max. or min. position, do not secure it against the end limits as this may impede the move- ment of the capacity slide. Consequently, on adjusting the V i -slide to max. or min. position, loosen the spindle by turning it 1/2 to one turn in the opposite direction from its extreme position. For correct adjustment of the Vi slide position, use the following diagrams as explained below:
On the above drawing, which is a section taken from the blue spare parts drawing, the construction of the manual system, which works as follows, is shown.
Function The Vi slide pos. 190 functions as a movable stop for the capacity slide and can thus regulate the discharge port’s (pos.140/141) size and hence the compressor ’s built-in volume ratio Vi. The Vi slide is moved by giving the spindle pos. 180 a predetermined number of turns. If the spindle is turned clockwise a lower Vi is obtained Turning it counter-clockwise gives a higher Vi.
84
For the actual refrigerant and evaporation temperature TE, follow the horizontal line to the intersection with the curve for the actual condensing temperature TC. From this point of intersection two readings can be made by following the line either vertically up or down: vertically up, reading the Vi-ratio which refers to the scale on the compressor capacity indicator. Notice, whether the compressor is connected to an econo-mizer or not. vertically down, reading the number of re-volutions the spindle pos. 180 must be turned counter-clockwise - from its extreme position - in order to achieve optimum efficiency at the given temperatures TE and TC. Notice, whether or not the compressor is connected to an economizer.
0178-085-EN
Adjusting the position of the Vi-slide SAB 128 Mk3 R22 R134a R404A/R507 R407C
Volume ratio Vi
2
2.5
3
3.5
4
4.5
Vi Economizer
2
3 3.5
4
4.5
Vi One stage
TE 20
10 e r u 0 t a r e p –10 m e t g –20 n i t a r o –30 p a v –40 E
e r u t a r e p m e TC t g ° C i n s n e 55 d 50 n o 40 C
30 20 10
–50 –60
–25 –20
°C
–10
0
One stage 0
20
30
33 N turns by the adjusting screw
Adjustment 0
T250809
Adjusting the position of the Vi-slide SAB 163 Mk3 R22 R134a R404A/R507 R407C
Economizer
2
10
2.5
20
3
3.5
30
33 N turns
4
4.5 Vi
Volume ratio VIi
Economizer
2
3 3.5
4.5
4
Vi One stage
TE 20
10
e r u t 0 a r e p m –10 e t g n –20 i t a r o –30 p a v E –40
30 20 10
–50 –60
–25 –20
°C
0 20
30
–10
0
One stage 40 42 N turns by the adjusting screw Economizer
Adjustment 0 10 20 250811
0178-085-EN
e r u t a r e p m e TC t g n i ° C s n e 55 d 50 n o 40 C
30
40
42
N turns
85
Adjusting the position of the Vi-slide R717 - SAB 128 Mk3
2 2.5 3 3.5 Volume ratio Vi 2 2.5 3 3.5 4
4
Vi
4.5
Economizer 4.5 Vi
One stage TE 20
10 e r u 0 t a r e p –10 m e t g –20 n i t a r o –30 p a v E –40
e r u t a r TC e p m ° e C t g n 55 i 50 s n e 40 d 30 n o 20 C
10 0
–50 –60
–25
°C
–20
–10
One stage 0 10
20
30
N turns of the adjusting screw Economizer
Adjustment 0 10
T250810
Adjusting the position of the Vi-slide R717 - SAB 163 Mk3
20
30
2 2.5 3 3.5 Volume ratio Vi 2 2.5 3 3.5 4
33 N turns
4
4.5 Vi Economizer
4.5 Vi
One stage TE 20
10 e r u 0 t a r e p –10 m e t g –20 n i t a r –30 o p a v –40 E
e r u t a TC r e p ° C m e t 55 g n 50 i s 40 n e d 30 n o 20 C
10 0
–50 –60
–25
°C
–20
–10
One stage 0 10 20
30
40 42
N turns of the adjusting screw
Adjustment 250812
86
Economizer 0 10 20
30
40
42 N turns
0178-085-EN
Metric thread (ISO 8.8) M Kpm
2 1 . 4 9
4
5
6
8
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) M
N E 5 6 4 1 7 1 0
Kpm
4
5
6
8
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
87
Bolt on discharge valve
AMR
HPO/CMO
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
HPC/ SMC/ TSMC NORMEX
A
ft.lbf.
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
M8
2.2
16
22
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
163 128
Series 52
163
A
202
X E H148 M R O H168 N 2 5 s e i r e S
depending 2 5
VMY
on the motor size
88
Torque (A) Kpm.
128 SAB
Thread
s e i r e S
0172-133-EN
In the component descriptions in this section the position numbers are the same as on the piping diagram. Wherever a component com-
prises wearing parts or gaskets the spare part numbers can be found in the unit spare parts lists.
Oil separator Fig. 1 Oil separator SAB 128 Mk3
A
5 0 . 8 9
B
N E 8 5 0 8 7 1 0
Oil separator SAB 163 Mk3
A
B
The oil used in the compressor for lubrication, sealing and cooling of compressor block is mixed with the refrigerant gas and together they are transferred to the oil separator.
In the oil separator oil and gas are separated and the now almost oil-free gas leaves the
0178-085-EN
compressor unit through discharge branch pos. A. Two filter elements separate the oil from the gas, of which the major part is separated in the demisters and drained to the bottom of the oil separators on SAB 128 and down into the separate oil vessel on SAB 163 as shown on the schematic outlines in fig. 2.
89
Fig. 2 SAB 128 Mk3
SAB 163 Mk3 Demister
A
A
52
52
53
53
Reservoir
The remaining oil in the gas is separated in fine separator element pos. 55 and led back to the compressor through throttle valve pos. 52 and sight glass pos. 53. See fig. 2 and the piping diagram at the end of this manual. The purpose of the throttle valve pos. 52, described in a separate section (see table of contents), is to regulate the oil flow back to the compressor. The throttle valve should only be opened as
90
much as is required in order for the gas bubbles to be visible in sight glass pos. 53, and so that the pipe after the valve feels slightly warm.
Fine separator element Normally, it is superfluous to remove or replace the fine separator element, but at an increasing oil consumption it is possible to inspect the filter or extract it through flange pos. B.
0178-085-EN
Oil level glass, pos. 31 It must always be possible to see an oil level in one of the two oil level glasses. In case of recharging with oil the oil level will rise approx. 10 mm if you keep to the indicated amounts of oil:
Discharge stop valve and non-return valve Discharge stop valve: Standard units are delivered with a stop valve welded on the discharge branch of the oil separator. The discharge branch of the stop valve is made for welding connection and has the following dimensions:
Units with the following compr.types
Stop valve dimension mm
10 mm SAB 128
DN 65
SAB 163
DN 100
Non-return valve:
SAB 128 Mk3 : 6 litres of oil SAB 163 Mk3 : 4 litres of oil In the table on oil charging you may see the oil quantity for the compressor unit but it does not include the amount of oil which is circulating in the refrigerating plant. In R22 systems with large quantities of refrigerant special allowance must be made for the amount of oil dissolved in the refrigerant. Consequently, attention must also – during the operating period after the initial start-up – be paid to the fact that the oil level may sink rather quickly until the oil contents in the refrigeration system has stabilized.
Stop valve, pos. 34 Under the oil reservoir a stop valve pos. 34, has been fitted, used for draining or charging of oil.
0178-085-EN
Next to the discharge stop valve a non-return valve must be fitted in the discharge pipe which closes tightly whenever the pressure in the oil separator is reduced to suction pressure in the unit standstill period. The non-return valve must be positioned on the uppermost part of the discharge pipe as shown in fig. 3. This prevents any condensation that may have been created in the discharge pipe during the standstill of the unit from running into the oil separator during restart of the unit. The size of the non-return valve must be calculated on the basis of the current operating conditions of the unit. Fig. 3
Non-return valve
Common discharge valve Stop valve on unit
91
In order to keep the lubricating oil in the compressor warm during a period of standstill, the oil reservoir has one or two heating rods built in. Before start-up, the heating rod (s) must have been activated for 6-8 hours in order to ensure that there is only a minimum of refrigerant in the oil. When containing much refrigerant, the oil will lose its lubricating property and the following operational interruptions may occur: In reciprocating compressors there is a serious danger of vigorous oil foaming when the compressor starts as a result of a falling suction pressure. For screw compressors starting with much refrigerant dissolved in the oil, there is a risk of the compressor being stopped by the Flow Switch as the oil will be foaming owing to the fall in pressure through oil pipe and oil filter.
As illustrated on the drawing the heating rod consists of an electric heating element, incorporated in a dia. 30 mm pipe. The entire heating cartridge is screwed on tight at the G 1 1 / 4” thread. Note: The heating rod must not be energized if the oil level in the reservoir is below the minimum mark in the sight glass, and it should generally be switched off during compressor operation. Remember to turn off the heating rod whenever the crank- case 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
G 1 1/4”
Prod. nr. Watt Volt Manu. date 0 3 Ø
0 3 0 5
L1 80
L2
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.
92
0178-085-EN
5 0 . 8 9
N E 7 1 0 0 7 1 0
4
2
3
5
6
1 T0177037_0
0 1 . 5 9
N E 1 6 5 1 7 1 0
No
Used for
1 2 3 4 5 6
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 oil’s passage through the cooler, thus causing the oil to flow across the tubes,
0178-268
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:
93
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. 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.
94
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 manufacturer ’s instructions should be followed precisely.
0178-268
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: If necessary, use a temperature-regulated three-way valve to regulate the oil flow through the cooler.
On SAB 202 the oil temperatur regulation is based on a two-way valve incl. pilot valve. See piping diagram.
0178-268
Or use a temperature-regulated three-way valve on the water side in connection with a water pump to maintain the prescribed water flow through the oil cooler.
Closed system: OWSG If this oil cooler is connected in a closed system, such as a heat recovery system, the water flow can still be regulated. OWRG Only use the mentioned oil coolers for the prescribed water flow in order to minimize the risk of corrosion as a result of the combination of high temperature and Cl content in the cooling water.
Therefore, we recommend the use of the same regulating system as prescribed under Open system.
95
5
2
3
1
4
No. 1 2 3 4
Used for Hot oil inlet Cooled oil outlet Water inlet Water outlet
0 1 . 5 9
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.
96
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 water’s 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.
0178-250-EN
N E – 2 6 5 1 7 1 0
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: Adjust the oil flow through the cooler by means of the temperature regulated threeway valve.
0178-250-EN
Or use a temperature-regulated three-way valve on the water side in connection with a water pump to maintain the prescribed water flow through the oil cooler.
Closed system Only use the B-type oil coolers for the prescribed water flow in order to minimize the risk of corrosion as a result of the combination of high temperature and Cl content in the cooling water.
Therefore, we recommend the use of the same regulation system as prescribed under Open system.
97
4 5 1 pass
2
1 3
6
4 2 pass
5
2 1 3
6
T0177101_0/1
1 2 3
Oil inlet Oil outlet Refrigerant inlet
Construction The oil cooler consists of a cylindrical shell with welded-on tube plates in which is welded a number of tubes. Each tube plate has an end plate welded in. The oil cooler is thus an assembled, all-welded construction. The end plates are provided with welding branches for oil connection and drainage. The shell has welding branches for refrigerant connection, and for draining oil when operating with the R717.
2 0 . 7 9
4 Refrigerant outlet 5 Oil draining (oil side) 6 Oil draining (refrigerant side)
For cooling of the oil, liquid refrigerant from the system receiver or a special priority tank is fed to the oil cooler. The refrigerant partly evaporates on the outside of the tubes, and the mixture of liquid and gas is piped to the condenser. The receiver or priority tank is normally positioned at a suitable height above the oil cooler, thus supplying adequate refrigerant by natural circulation. Alternatively, a pump can be used to effect refrigerant supply.
Function
Cleaning
Oil flows through the tubes, which are designed for extremely efficient heat transfer between oil and tube walls.
Since both the oil side and the refrigerant side of the oil cooler form part of closed systems, no cleaning will be required.
98
0178-050-EN
N E 3 6 5 1 7 1 0
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 5 0 . 8 9
Three-way valve
Oil cooler
N E 7 7 2 8 7 1 0
A
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.
99
During operation the thermo element will ad just 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
C •
2 1
A Thermo element in cold position
The thermo element is factory set to maintain a mixed oil temperature of 48°C, allowing for a few degrees’ deviation and it cannot be readjusted. Service: As a rule, it is not necessary to dismantle a well-functioning three-way valve as it does not contain any gaskets or wearing parts that must be replaced at fixed intervals. Dismantling: During dismantling, if any, apply the following procedure: 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. 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
100
A
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. The thermo element can now be extracted from the valve housing by hand.
Assembling: Assembling the valve is done in the reverse order and attention should be paid to the following: The O-ring, fitted in the cover, should be replaced by a new one. See section Spare Parts Survey in this manual. No sealing ring should be fitted between the inner guideway of the cover and the valve cone. 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
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101
Function As the refrigerant vapours are compressed from evaporator pressure to intermediate pressure, a considerable amount of heat is generated, which must be dissipated in order to keep the gas and oil temperature at a suitable level. This is done by injecting liquid refrigerant from the receiver into the compressor at a suitable stage in the compression process, controlled by a modulating in jection valve type TEAT. The liquid refrigerant will evaporate in the hot mixture of oil and refrigerant gas, thereby cooling the mixture.
jection port to use as a function of evaporating and condensing temperature TE/TC. Fig. 2
TC
R717 40 97
35 30 25 20
95 96
2 1 . 6 9
15 TE
It is desirable to inject the liquid as late as possible for reasons of compressor power consumption. There are 2 different HLI connection ports, numbered 96 and 95 on the sketch fig. 1. Fig. 1
–50 –40 –30 –20 –10
0 T0177044_0
If operating conditions change, for example owing to the season, and the operating point alternates between the range for use of connection port 95 and that for port 96, the latter should generally be used. The thermocouple, which measures the discharge gas temperature above the oil bath in the oil separator, is type A for R717 with a working range of: A: 35-65°C
97
96
95
T0177044_0
The size of the injection valve and the temperature range of the thermocouple are chosen according to the refrigerant, evaporating temperature, condensing temperature, and cooling requirement specified in the order. The following diagrams for R717, show which in-
102
An economizer can be connected to the compressor. An economizer is a heat exchanger which cools the liquid refrigerant from the receiver to the plant. A minor portion of the liquid evaporates and is sucked into compressor port no. 97; see drawing fig. 1. The operating limit diagrams show the range in which it is permissible to use the economizer simultaneously with HLI cooling.
0178-050-EN
N E 5 6 5 1 7 1 0
The liquid supply to the HLI system must be tapped from a point in the installation always certain to contain liquid refrigerant. This will ensure that the compressor is kept cooled at all times.
Adjustment The injection valve is factory-set to opening temperature at the mid-temperature range of the thermocouple. Before start-up of the compressor, the opening temperature of the injection valve must be set at:
0178-050-EN
20K lower than the desired discharge gas temperature See Table of adjustment values and Danfoss instructions for setting the injection valve. Fine-adjust the valve once the installation is in stable operation. A thin layer of foam normally develops on the surface of the oil in the oil separator when operating with HLI. Vigorous foaming may be an indication of excessive liquid supply, in which case check that the tempe- rature of the discharge gas is not too low in relation to the condensing temperature! See table of settings.
103
It is a needle valve with an adjustment that can be varied infinitely to a steady oil flow through the valve.
Fig. 1
C 5 . 8 7
1/4”G
With the handle adjust the flow of the oil, and by means of the scale on the handle a fine adjustment can be obtained.
A
B
1/4”G
48
All dimensions are in mm
The throttle valve is used for adjusting the amount of oil flowing from the fine filter element of the oil separator and back to the compressor. See piping diagram in this manual.
104
Mount it in the pipe line so that the flow direction is the same as that of the arrow, as shown by fig. 1.
By turning the handle clockwise, the velocity of the capacity slide is reduced. By turning the handle anti-clockwise, velocity is increased. A locking screw Pos. C is fitted in the handle which, when tightened, secures the handle and consequently the adjustment. Notice: The throttle valve cannot be used as a shut-off valve.
0178-050-EN
0 1 . 5 9
N E 2 6 0 8 7 1 0
The pump principle 1
2
3
0 1 . 5 9
N E 0 7 5 1 7 1 0
Description The oil pump is an internally toothed gear pump with built-in pressure relief valve and slide ring shaft sealing. The pump is fitted with suction inlet facing downwards and 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.
Service The oil pump is designed as one unit and should not be separated. However, the shaft seal is regarded as a wearing part which can be replaced in case of leaks. If the shaft seal is going to be replaced, you can do one of two things:
Start-up
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 neces-
0178-050-EN
105
sary 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.
damage the lapped surfaces on the shaft seal parts. Screw shaft seal housing completely into the pump housing. Make sure that the spring provides the necessary tightness. Remount key and half-section of coupling.
Replacement of shaft seal The easiest way to replace the shaft seal is to follow below procedure: Remove the half section of coupling and the key fitted in the oil pump shaft. Unscrew shaft seal unit pos. 8, 9 and 10 from pump housing pos. 5 by means of a pin spanner, positioned between the two axial holes. After lubricating the shaft in refrigerant machine oil, mount the carbon ring unit on shaft and in spring pos. 7. Take care not to
106
Mount oil pump on the intermediate piece of the motor, making sure that the halfsections 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.
0178-050-EN
Spare Parts Drawings
1. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13.
Cover Shaft pin Gear wheel Pump housing Rotor Rotating shaft seal unit O-ring Fixed shaft seal unit Bearing Bearing O-ring Relief cylinder
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107
whenever there is no oil flow through the housing and the power supply through the reed switch will be interrupted. If oil passes the float ball will lift ifself to its highest position, hereby establishing a connection.
Fig. 1
For compressor units with instrument board: Should the ball sink, hereby interrupting the power supply, a time relay will stop the compressor after 10 sec.
1 / 0 – 1 0 T 1 6 1 4 T
For compressor units with UNISAB II the signal is transmitted to UNISAB II, stopping the compressor once the encoded time has expired and after the ball has cut off the flow connection. For details, see the UNISAB II instruction manual.
In order to ensure a continuous lubrication of the compressor, the compressor block has a built-in flow security which works as follows:
Note It is essential that the float valve is posi- tioned as shown on the drawing as it will otherwise work in the opposite direction.
The float ball contains a permanent magnet and envelopes a pipe in which a reed switch is built in. It will be in its lowest position
The float ball has the same text engraved as the one shown on the drawing, and the ”NO” must be facing upwards.
108
0178-050-EN
0 1 . 5 9
N E 9 5 0 8 7 1 0
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 Pos. 28
0 1 . 5 9
Safety valve on oil separator with exhaust to the atmosphere. The exhaust line must be routed from the engine room out into the open air. The SAB 110 compressor has a built-in by-pass safety valve which, in case of too high differential pressure across compressor, will lead gas from the oil separator to the compressor suction chamber. The opening pressure the of safety valve is indicated on its name plate.
N E 6 6 5 1 7 1 0
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 TÜV (Germany ), the KP5 is replaced by a pressure cut-out KP 7ABS which has been approved by TÜV. 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
109
due to impurities, the pressure cut-out will stop the compressor and a pilot lamp will light. Futher, the differential pressure cutout contains a visual indication of presure drop represented by a green field for permissible pressure drop and a red field indicating excenssive a pressure drop across oil filter in which case the pressure cut-out will stop the compressor. Pos. TAZ12 Thermostat KP79 with sensor in oil flow control. Designed to safeguard against excessive oil temperature. Pos. TAZ13 Thermostat KP79 or KP81 with sensor in oil separator. Designed to safeguard against excessive discharge gas temperature. Pos. TC14 Thermostat KP77 with sensor in oil separator. Designed to safeguard against too low discharge
110
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
Operational reliability The prime causes of operating malfunctions to the plant are: 1. Incorrect control of liquid supply to the evaporator. 2. Moisture in the plant. 3. Air in the plant. 4. Anti-freezing liquid is missing. 5 0 . 4 9
N E 4 6 4 1 7 1 0
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
bled of refrigerant. Adjust any constantpressure valves to bring evaporator pressure down to atmospheric. 3. Start up the compressor. Adjust regulating system to lower suction pressure. 4. Keep a close eye on the suction pressure gauge! When the suction pressure is equal to atmospheric, stop the compressor and quickly shut off the discharge stop valve. Shut off any stop valve in the oil return line. If the receiver has an extra stop valve in the feed line, this can be closed; practically the entire refrigerant charge will then remain shut off in the receiver. Note: The receiver must not be overfilled! There should be a minimum gas volume of 5%. 5. A slight overpressure should normally remain in the piping system - this safeguards the system against the penetration of air and moisture. 6. Before dismantling parts, the operator should put a gas mask on.
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.
111
3. Note: If the piping system is colder than the sur- roundings, there is a considerable risk of damp precipitation (condensation) on cold plant parts. Plant components to be dis- mantled must be warmer than the ambi- ent temperature.
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.
112
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
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.
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. 1 0 . 5 9
N E – 7 2 6 1 7 1 0
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 mal- functions 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
4
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
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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
113
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
114
Cause
Code
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
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
Cause Water filter clogged Filter before valve in liquid or suction line clogged Excessive suction gas superheating Freezing-up of thermostatic expansion valve Thermostatic expansion valve has lost its charge Excess flow through expansion valve (liquid in suction line) Loose or misplaced sensor Solenoid valve in liquid or suction line not opening Oil filter needs cleaning - pressure cut-out has cut Oil pressure too low - pressure cut-out has cut
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
Liquid in suction line
Regulate expansion valves or float valves
2.32
Loose or misplaced sensor
Check whether sensors are making good contact with suction pipe and whether correctly 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
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115
4. Compressor starts and stops too frequently at low-pressure cut-out 4.1
See point 3.1
4.14
See point 3.14
4.27
See point 3.27
4.28
See point 3.28
4.29
See point 3.29
4.30
See point 3.30
4.33
See point 3.33
4.39
Low-pressure cut-out set too high
4.42
See point 3.42
4.49
Evaporator soiled or iced up
Adjust pressure cut-out
Clean or defrost evaporator
5. Excessive suction pressure 5.2
Compressor lacks capacity
Regulate compressor capacity
5.48
Safety valve leaky or opening prematurely
Adjust or repair valve
6. Compressor starts and stops too frequently at high-pressure cut-out See point 7
7. Excessive condensing pressure
116
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
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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
Compressor lacks capacity
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
Excessive capacity during decrease in temperature
Excessive capacity during temperature decrase (run-down) may result in liquid being sucked along in suction line. This liquid may cause the oil in the oil reservoir to foam vigorously so that the oil pressure drops, thus stopping the machine. Before restarting, check whether there is liquid in the oil reservoir. This liquid must be boiled off using a heating element or by heating the oil reservoir with hot water or steam. The plant must therefore be rundown at reduced capacity.
9.11
Oil pressure regulator set too low
The regulator is set to the 2.5 kp/cm prescribed by the manufacturer, but must be checked during operations.
9.31
Excess flow through expansion valve (liquid in suction line)
See comments under point 9.5
9.32
Loose or misplaced sensor
Loose sensor on expansion valve may cause liquid throughflow to suction line - see also comments under point 9.5.
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117
10. Oil temperature too high 10.13
Thermostat cut out
See section Pressure and temperature settings for setpoint.. The reason for the oil overheating must be found in the following points
10.18
A valve in the oil line is being 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
Safety valve leaky or opening prematurely
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
118
14.3
See point 13.3
14.4
See point 13.4
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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
Excess flow through expansion valve (liquid in suction line)
Check expansion valve
16.32
Loose or misplaced sensor
Check sensor positioning
17. Oil reservoir sweating during standstill 17.47
Main switch interrupted
If the compressor is stopped and the current 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
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119
18. Abnormal noise from compressor If any abnormal noise is coming from the compressor, the machine must be stopped immediately, and the cause pinpointed and remedied before restarting. 18.5
Excessive capacity during 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
Liquid in suction line
Check and adjust the valves with excess throughflow
18.32
Loose or misplaced sensor
Check sensor positioning
18.48
Safety valve opens
Check opening pressure of safety valve
19. Compressor motor will not start
120
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
Main switch interrupted
Switch power on
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20. Compressor runs continuously 20.2
Compressor lacks capacity
See under point 14
20.3
Solenoid valve in capacity regulating system fails to open
See under point 13.3
20.4
Timer or other automatic control out of order
See under point 13.4
20.42
Insufficient charge on plant
Top plant up with refrigerant
20.48
Safety valve leaky or opening prematurely
See point 10.48
20.49
Evaporator soiled or iced up
Clean or defrost evaporators
21. Liquid in suction line 21.1
Compressor has excessive capacity
Reduce capacity
21.31
Excess flow through expansion valve
Adjust expansion valve
21.32
Loose or misplaced sensor for expansion valve
Check sensor positioning and rectify
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During the past few years YORK Refrigeration has experienced a number of problems with mineral oils, particularly in R717 plants. The problems can be divided into two groups: a: The oil changes viscosity b: The oil decomposes (becomes very black) The problems have been seen with several mineral oil brands, often occuring within a few operating hours and resulting in severe consequences for both compressor and plants. Following the careful investigation undertaken by YORK Refrigeration during the past few years, it has been decided to introduce a range of synthetic oils which can fulfil the demands of modern refrigeration plants. Mineral oils may continue to be used in re- frigeration plants, providing the lubricating quality is carefully monitored. For modern, high capacity refrigeration plants, where long lifetime for both lubricants and moving parts is expected, YORK Refrigeration recom- mends the choice of synthetic lubricating oils. The application areas and specifications for these synthetic oils can be found in the following pages. Installers and/or users are at liberty to choose either YORK Refrigeration’s 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.
122
Lubricating oils with relatively high viscosities must be used to ensure satisfactory lubrication of refrigeration compressors. To obtain the best lubrication, the oil must: Provide the required fluidity at the lowest evaporating temperature encountered in the plant and at the highest permissible temperatures in the compressors. Provide acceptable fluidity at start-up. Provide sufficient oxidation stability (the oil must be moisture-free when added to the system). 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
2 0 . 9 9
N E 1 5 1 0 7 1 0
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 chang- ing on SABROE compressors later in this publication. Selecting the lubricating oil There are a number of operating diagrams for the selection of lubricating oils for Sabroe compressors operating with various 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
M
Mineral oil
A
Synthetic oil based on Alkylbenzene
PAO
Synthetic oils based on Polyalphaolefin
AP
Mixture of A and PAO-oils
E
Synthetic ester-based lubricants
0170-151-EN
In the oil recommendation diagrams for each refrigerant and compressor type, it is 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,
123
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 oil’s effectiveness in the compressor and the refrigeration plant as a whole. Pay particular attention to the following aspects: Oil type Refrigerant type Compressor type Miscibility between refrigerant and oil 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
124
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
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.
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 100°C the material tends to swell, and at an aniline point higher than approximately 120°C 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: Optimum viscosity range (to be designed for) = 20 to 50 cSt Max. permissible viscosity =100 cSt Min. permissible viscosity =10 cSt (only applicable to HCFC and HFC under cartain operating conditions: 7cSt) 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 capac- ity refrigeration plants, in which a long life- time for both lubricant and moving parts is expected, YORK Refrigeration recommends using synthetic lubricating oils.
A benefit of using the synthetic lubricant oil is a much lower oil carry-over to the plant and longer intervals between oil changes. A better fluidity at lower temperatures also gives an easier drainage at the cold parts of the plant.
How to use the oil recommendation 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.
125
the example above, a oil code number E5 can be selected.
Example (recip. compressors): Refrigerant: R134a Condensing temp. TC +35°C Evaporating temp. TE –3°C
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 tem- peratures due to seasonal changes. By plotting TC and TE in the oil recom- mendation diagram, this example would require a No 1 oil. If, however, TE changes at certain times, e.g. from – 3 to +7 °C, a No 2 oil should be utilised. But, as +7 °C is inside the marked area, the No 1 oil can be utilised also at this TE. R134a TC °F
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.
140 60 122 50 40
•
30
•
20 10 0
14 -10 -4 -20
-22 -30 -60 -50 -40 -30 -20 -10
0
10
20 30 ° C
32 50 68 86 ° F Evaporating temperature
-76 -58 -40 -22
-4
14
TE
By referring to the Oil recommendation table placed at the bottom of each oil recommen- dation diagram , it is possible to select the code number for the appropriate oil type. In
126
E9
°C
158 70
e r u t 104 a r e p 86 m e t 68 g n i s 50 n e d n 32 o C
E5
2
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.
:
In case of a new plant. Very suitable.
:
In case you wish to change from mineral oil
:
Max oil concentration in liquid phase at: TE: 2% W
: :
Max oil concentration in liquid phase: contact YORK Refrigeration
* :
Dry expansion systems only. Flooded systems to be considered individually: contact YORK Refrigeration
SH :
Suction gas superheat, K (Kelvin)
Min suction temperature –50°C: at TE< –50°C superheating must be introduced.
:
Zone in which both oils are useable
:
Calculation must be performed using COMP1
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127
Typical data for lubricating oils for Sabroe compressors
Sabroe code
Viscosity
Viscosity
Spec.
Flash p.
Pour p.
Anilin
Acid no.
grav. at 15°C
COC °C
°C
°C
point
mg KOH/g
cSt 40°C
cSt 100°C
Index
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 Refrigeration’s Sabroe compressors.
128
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
Mobil Gargoyle Arctic SHC 230
PAO 9 (P220)
1231-284
1231-285
Mobil EAL Arctic 68
E 3 (E68)
1231-272
1231-273
Mobil EAL Arctic 100
E 5 (E100)
1231-274
1231-275
Mobil EAL Arctic 220
E 9 (E220)
Sabroe H oil
E11 (E370)
1) 18.9
1231-279 3914 1512 954 1)
9415 0008 000
litre pail (5 US gallons)
The oils recommended by the former Stal Refrigeration correspond to the following oils: Stal Refrigeration oil type A B C H
0170-151-EN
Sabroe oil
– Sabroe Oil PAO 68 – Mobil Gargoyle Arctic SHC 230 – Sabroe H oil – Mobil Gargoyle Arctic 300
M1 (M68) PAO 3 (PAO 68) PAO 9 (PAO 220) E 11 (E 370)
129
one-stage reciprocating compressors
TC °F
°C
122 50 104 40
Code no
Area no
e r u t 86 a r e p m68 e t g n 50 i s n e d 32 n o C
30 20
10 0
14 -10
1 PAO 3 AP 1 M1
/
-4 -20 -22 -30
See note
-60
-50
-40
-30
-20
-10
0
10
20
°C
-76
-58
-40
-22
-4
14
32
50
68
°F
TE
Evaporating temperature
Note: YORK Refrigeration recommends that the use of M oils is restricted to moderately loaded compressors and that the oil quality is monitored carefully via regular oil analyses. :
130
: In case of a new plant. Very suitable. In case you wish to change from mineral oil
0170-151-EN
TC
two-stage reciprocating compressors
°F
°C
122 50 104 40
Code no
Area no
e r u t 86 30 a r e p m68 20 e t g n 50 10 i s n e 0 d 32 n o C 14 -10
1
PAO 3 AP 1
/
M1
See note
-4 -20 -22 -30 -60
-50
-40
-30
-20
-10
0
10
20
°C
-76
-58
-40
-22
-4
14
32
50
68
°F
TE
Evaporating temperature
Note: YORK Refrigeration recommends that the use of M oils is restricted to moderately loaded compressors and that the oil quality is monitored carefully via regular oil analyses. :
: In case of a new plant. Very suitable. In case you wish to change from mineral oil
0170-151-EN
131
TC
HPO and HPC reciprocating compressors
°F
°C
176 80 158 70 e r u t 140 a r e p 122 m e t g104 n i s n e d 86 n o C 68
60
50 40 30 20
50 10 Code no
Area no 1
PAO 5
32
0 -30
-20
-10
0
10
20
30
40
50
°C
-22
-4
14
32
50
68
86
104
122
°F
TE
Evaporating temperature
Please observe: PAO 5 oil is the only oil which can be used in the HPO and HPC compressors.
132
: In case of a new plant. Very suitable.
0170-151-EN
TC
one-stage reciprocating compressors
°F
°C
122
50
104
40
e r u 86 30 t a r e p 68 20 m e t g 50 10 n i s n 32 0 e d n o C 14 -10
Code no
Area no
-4
-20
1 A3
-22 -30 -60
-50
-40
-30
-20
-10
-76
-58
-40
-22
-4
14
0
10
20
°C
32
50
68
°F
TE
Evaporating temperature
: In case of a new plant. Very suitable. : Max oil concentration in liquid phase at: TE: 2% W
: Min suction temperature –50°C: at TE< –50°C superheating must be introduced.
0170-151-EN
133
TC
two-stage reciprocating compressors
°F
°C
122 50 104 40 e r 86 u t a r e p 68 m e t g 50 n i s n 32 e d n o 14 C
Code no Area no
30
20 10 0 -10
-4 -20
1 A3
-22 -30 -60
-50
-40
-30
-20
-10
0
10
20
°C
-76
-58
-40
-22
-4
14
32
50
68
°F
TE
Evaporating temperature
: In case of a new plant. Very suitable. : Max oil concentration in liquid phase at: TE: 2% W
134
: Min suction temperature –50°C: at TE< –50°C superheating must be introduced.
0170-151-EN
TC
°F
one-stage reciprocating compressors
°C
158 70
140 60 122 50
e r u t 104 a r e p 86 m e t 68 g n i s 50 n e d 32 n o C 14
Code no
Area no 1
-4
40 30
20 10 0 -10 -20
2 -22 -30
E5 E9
-60 -50 -40 -30 -20 -10
0
10
20 30
°C
-76 -58 -40 -22
32
50
68
°F
-4
14
86
TE
Evaporating temperature :
:
In case of a new plant. Very suitable. Zone in which both oils are useable
0170-151-EN
135
two-stage reciprocating compressors
TC °F
°C
158 70 140 60 122 e r u t 104 a r e p 86 m e t g 68 n i s 50 n e d 32 n o C
50
40 30 20 10 0
14 -10 -4
Code no Area no 1 E5
-20
-22 -30 -40 -40 -70 -60 -50 -40 -30 -20 -10 -94 -76 -58 -40 -22
-4
0
10
20
30
°C
14 32
50
68
86
°F
TE
Evaporating temperature
136
: In case of a new plant. Very suitable.
0170-151-EN
one-stage reciprocating compressors
TC °C
°F
122 50 104 40 e r 86 u t a r e p 68 m e t g 50 n i s n 32 e d n o 14 C
Code no Area no
30 20
10 0 -10
-4 -20
1 E3
-22 -30 -60
-50
-40
-30
-20
-10
0
10
20
°C
-76
-58
-40
-22
-4
14
32
50
68
°F
Evaporating temperature
:
In case of a new plant. Very suitable.
:
Max oil concentration in liquid phase: contact YORK Refrigeration
:
Min suction temperature –50°C: at TE< –50°C superheating must be introduced.
0170-151-EN
TE
137
two-stage reciprocating compressors
TC °F
°C
122 50 104 40 e r 86 u t a r e p 68 m e t g 50 n i s n 32 e d n o 14 C
Code no Area no
30
20 10 0 -10
-4 -20
1 E3
-22 -30 -60
-50
-40
-30
-20
-10
0
10
20
°C
-76
-58
-40
-22
-4
14
32
50
68
°F
Evaporating temperature
:
In case of a new plant. Very suitable.
:
Max oil concentration in liquid phase: contact YORK Refrigeration
:
Min suction temperature –50°C: at TE< –50°C superheating must be introduced.
138
TE
0170-151-EN
TC
one-stage reciprocating compressors
°C
°F
122 50
104 40
Code no
Area no 1
E3
2
e r 86 u t a r e p 68 m e t g 50 n i s n 32 e d n o 14 C
30 20
10 0 -10
-4 -20
-22 -30
E5
-60
-50
-40
-30
-20
-10
0
10
20
°C
-76
-58
-40
-22
-4
14
32
50
68
°F
Evaporating temperature
:
In case of a new plant. Very suitable.
:
Min suction temperature –50°C: at TE< –50°C superheating must be introduced.
:
TE
Zone in which both oils are useble
0170-151-EN
139
two-stage reciprocating compressors
TC °F
°C
122 50 104 40 e r 86 30 u t a r e p 68 20 m e t g 50 10 n i s n 32 0 e d n o 14 -10 C
Code no Area no
-4 -20
1 E3
-22 -30 -60
-50
-40
-30
-20
-10
0
10
20
°C
-76
-58
-40
-22
-4
14
32
50
68
°F
Evaporating temperature
:
In case of a new plant. Very suitable.
:
Min suction temperature –50°C: at TE< –50°C superheating must be introduced.
140
TE
0170-151-EN
HPO og HPC reciprocating compressors
TC °F
°C
122 60 104
50 40
e r 86 u 30 t a r 68 e 20 p m e 50 10 t g n i 0 s 32 n e -10 d n 14 o -20 C
Code no Area no 1 E5
-4
1
-30
-22 -40 -60 -50 -40 -30 -20 -10
0
10
20
30
40
50
TE -76 -58 -40 -22
-4
14 32
50
68
°F
Evaporating temperature
:
:
In case of a new plant. Very suitable. Max oil concentration in liquid phase at: TE: 2%
0170-151-EN
141
TC
one-stage reciprocating compressors
°C
°F
122 50 104 40 e r 86 u t a r e p 68 m e t g 50 n i s n 32 e d n o 14 C
Code no Area no
30 20
10 0 -10
-4 -20
1 E5
-22 -30 -60
-50
-40
-30
-20
-10
0
10
20
°C
-76
-58
-40
-22
-4
14
32
50
68
°F
Evaporating temperature
:
In case of a new plant. Very suitable.
:
Min suction temperature –50°C: at TE< –50°C superheating must most be introduced.
142
TE
0170-151-EN
TC
two-stage reciprocating compressors
°C
°F
122 50 104 40 e r 86 u t a r e p 68 m e t g 50 n i s n 32 e d n o 14 C
Code no Area no
30
20 10 0 -10
-4 -20
1 E5
-22 -30 -60
-50
-40
-30
-20
-10
0
10
20
°C
-76
-58
-40
-22
-4
14
32
50
68
°F
Evaporating temperature
:
In case of a new plant. Very suitable.
:
Min suction temperature –50°C: at TE< –50°C superheating must be introduced.
0170-151-EN
TE
143
TC
Screw compressors
°F
°C
122
50
104
40
e r u t 86 a r e p m 68 e t g n 50 i s n e d 32 n o C
Code no Area no 1 PAO 3
AP 1
/
M1
See note
30 20
10 0
14 -10
-4
-20
-22 -30 -60
-50
-40
-30
-20
-10
0
10
20
°C
-76
-58
-40
-22
-4
14
32
50
68
°
F
TE
Evaporating temperature
Note: YORK Refrigeration recommends that the use of M oils is restricted to moderately loaded compressors and that the oil quality is monitored carefully via regular oil analyses. HLI:
Calculation must be performed using COMP1
:
In case of a new plant. Very suitable.
:
In case you wish to change from mineral oil
:
Min suction temperature –50°C: at TE< –50°C superheating must be introduced.
:
144
Calculation must be performed using COMP1.
0170-151-EN
TC SH25
Screw compressors
°F
°C
122 50
104 40
Code no
Area no 1
2*
e r u t a r e p m e t g n i s n e d n o C
SH20 SH5
86 30
SH10
68 20
50 10 32
0
14 -10 SH20
-4 -20
A3
-22 -30
PAO 5
-60
-50
-40
-30
-20
-10
0
10
20
°C
-76
-58
-40
-22
-4
14
32
50
68
°F
TE
Evaporating temperature
Using the calculating programme COMP1 it is possible to optimize the requirement for suction superheat values (SH) as stated in the diagram. See Oil types and oil companies in this section. Due to the ongoing development of lubrication oils, please contact YORK Refrigeration for an update on the requirement for superheat. HLI: Calculation must be performed using COMP1. : :
In case of a new plant. Very suitable. Max oil concentration in liquid phase at: TE: 2% W
:
Min suction temperature –50°C: at TE< –50°C superheating must be introduced.
* :
Dry expansion systems only. Flooded systems to be considered individually: contact YORK Refrigeration
SH :
Suction gas superheat, K (Kelvin)
:
Calculation must be performed using COMP1
0170-151-EN
145
TC
Screw compressors
SH30
°
F °C 158 70
SH20
140 60 122 e r u t a r 104 e p m 86 e t g n 68 i s n e d 50 n o C 32 Code no
SH10
40 30
SH5
20
10 0
Area no (See note)
1 E5 E9
50
2
14 -10 SH20 -4
-20 -50
-40
-30
-20
-10
0
10
20
30 °C
-58
-40
-22
-4
14
32
50
68
86
°F
TE
Evaporating temperature Note: For the compressors type ”S”, ”Rotatune”, ”SAB 81”, ”SAB 83”, and ”SAB 85” only Sabroe oil H is approved. Using the calculating programme COMP1 it is possible to optimize the requirement for suction superheat values (SH) as stated in the diagram. See Oil types and oil companies in this section. Due to the ongoing development of lubrication oils, please contact YORK Refrigeration for an update on the requirement for superheat. HLI: Calculation must be performed using COMP1. :
In case of a new plant. Very suitable.
SH :
Suction gas superheat, K (Kelvin)
:
Zone in which both oils are useable
:
Calculation must be performed using COMP1
146
0170-151-EN
TC
Screw compressors
°F
°
SH15
104 40
Area no (See note) 1 2 3
Code no
86 30 e r u t a r 68 20 e p m e 50 10 t g n i 0 s 32 n e d n 14 -10 o C
E3 E5 E9
SH10
-4 -20
SH15
-22 -30 -70
-60
-50
-40
-30
-20
-10
-94
-76
-58
-40
-22
-4
14
0
10
°
32
50
°F
TE
Evaporating temperature
Note: For the compressors type ”S”, ”Rotatune”, ”SAB 81”, ”SAB 83”, and ”SAB 85” only Sabroe oil H is approved. Using the calculating programme COMP1 it is possible to optimize the requirement for suction superheat values (SH) as stated in the diagram. See Oil types and oil companies in this section. Due to the ongoing development of lubrication oils, please contact YORK Refrigeration for an update on the requirement for superheat. HLI: Calculation must be performed using COMP1. :
In case of a new plant. Very suitable.
: :
Max oil concentration in liquid phase: contact YORK Refrigeration
SH :
Suction gas superheat, K (Kelvin)
Min suction temperature –50°C: at TE< –50°C superheating must be introduced.
:
Zone in which both oils are useable
:
Calculation must be performed using COMP1
0170-151-EN
147
TC
Screw compressors
°F
°
122
50 SH10
104 e r u t a r e p m e t g n i s n e d n o C
Code no
Area no (See note) 1 2
E3 E9
40 SH5
86
30
68
20
50
10
32
0
14 -10 -4
-20
-22
-30
SH5 -70
-60
-50
-40
-30
-20
-10
-94
-76
-58
-40
-22
-4
14
0
10
20 °
32
50
68
TE
°F
Evaporating temperature
Note: For the compressors type ”S”, ”Rotatune”, ”SAB 81”, ”SAB 83”, and ”SAB 85” only Sabroe oil H is approved. Using the calculating programme COMP1 it is possible to optimize the requirement for suction superheat values (SH) as stated in the diagram. See Oil types and oil companies in this section. Due to the ongoing development of lubrication oils, please contact YORK Refrigeration for an update on the requirement for superheat. HLI: Calculation must be performed using COMP1. :
In case of a new plant. Very suitable.
:
Max oil concentration in liquid phase: contact YORK Refrigeration
: SH :
Min suction temperature –50°C: at TE< –50°C superheating must be introduced. Suction gas superheat, K (Kelvin)
:
Zone in which both oils are useable
:
Calculation must be performed using COMP1
148
0170-151-EN
TC
Screw compressors
°F
104
°
40
SH5
86 30 e r u t a r 68 20 e p m e 50 10 t g n i 0 s 32 n e d n 14 -10 o C Code no
E5 E9
Area no (See note) 1 2
SH5
SH15
-4 -20 SH30 -22 -30
-70
-60
-50
-40
-94
-76
-58
-40
-30 -22
-20
-10
-4
14
0
10
°
32
50
°F
TE
Evaporating temperature
Note: For the compressors type ”S”, ”Rotatune”, ”SAB 81”, ”SAB 83”, and ”SAB 85” only Sabroe oil H is approved. Using the calculating programme COMP1 it is possible to optimize the requirement for suction superheat values (SH) as stated in the diagram. See Oil types and oil companies in this section. Due to the ongoing development of lubrication oils, please contact YORK Refrigeration for an update on the requirement for superheat. HLI: Calculation must be performed using COMP1. :
In case of a new plant. Very suitable.
:
Min suction temperature –50°C: at TE< –50°C superheating must be introduced.
SH :
Suction gas superheat, K (Kelvin)
:
Zone in which both oils are useable
:
Calculation must be performed using COMP1
0170-151-EN
149
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
M
A
PAO
AP
Aral
•
Avia
•
BP
•
•
•
•
Castrol
•
•
•
•
Chevron (UK: Gulf Oil)
•
•
•
CPI Engineering Services
•
•
•
DEA
•
•
•
•
Elf / Lub Marine 1
•
•
Esso/Exxon
•
•
Fina
•
•
Fuchs
•
•
•
•
Hydro-Texaco
•
•
•
•
•
• • •
ICI
•
Kuwait Petroleum (Q8)
•
Mobil
•
Petro-Canada
•
Shell
150
E
• •
•
•
•
•
Statoil
•
•
Sun Oil
•
•
• • •
0170-151-EN
Notes:
0170-151-EN
151
The following is a schematic description of what to do in connection with the installation of a compressor unit. 1. Alignment of compressor unit on foundation. 2. Connecting electricity and refrigerant supplies as well as cooling water, if any. 3. Alignment of coupling. 4. Mounting of coupling guard. In order to assure compressor and motor a long life and a noiseless and vibrationless running, compressor unit and coupling need to be aligned with care. Misalignment of compressor unit or coupling may produce stresses and vibrations which can be transmitted to the compressor bearings and thus be the cause of break-down. Vibrations may be caused by the following: Distortion between compressor unit and foundation.
Incorrect alignment of coupling between compressor and motor. Untruth in compressor or motor shafts. Untruth in coupling. Imperfect balancing of coupling. Imbalance in compressor and motor.
The fitter who sets up the unit is responsible for the points up to and including the alignment of the coupling. 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.
1.0 Alignment of unit on foundation When installing the unit on the foundation or the machine floor, the unit must stand free from stress and be even on all supports. The unit can be installed as follows: on vibration dampers,
Distortion between compressor and base frame. Distortion between motor and base frame. Strains from pipe connections between compressor and plant.
152
directly on foundation, with foundation bolts.
In both cases the unit must be aligned before fitting the connecting pipes to the installation.
0178-050-EN
0 1 . 5 9
N E 5 5 0 8 7 1 0
1.01
Fitting of vibration dampers
Fig. 1 Industrial type
A1 H
A2 H max.
Marine type
A1 A2
T0177040_0
Depending on whether the compressor unit is to be used on land or on board a ship, the vibration dampers shown at the top or bottom of fig. 1 are included in the supply. The purpose of the vibration dampers is to damp the propagation of vibrations from the compressor unit to the foundation. In addition, the marine vibration dampers serve to cushion vibrations from the foundation to the compressor unit, at the same time securing the unit on its foundation. It is extremely important that the vibration dampers be fitted correctly, as shown in the filled in drawing forwarded to the customer or the distributor. This drawing is valid only for the unit in question. When using vibration dampers, it is a condition that the foundation possesses the necessary bearing strength and is level so that the adjustment of the vibration dampers can be
0178-050-EN
kept within the ajustment measures stated on the drawing submitted. To make each individual vibration damper function properly, it must be sufficiently loaded. Measure A1 and H in an unloaded and A2 in a loaded situation. Industrial type 1
Marine type 2
Flexion
min 1,0
min 3,0
A1-A2
max 2,0
max 5,0
Height adjustment
H
= H+12 max
All measures are in mm
The flexion of the industrial type is adjusted by increasing or reducing the load in proportion to the other supports. The foot can be raised by screwing the adjusting spindle down, thereby increasing the load and hence also the flexion.
153
Vibration dampers of the marine type are not adjustable. Therefore, it is essential that the foundation is even within a max. deviation of 2 mm. If the foundation is not even within max. 2 mm, line under the vibration dampers until the prescribed flatness is obtained. Once the plant has cooled down, check during operation that the flexion of the dampers is still correct! 1.02
Mounting directly on the foundation
When mounting directly on a foundation with embedded foundation bolts, it must be carefully checked that all 4 legs are stable. Alternatively, liner plates must be used in order to avoid distortion of the compressor unit.
1.1 Alignment of compressor against base frame Since the compressor stands on a threepoint fixture there is no risk of distorting the compressor housing.
Besides, coupling alignment becomes considerably easier when there is no distortion between the electric motor and the foundation.
2.0 Making various connections Connect the compressor unit to refrigerant and electricity supplies as well as to cooling water, if any. Pipes which are exposed to sizeable temperature fluctuations must be laid so as to allow deflection at appropriate points. This will ensure that no excessive forces are transmitted to the compressor and the unit. Enclosed pipes may give rise to very large strains, for instance in connection with temperature changes from installation temperature to operating temperature. Once the installation has cooled down, check the vibration dampers on the compressor unit for correct flexion. In Fig 2 is shown a rigid and unacceptable piping (1) and a more flexible one (2).
Check that all screws are properly tightened.
1.2 Alignment of motor against base frame
Fig. 2
> 1.5 m
Check that the motor stands with all feet on the base frame’s milled off surfaces. Make sure that all surfaces are clean and free from burrs. Perform this check with the fixing bolts loosened. If there is a slip at one or more resting surfaces, line up before securing. If this is not done, there is a risk that the motor will be submitted to stresses which will damage the bearings.
154
1
2
T0177057_0
0178-050-EN
With the coupling intermediate section dismounted, check that the rotating direction of the compressor motor is correct as shown by the cast arrow on the suction cover above the rotor shaft.
3.0 Alignment of coupling between compressor and motor
Large motors can be lifted with the screws supplied as shown in fig. 3.1 for insertion of liner plates. The clamps shown in fig. 3.2 are used for sideways shifting of the motor.
Fig. 3.1
When the suction and discharge pipes are connected to the unit, align compressor and motor so that the two shafts are placed end to end. The mounting of the two types of coupling is described in the following section and the alignment procedure is the same for both couplings.
Fig. 3.2
Auxiliary tools for coupling alignment Four clamps with adjusting screws are supplied with each unit as shown in fig. 3.2, as well as four sets of liner plates. Each set consists of: T0177059_0
No. 1 2 3 2 2
0178-050-EN
Thickness (mm) 3,0 1,0 0,25 0,15 0,10
Further, an alignment tool and a feeler gauge are delivered for alignment of the coupling as shown in fig. 8.
155
Mounting of Series 52 coupling Series 52 is a coupling of the flexible disc type which is torsionally stable and as such does not cause any torsional fluctuations between motor and compressor. The flexible discs and the intermediate section provide the coupling with the necessary radial and axial flexibility to absorb the minor radial and axial displacements between motor and compressor.
These displacements occur as a consequence of the heat and power impacts during operation. Mounting Assemble coupling as shown in fig. 4 and mount it on the compressor and motor shafts as described in the following: On mounting, pay attention to the measures C and E in the table below fig. 4.
Fig. 4
E
C T0177120_0/V1
Compressor type
SAB 128Mk3
Coupling type
Bolt dimension spanner
225
1/2”
C mm
E mm 14 0.5
127 0.5 SAB 163 Mk3
262
Before mounting the coupling flange on the compressor shaft, clean coupling flange, the individual parts in the bushing and the rotor shaft.
156
9/16”
10
+1.0
0
Next, lubricate all parts in a little of the refrigerant machine oil. Do not lubricate with Molybdändisulfid, high-pressure oil or grease.
0178-050-EN
Assemble bushing as shown in fig. 5 and loosen screws pos. 1 1 turn. Fig. 5
1
By means of the torque key tighten all screws pos.1 crosswise by first tightening with half the torque moment of Ms and then with Ms as indicated in the following table:
Torque moment Ms Compressor type
In the dismantling holes with thread mount some of the screws pos. 1 as shown in fig. 6 and adjust by hand so that the surfaces are even as indicated by the mark
.
Fig. 6
1
Screws pos.1 number x dim.
Torque moment Ms [Nm]
SAB 128 Mk3
8 x M6
15
SAB 163 Mk3
8 x M8
35
Repeat the tightening with torque moment Ms crosswise until none of the screws can be turned any more.
Dismounting of coupling flange On dismounting the coupling flange from the compressor shaft apply the following procedure: Loosen screws pos. 1 a few turns.
Next mount the bushing in the coupling flange and push it right to the bottom as shown in fig. 7 marked
.
Fig. 7
Mount screws pos. 1 in the dismantling holes as shown in fig. 6 and tighten evenly crosswise until the two taper rings have been pressed apart and have loosened the coupling flange from the shaft. Now take out coupling flange with bushing by hand.
Remove screws from the dismantling holes and remount in the bushing as shown in fig. 5. Tighten screws by hand.
0178-050-EN
It is recommended to press on the coupling flange on the motor by means of a threaded rod with nut and tightening bar. If the coupling flange is knocked on, this may cause damage to the bearings. Fasten coupling flange to the motor shaft with pointed screw and tongue connection.
157
In case the coupling is delivered unbored
Mounting
because of the motor being unknown at the
Mount the two coupling parts, motor flange F and compressor flange G as described earlier. See fig. 8. Pay attention to the measure E as shown in fig. 4.
time of delivery, the coupling flange must be balanced acc. to VDI 2060 Q 6.3 to a max. of 3600 rpm without tongue, but with the pointed screw.
Dismantling of coupling On dismantling the coupling it is important to note the position of bolts, washers, and nuts as they must be fitted again in the same order. Tie a string or a piece of thread through one of the bolt holes in the coupling discs in order to avoid that the plates are turned in relation to each other and in relation to the flange.
158
Mount motor and compressor and secure to the base frame as described in sections 1.1 and 1.2 Check distance C as shown in fig. 4. Mount the coupling intermediate sections and the two flexible discs and secure with the bolts as shown in fig. 8. The torque moment is shown in the table below fig. 8.
However, do not mount the bolts that secure the flexible discs to the motor flange until the alignment has been completed.
0178-050-EN
Alignment procedure
indicated in the table below fig. 8.
The series 52 coupling is aligned as described in the following, and the accuracy whereby the coupling must be aligned is
In principle, the alignement is a question of moving the motor so that its shaft is placed in continuation of the compressor shaft.
Fig. 8
1 2
Z
X
a
A
•
F H
C
G
T0177120_0/V1
Max. variation at 180 ° rotation Coupling No
Diam. A mm
225
145
262
168
0178-050-EN
Distance C mm
127 0.5
Torque moment Nm 34 41
Pos. 1
Pos. 2
Horizontal mm
Vertical mm
0 – 0.05
0 – 0.10
mm
0 – 0.10
159
Parallel shafts on a horizontal level 1. Turn Turn the couplin coupling g so that the align alignment ment tool is in top position. 2. Guide Guide measurin measuring g pin (pos. (pos. 2) towards towards the coupling flange with a 1 mm feeler gauge in between and secure the pin. Remove the feeler gauge. 3. Turn Turn the the coupling coupling 180°. Motor and compressor are turned at the same time. Measure with feeler gauges how much the distance from measuring pin to coupling part has changed. The change is called X. 4. Measure Measure the distance distance b between the motor’s feet, as shown in fig. 9. Measure the distance a from the middle of pin 2 to the centre line of the motor as shown in fig. 8. 5. Insert Insert liners liners with with thickn thickness ess Y either under both front feet or both rear feet, tilting the motor at the desired end. Use the following formula for calculation of the liner thickness: Y=X
•
1. Turn Turn the couplin coupling g so that the alignm alignment ent gauge faces downwards. 2. Guide Guide the the me measur asuring ing pin pos. 1 towards towards the coupling part with a 1 mm feeler f eeler gauge in between. Secure the pin and remove the feeler gauge. 3. Turn Turn the the coupling coupling 180° and measure with feeler gauges how much the distance has increased. The increase increase is called Z. 4. Then lift lift the motor motor by placing placing liners liners with with half the thickness. i.e. Z/2 under all under all four feet. 5. After securin securing g the motor, motor, repeat the meameasuring and compare the result with the table values.
Parallel shafts on a vertical level 1. Turn Turn the couplin coupling g so that the alignm alignment ent gauge faces horizontally out to one side.
b 2a
2. Move both both measuri measuring ng pins toward towards s the coupling with a 1 mm feeler gauge in between. Lock the pins and remove the feeler gauges.
Fig. 9
y
b
T0177056_0
6. After havin having g tightened tightened the motor motor bolts, bolts, repeat the measuring and compare the result with the table t able values.
160
Parallel displacement to correct centre height
3. Turn Turn the coupli coupling ng as close close to 180 180° as allowed by the cap cover and measure with feeler gauges the deviations from the original one millimeter on millimeter on both pins. 4. Moving Moving and turnin turning g the motor motor sideways sideways with the adjustment screws and repeating the measuring, align the motor in accordance with the table. Remember that the motor must be secured during each measuring. measuring.
0178-050-EN
Final installation 1. Tighten the fixing fixing bolts on the motor. motor.
6. Recheck Recheck the couplin coupling g with a compresso compressorr still warm from operation and with pressure on pipe connections.
2. Dismantl Dismantle e the align alignment ment tool. 3. Mount Mount bolts between between the flexib flexible le discs and and the coupling flange of the motor. Tighten all bolts with the torque moment as indicated in the table below fig. 8.
Fig. 10
4. Che Check ck dist distanc ance e C. 5. Once the the coupling coupling alignme alignment nt has been been carried out correctly, fit the outer shell of the coupling guard on the adaptor plate which is secured on the t he compressor shaft seal cover. Push the outer shell, which is placed inside the inner shell, so far towards the driving motor that access to the rotating parts is made impossible. impossible. See fig. 10.
0178-050-EN
T0177045_0
161
PT 1
Pressure transducer (suction pressure)
PDAZ10 PDAZ10
Oil pressu pressure re differ differenc ence e cut-ou cut-outt (oil pressure - discharge pressure)
PT 2
Pressure transducer (discharge pressure)
PDAZ11
PT 3
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
PT 5
Pressure transducer (oil pressure after oil pump)
Thermostat (discharge gas temperature)
TC14
Thermostat (pilots solenoid valve pos. 82)
TT5
Temperature transducer (discharge gas temperature) t emperature)
TT6
Temperature transducer (oil temperature in flow control)
PT 4
PI15
Suction pressure manometer
PI16
High-pressure manometer
PDI17
Oil difference manometer
Temperature transducer (suction gas temperature)
FT18
Level switch
19
Compressor safety valve
Position transmitter (c (capacity slide)
20
Suction stop valve
21
Non-return valve
GT9
Position transmitter (Vi slide)
22
PAZ10
Safety pr pressure cu cut-out (for TÜV, SDM and SA only)
Flanged joint discharge pipe compressor
23
Suction filter built into compressor
Low-pressure cu cut-out (only for classified systems)
24
Service valve - air purge valve
25
Oil separator
PAZ2
High-pressure cut-out
26
PDAZ PD AZ3 3
Diff Differ eren enti tial al pres pressu sure re cutcut-ou outt (pressure drop across across oil filter)
Non-return valve in outlet pipe from oil separator
27
Thermometer (discharge gas temperature)
Stop and non-return valve in outlet pipe from oil separator
28
Safety valve - the unit
T I6
Thermometer (o (oil te temperature)
29
T I7
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)
TT7 GT8
PAZ1
T I5
GT8
162
Position transmitter (capacity slide)
0178-085-EN
1 1 . 9 9
N E 5 7 5 1 7 1 0
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
163
95 96
Liquid supply for HLI cooling Vi 4.0
127
Stop valve
128
Stop valve
Liquid supply for HLI cooling Vi 2.6
129
Solenoid valve (NC)
130
Stop valve
131
Stop valve
132
Liquid filter
140
Stop- and non-return valve
141
Main valve
142
Pilot valve
143
Solenoid valve
144
Stop valve
145
Float valve
147
Liquid filter
148
Stop valve for oil purge
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
205
Filter
97
Economizer connection
98
Oil connection from flow switch
99
Oil to and from Vi regulation (only by auto-Vi)
100
Oil return from fine oil separator
101
Bypass throttle valve at suction stop valve
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
122
Main valve
206
Nozzle
123
Solenoid valve (NC)
207
Solenoid valve (NO)
124
Stop valve for oil drainage
208
Solenoid valve (NC)
125
Safety valve
FT209
Oil level switch in oil separator
126
Float valve
210
Non-return valve
164
0178-085-EN
211
Stop valve
223
Brake motor for capacity slide
212
Service valve - air purge valve
224
Three-way solenoid valve
213
Non-return valve
225
Oil return pump
214
Filter
226
Solenoid valve for baby slide (NC)
215
Non-return valve (5 bar)
227
Quick closing oil drain valve
220
Compressor protecting valve (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
165
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. Forwarding instructions
Shop No.
All compressors are fitted with an identification plate, which states the type and shop no. of the compressor and indicates what refrigerant is to be used. 2.
Part No.
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 SABROE’s stores. When you order spare parts, please always advise at least the designation and part num-
166
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
5 0 . 4 9
N E 6 6 4 1 7 1 0
