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PPV VFF DDT POG Perea Compressor Instructions T08-A-1502 Ww Sabroe Refrigeration TP 1995-08 COMPRESSOR Maintenance and Service Instructions hese Maintenance and Service Instructions are intended for your Stal Compressor, They contain technical data con the compressor, lubrication recommendations, liste of patts, recommendations on routine maintenance and information necessary for the installalion of the compressor, in accordance with our Delivery Coneitions, we give a one-year guarantes for the comprassor with regard to os ‘tnaterial and workmanship, provided the comperssor is correctly installed and that the plant, in which it is incorpo- > rated, is properly designed, Since proper oparation and maintenance of the compressor also constitute conditions {or the validity of the guarantee clause in our Delivery Condftions, it is imperative that the operating personne| should be welt 2cquainted with these instructions. ~ The documentation contained herein must not be copied without our consent, nor must its contents ba made: | known to others or cthenvise used in an unauthorized way. 4, _ Sabroe Refrigeration AB gent a i 5 eB bbe Compressor Designation .. - soe 3 2 Compressor Mfg. No. severe u rteoeate BOLO E Q EB Inthe event you should need any addtional intormation on your Stal Compressor, please contact your 5 Reel representative, or Sabroe Refrigeration AB 601 87 NORRKOPING Telephone: + 46 $121 40 00 (Tee +4613 1028.42 When communicating, please always quote the above reference number,yyVV,VOVD ’ rrr FVYPRPP PEPE E HOO OO DVIOPIVF PAHOA EDV my > Sabroe Refrigeration Stal-Maxi SV80 4848-A-7300E Screw compressor units We TP 1995-07 INSTRUCTION FILE, LIST OF CONTENTS For unit types SV, SZ 85 Heading | Manual sheet SVA| SVR | SZ | Scops Code position | sve | ! Variant code letter [Fretace 709-AA5E x | x | x | Preface | 4848-A-730 x | x | x [Ustoteontents 4 Unit description | 4848-E-7108 x bx | Declaration of airborne | I i noise emission . | |,4848-C-700F i ___| Deseription [ce-6, HB-E | 4848-0-710E Desoription CH, HEE | 4848-07208 | Deseriotion — 1GB-GHA | 48420-7906 . |Description [CH HA ABA-HTO0E Dimensional sketch HB-D, Ml (ARAB 701E Dimensional sketch | HIB, MIB-K | 4848-H-704e —x__| Dimensional sketch | HA, ML-F_ _ | 4848-H-705E Bl Dimensional sketch HIA,MIB-K Installation and _4848-N-S30E- a | installation B-D operation ABAONSSSE TEx | instaltation | HIA | 4848-N-540E __| ttting instructions [ABdeNMSE “| | Lifting instructions #4948-N-S0OE oh ‘Operating instructions, 4248-N-S10E und x _| Operating instructions: 4848-C-750E ___ | Technical data [484a.G-760E ue |x| Technicaldata Compressor = daawAioE | x | x | x_| Electric dive motor } 4848-C-005E, xix tx . ~ 4848-C-020E xi x | x i Variable vi x |x |__| Capacity contol “| x | x | x_ | Movable economizer pot | . xx |x _| Intemal oil system iL x___x_|_ x | Working range { |x | Dimensional sketch | [apqenco7oE x |x | _x_| Lubricating ols, - 14848-N-260E x |x | x | Suction fiter |4848-A-730bE StakMaxi SV80 22 Screw compressor units a TP 1995-07 Sabroe Refrigeration Heading Manual sheet | SVAT Sve] Sz | Scope Code position SVB Variant code ! Lo} | etter Control 4848.5 710E Control cabinet _. Clk equipment ['a84a-J-500E fi ___| Staleetronic 700, CBB 4848-J-505E SlalExcom dataset list SE700 CBG 4B48-N-7B0E | Statsctronic 700 Operators Maral | C/B-G tO __.___| for $V80 Compressor Unit 1 4848-N-570E, _| Slide position sensor A868-NSTIE [E x_| Slide position sensor ‘Components | 4848-N-750E Oil separator oo 4848-N-TS1E _ | Dil separator THD . Lagae-Ns5se sx | x Ol fiter i 4348-N-760E HE Shaft coupling GB-E . _ ___| cer 4848.N-765E_ Suction filter, eeonomizer ACES | { 4848-N-590E Oil cooler i MB-K | 4848.N-5G1E | _ Ollecoler MILT 4848-N-5O5E Liquid injection _ DB-C 4848-N-506E | Ae Liquid injection _ DD siaa-c-40e | x | x FRI Velve ase 200 bas su3c-ssE | x | x | |VaveASC50 _ _ susc4se | x | x Valve AVAT-1 5143-C-56E | Valve ASC 65: | 4940-N-761E | Valve holder 5172-0-62E Satety valve - Spare parts | 4848-B-700E ‘Spare pars, compressor unit | 4848-87108, _| Spare parts, compressor unt HA 4e48-R2I0E | x 4B48-R-020E | x x -| Spare parts, commessor X_} Small set of toois Rarnark, Only manual sheets valid for the unit have been marked with a cross, Shaded areas mean thal mana sheets are chosan ace. to code postion and variant code latter. Pee EEO CECE eee LEE EEE ‘ ‘ CEE CE EE EEE EL CES wus GEE CER ERE EEK Eyradt POPP P EPID VIPVFHA HOPPE KI VIVG yrPrVIV VOD ) , VII be Ses SABROE REFRIGERATION AB 1995-06-13 INSTRUCCIONES DE SEGURIDAD Para usar la maquina deberan cumplirse las siguientes condiciones: 4. Solo deberd emplearse para la compresién de gases que generen reftigeracién o calor. S6io deberé emplearse con el refrigerante especificado en la placa de caracteristicas La maquina no debera usarse para otras finalidedes. Sabroe Refrigeration AB no asume responsabilidad alguna sobre la maquina ésta ha sido modificada. La maquina no debera emplearse en atmosferas explosivas. No debera colocarse de forma que enire en contacto con alimentos. Durante la instalactén, operacién y mantenimiento, debera dedicarse una atencién especial a lo siguiente: 4. Todas las tareas de instalacién, operacién y mantenimiento de la maquina sélo deberd realizarias personal adiestrado y cualificado. Deberan feerse as instrucciones antes de la instalacién, operacién o manienimiento. Su ubicacién en la sala de maquinas debera permitir una répida evacuacion de! personal. Atizaria se corre ol riesgo de accidentes. Usar para ello las anillas de elevacion de la maquina y un equipo de elevacién aprobado y adaptado al peso de fa maquina. No circular cerca de una maquina parada, puestc que puede ponerse en marcha sin preaviso si esta equipada con control remote o automatico, y causar dafios personales, No petmitira personas no autorizadas entrar en la sala de maquinas. Sekanvspsdocroy PY YI VVIVD ye vPRP XVOD vy vv red? peat + ,eTP I Vd we 10. 11. 12. 13. 14, 15. Las tuberias y otros componentes pueden estar muy calientes o muy frios, cavsando quemaduras 0 congelacién, respectivamente. Es necesario obrar con precaucion al tocar la maquina Utlizar protecci6n auditiva en las proximidades de la maquina para evitar lesiones en e! oido. El trabajo de mantenimiento debe hacerse s6lo por personas autorizadas. Durante las operaciones de manteniimiento, debera obrarse de modo que el compresor no pueda ponerse en marcha, para evilar el riesgo accidentes. Desconectar el interruptor de suminisiro eléctrico del cireuito principal. Ese interruptor deberd estar cerrado bajo llave mientras se esté trabajando en ia maquina. Durante las tareas de mantenimiento y otros trabajos, existe ei riesgo de inhalar gases peligrosos. Asegurar una ventilacién apropiada alrededor de la maquina. Asegurarse de que la maquina esté bien fria antes de empezar a trabajar en ella, para evitar el riesgo de sufrir quemaduras. No tlevar ropa de vestir suelta o demasiado holgada, joyas 0 reloj de pulser al trabajar con la maquina. Asegurarse de que el cabello, si es largo, no enire en contacto con ka maquina. El sistema de refrigerante esta presurizado. Antes de empezar a trabajar en él sistema, la presion debera reducirse cuidadosamente al nivel atmosférico. Los escapes de gas pueden produeir dafies. El refrigerante no deberd evacuarse al aire, debido a que constituye un peligro para ef ambiente, Las tuberias utilizadas para vaciar o lienar con reftigerante deben soportar las presiones existentes, de lo contratio se corre ei fiesgo de que revienten. El reftigerante puede ser peligroso para fa salud. Usar el equipo de proteccidn preserito, por e}. quantes, anteojos y caretas de respiracion. En caso de que entrara en contacto con fa piel, inhalacion, etc., seguir las instrucciones aplicables al refrigerante respective. Ponerse inmediatamente en contacto con un médico El aceite puede ser peligroso para la salud y causar lrritacién en fa piel. Usar el equipo de proteccién prescrito, por ej. guantes, anteojos y caretas de respiracién. En caso de que entrara en contacto con la piel, o de inhalacion, seguir las instrucciones aplicables al aceite respective. Ponerse inmediatamente en contacto con un médico.rep yore yrrvrs > Pe ee en ee pyar eve vrs Ve> VE DHID , 0 16. 17. 18. 19. 20, at. 22, 23. 24. “a SABROE ‘Al cambiar el aceite, recordar que éste puede tener una temperatura elevada y contener gas reftigerante, y ocasionar quemaduras y otras lesiones. Fs esencial obrar con precaucién. Las herramientas y repuestos olvidados después de las tareas de mantenimiento pueden causar lesiones o dafios. No intentar localizar fas fugas con las manos o cualquier otra parte del cuerpo. Se corre el riesgo de dafios por congelacion, No exponer la méquina a una temperatura superior a la permitida, debido a que se corre el riesgo de explosién. Antes de poner en marcha la maquina después de haberle dado mantenimiento, controlar que: Se hayan montado todas las protecciones de seguridad, correctamente ajustadas. Todos los pernos y tornilios estén correctamente apretados. Todas las valvulas estén correctamente ajustadas. No haya personas en la zona de riesgo. No se hayan olvidado herramientas en la maquina o en sus proximidades. No permanecer sobre la maquina, puesto que se corre el riesgo de resbatar. Pueden producirse dafos en las tuberias y el equipo de seguridad, Mantener la maquina fimpia, eliminando el polvo y la suciedad, ya que pueden causar incendios o perturbaciones operativas. Controlar periddicamente que los letreros de advertencia, ete, estén intactos y facilmente visibles. Los letreros perdidos 0 dahados, etc., deben reemplazarse inmediatamente. Sabroe Refrigeration AB no asume responsabilidad alguna por el uso de repuestos que no sean originales. Sabroe Refrigeration AB 601 87 Norrkbping SusciaVVVIPPVVRD vy err er rrr O?D pyre ee? bayer r rare VOTTIIIT 7 Peer e ddd StalMaxi SV80 4848-E-710E Screw compressor units Ww Sabroe Refrigeration TP 1995-05 DECLARATION OF AIRBORNE NOISE EMISSION DECLARED NOISE EMISSION VALUES in accordance with ISO 4871 > Declared A-weighted Sound Power Level, 103 dB(A) Lavra, in dB re 1 pW. + Declared A-weighted Emission Sound Prassure Level, 86 dBIA) Lyad in dB re 20 Pa, at 1m distance from the reference bax in free fiald conditions. geal Hs FEEL Measurements are taken in accordance with |S 9614-2 HG] Determined A-weightas Emission Sound Pressure Level in accordance with !SO 11 203, Egis® Be i Operating conditions at measurement aa Working medium — ; R22 SEgse #ig, — Suctionpressure + 5.0 Bara Discharge pressure : 19.8 Bara } Oil separator 2 TAS 10006 Electric motor : Schorch BN 815X (400 kW) IP23 NOTE! The acousiie nature of the surroundings in which the unit is mounted and focated, may alter the characteristic and! level of noise, These site conditions are not under ABB Stal Refrigeration's controlPPV VVIOVY IPI? vad yoyo ’ Dnata Sec puipnes tcenatsenor tos ieee ema Pras Wada dads teat abe do reve aryraye Stal-Maxi S80 4848-A-O10E Screw compressors 14 UP 1994-03 ELECTRIC DRIVE MOTORS Al screw compressor units are adapted for standard: motors in 2-pole version, ‘A motor dimensional sketch must always be en- closed with the order specification, For units of type SVA, SVB and SVR Wt is recom- mended that the motor terminal box is mounted on op of the motor. fa side-mounted terminal box is selected, it should be mounted as a first choice on the left side of the motor as seen towards the shaft end of the motor. If terminal box mounted on the right side is selected, the dimensions of the box must be checked against tho dimensions of tha unit in order to avoid any collision with the oil cooler. ‘The cable inlet on the terminal box should always point upwards when the box is mounted an the side of the motor. The motor should be selacted on the basis of the compressor power consumption. Remember that more power fs consumed during a defrosiing cycle or cooling process (high evaporating temperature) than al normal working conditions, ‘The output reting of the motor should be at least 54% higher than the compressor's highest power oon- sumption. However, for compressor units equipped with the Stalectranie systam, motor output can be lr itac automatically to prevent overioeding, This means that if Stalactronic system is inslalled, the motor will not have to deliver any "excess output” Moreover, the Stalectronic system is equipped with a built-in time delay function which makes certain that the startup rate does not exceed four starts per hour. Cheok to see that the motor you have selected will permit this startup rate, For Y/D-starting, the motor starting torque must be ‘checked against that of the compressor. The diagrams on the following pagas show the com- prossor stating forque at diferent discharge pressures. ‘These compressor slatting torques can be reduced with 15% in the speed range 0-2500 rpm, # P1 (dis- charge pressure) is higher than 6 bar(a) and the pres- sure ratio P'/P2 (discharge pressure/suation pres- sure) is lower than 6. ‘The motor starting torque must be al least 10% higher than the compressor stating torque through- out the entire speed range. Note that the torque of the aolor will be reduced in proportion to the square of the vatage drop, For all units and compressor sizes, the direction of rotation of the motor must he counter-clockwise as, seen towards the shaft end of the motor.4248-A-010E Bid UP 1994-03 Starting torque (Nm) Starting torque (Ney StalMaxi $20 Screw compressors Sabroe Refrigeration $81 ‘Moment of inertia J=0,46 kgm* incl. shaft coupling 800 47 — T bp P1=20 500 |}! _ =| Pisté 400 = Po A Prete 300 Pis 200 100 — yy i 5 it © 500 t000 1500 2000 2500 3009 3500 4000 Speed (rpm) Pi =Discharge pressure, bar(a) S83 Momeni of inertia J=0,65 kgin® incl. shaft coupling 0 — : 4 700 - Pt1=20 | pot + 600 T ot: — ae Pi=i6 500 | Pr=t2, 400 = _ Piss i 300 pt ja - Piss 200 I= = PI=3.5 i Pi=25 190 a et L 1d © 500 1000 1600 2x0 2500 3600 3500 -4000 Speed (rpm) Pt=Discharge pressure, bar(a) Cece ee CECE CEE REC CEL ‘ CECT ERO CRE COE CE EE EEOC ES EE EE EEE ECE ESEy vor ar er areyrrryg yer PTIVD VPP RV DOD ay Vy DD PvE VIDaG 3 4 Stal-Maxi S80 4848-A-O10E "a Sorew compressors 3/4 Sabroe Refrigeration UP 1994-03 S85 ‘Moment of inertia J=1,06 kgm? incl shaft coupling 41100 1000 P1=20 900 = 800 P1st6 E = 10 3 Piei2 eg Pig 2 500 2 s Pies a a0 picks 200 THe, 100 eX @ 800 1000 1500 2000 2500 3000 3500 4000 P1=Discharge pressure, barfa) ‘Speed (rpm) S87 Moment of inertia J=1,68 kgm’ incl, shail coupling 1600 4 1400 - ae Pi=20 4800 pp : 4200 To | Pi=16 i 1100 - ] | E + _+ & em TH i pret2 ‘> 200 + 3 s0}-—— a Pad 2 700 2 oo LA 2 f i 7 B50 i Lt pias b 400 = >] FI-38 300 fs PIH25 200 = ‘00 4 — (EA. it 809 1000 1500 z000 2500 2600 9500 4000, Speed (rpm) P1=Discharge pressure, barfa}4848-A-010E Stai-Maxi S80 4i4 Screw compressors UP 1994-03 Sabroe Refrigeration S89 Moment of inertia P1220 Prats Piate Pte ischarge pressure, barla) © 500 1000 1500 2000 2500 3000 3600 4000 Speed (rpm) CeO CREE EEE BEER EEE EE CE LES ‘ & CERO EE EE COE E REECE EC EE CECE KEEyoyeOry rae rey VOR VOD Pr PRPO DIOP TF POPP OV ODID PrP esa ae 3 ec) = Prince sane Rpgercton Stal-Maxi S80 4848-C-005aE Screw compressors tale TP 1994-10 Sabroe Refrigeration SCREW COMPRESSORS TYPE S80 Inspection cover Suction strainer Suction inlet Capacity contro! The S80 serias of StatMaxi screw compressors Incorporates benefits based on more than 30 years of experience in designing, manufacturing and operating screw compressors. Besides the new and different appearance, there are a number of properties contributing to high efficiency, environmental qualities, high relablity and easy maintenance. The series consists of five different sizes, each individually optimized in terms of rator dimensions, thereby ensuring the best efficiency possible Swept volumes Compressor | Swept Volume | Swept Volume | Rotor Diameter | — L/D-ratio Weight Size 2o50mm | SedQrpm | _ (mim | mth) emt () tka) 881 | soi 198 | 1, Hl 875 i I st 883, P1913 212 [ P1100 S85 [seo 887, I 1300 | | i I i Other data Rotor fobs combination 547 ‘Male rotor drive, rotation clockwise ‘Angular contact bail bearings (thrust) Cylindrical roller bearings (racial) Self-shifting volume ratio, 2.6 and 4.8 Max permissible suction pressure: 10 bar abs Max permissible discharge pressure: 26 bar abs. Integrated suction titer: 6p.4848-C-005aE, Stal-Maxi S80 2f2 Screw compressors New and different Integrated suction fiter ‘Compared to conventional screw Low height compressors, the design of the S80 com- pressoris very different, as is shawn by the orientation of the rotors, the integrated suction fiter and the absence of connec- tions under the compressor, This means benefits when it comes (o installation, reliability and maintenance, The S80 also incorporates other ‘examples of new design, such as rotors with the 5+7 lobe combination and a novel esign and installation of the slide valve. No cennections undemeath Excellent efficiency ‘A notable feature is the movable econo- mizet port, which maibtains a true interme diate pressure at partial ioads, and thus increases the COP. In addition, the capacty and volume ratio controls are separated, thereby eliminating conflicts. Furthermore, each size in the series is individually optimized in terms ofthe ratio between the length and diameter of the rotors, Which ansures better overall efficiency and a broader operating range compared to conventions’ series, consisting of "iong” and "short" machines. Environmental qualities Because of numerous internal channels, and the integrated oil pump, almost al external pipes for distribution of oil and control are eliminated, Thus, the potential leakage risks are reduced to a minimum. Also important to the local environment is ‘the low sound level of the S80 compres- sors. Contributing features are the genie- rously dimensioned castings, the 547 rotor ‘obe combination in connection with a new rotor profile, ¢ novel design of the discharge por! and a muffer in the rotor housing. New design of radial cutiot intemal channels Reliability and maintenance Reliability and maintenance heve been two. vary important keywords in development of the ‘SB0 compressor, For example, with normal running conditions with ammania the life expectancy of the anti- friction bearing system Is 100.000 hours of operation, Maintenance is simplified due to faw outside ‘sonnestions and no connections under the compressor. It is possible to inspect the rators without disassembling the compressor and ail Dearing clearances are final and factory set. CECE CEM EEE CECE CE EOR ECE CHEESE PeeCE EEE ‘ c PEOCOCE OEE E CER EEE EEEyryre? yo 1 vy = DVy POH RPMI OG we m) Say one ae Sigua sy ) ,o Poteg Sabens ae Sey chau pr sibsscaed Sse y VER PV OO VOTO VIED? yay es Stal-Maxi S80 Screw compressors 7 1. 8 -pislon 2, Control valve 4848-C-020E UP 1993-17 Fig. 1 Type S80 Sial-Maxi scraw compressor HOW A SCREW COMPRESSOR OPERATES: ‘The screw comprassor oparates with distinct working phases and puit.n volume ratio. For optimum efficiency, the builtin volume ratio 2 must have a fixed relation- ship to the actual volume ratio, namely: Pivp2 = (V2IV1)". See Fig. 2. This means that the pressure in the interlobe space, PX, at the instant when it opens to the discharge port, ‘musi be the same as the comprassor's discharge pressure. Pressure PPL 4 PA (x2y" PZ Any deviation from the optimum ratio causes losses in the compressor either in the form of overcompres- slen (s8€ Fig. 3) or reverse Tlow (see Fig. 4). Inthe past, requirements calling for a wide working range (and thus widely varying pressure ratios) were met by providing different fixed pressure ratios (0). Usually three fixed pressure ratios were provided, and ‘his required three cifferent versions of a compressor. v4 V2 Volume Fig. 2 Optimum operating ratio Pressure PR 4 Pi P2 vi v2 Volume Fig. S Loss caused by oversompression4848-C-020E Stal-Maxi S80 ar Screw compressors UP 1993-11 Pressure PI PK | P24 v1 v2 Volume Fig. 4 Loss caused by reverse flow Inpeinciple, there are two ways to vary 6}, continuously and in steps, Accontinuausly variable & requires @ highly advanced contol and regulating system, Stepped regulation, can be controlled with far simplier equipment. In the Stal-Maxi S80, this regulated in two steps. Changeover between steps is contralied by a pres- sure-sensing mechanical conttol valve connected dl rectly to the compressor (lem 1 in Fig. t). Stepped reguistion reciices the efficiency within a small, int ited range somewhat compared with whal can be at- ‘tained using continuous control. See Fig. 5. Inprectice, however, this dference s tually negligive. roond 1039 5 7 9 4 13.18 9 Pr/Pz Fig. 5, Comparison betwasn the Stal-Maxi system and @ continous #: radulation Sabroe Refrigeration DESIGN Ses Fig. 6 The regulating system consists of a Sipiston (1), hydraulic unit (2) and contvol valve (3}. The -piston Is cylindrical throughout most of fs length. One of is ‘ends is designed fo match the radial discharge port used for low 3 (26) inthe rotor casing, When tis in- serted all the way it contacts the rolors with minimum Clearance to the radial discharge port used for high (4.8). ‘The spiston is mounted to the discharge end plane. This provides an unbroken sealing tace betwoen the rotor casing and the drain casing which, in tum, makes it possible to dismount the hycraulic unit and piston for inspection or service without disassembling the entire compressor. The sipiston is secured rotationally with a’ guise pin (10) and is not joined permanently to the hydraulic Unit's piston rod (6). Both end faces of the @:piston ae always acted on by the compressor's high pressure (P2), bul the side ofthe piston tht faces the rotor casing discharge por is also acted on by the pres- sure in the dischargs port, As a result, itis always pressed against the hydraulic unit's piston rod (6). The hydraulic unit (2) consists of a cylinder (4), piston (5) and a piston rod (6). The atea of the piston on ‘he indicator sido (6) is acted on ny the compressor's high pressure (P1) at high 6; (4.8) or by the compres- ‘s0F'S ow pressure (P2) at low oi (2.6) The space between the piston and the eylindar on the piston rod side (5) is always connected to low pres- sure (P2}, The piston rod (8) is sealed into the cylinder by high pressure P1 and its free end is always acted on by high pressure P1, The indicator (11) shows the position of the S:pision, The outer end of the indicator (11) acts on atmospheric pressure. When the compressor is idle, the equalizing pressure makes the tpiston to move out (812.8) The piston (8) in the coniral valve is actuated by dif ferent pressure levels emanating from the compres- :801's working chartibet. The piston has iwo pressure- sensing ends that difer In size. The larger end is actualed by an intermediate pressure (Pm) in the compressor, and the smaller is actuated by a high pressure (P1). The iniddle part of the piston is connected to the com pressor’s suction pressure. The only purpose of the spring (2) is 10 move the piston when the compressor is idle fo the end posttion thet provides unloaded stari- ing. EECEEE EO EEE Cee GE a PEELE ECE OELEE CEE CEC ELE PEER ET EEEE EE EE EE GE2 Sabroe Refrigeration Stai-Maxi S80 Sorew compressors 4848-C-020E Sal? TP 1997-02 1. Sipiston 7. Cylinder 2. Hydraulle unit 8, Piston 8. Control valve 8, Spring 4, Oylinder 40. Guide pin 5. Piston 44. Indicator 6. Piston rod Fig. 64848-C-020E Stal-Maxi S80 4/7 Screw compressors va UP 1998-11 Sabroe Refrigeration OPERATION Changeover levels The intermediate pressure favel and the piston arses. have besn selected to provide a changeover level (P1IP2) of 5.0, See Figs. 6 and 7. Pi P2 Fig. 7 Change over level between: low {L) and bigh (H} 31 ‘The system's characteristics also provide a slight hysteresis effect that prevents the piston (and thus the valve body) from fluctuating. Low PuP2 -> low intermediate pressure Pm is a function of inet pressure P2, and also of the physica! position af the intermnedi= ate pressure aullet in the working chamber. See Fig, 8. Unavoidable internal leakage also affects the inier- mediate pressure, but to a very iimited extent. It is this slight internal leakage thai causes the aforesaid hys- teresis. This minimized and controlted internal leak- age thus has a postive attect A low P1/P2 thus provides a low P1/Pm and vice versa. Pressure Pq vi vM v2 Volume Fig, 8 Intermediate pressure thal depends on inlet pressure CREREOE EER LEO EEL ‘ wt CHEERS EEE CECE ELE Se OEE COKE ‘ COREE EEEPVP THEY TH PVE POH VVIF OYA OOO IHEP OPP PHOHOO HY EDF VIFDH OID? Sabroe Refrigeration StalMaxi S80 4848-C-020E Screw compressors Sal? TP 1997-02 Fig. 9 shows the piston at its low position. ‘The free end of the piston rod (6) Is acted on by P1, and as-a result the oil in this space is drained via the intormediate pressure Pr acts on the piston’s (@} aoe tel valve to the compressors inlet pressure bet ean ato Oe acest The sspiton (1) s pressed ouward together with that exerted by high pressure P1 on the smaller area wheeler Ae crccut te pslon moves othe po- He ton rod To ow dipostlon By the pressura in the stion shown in the illustration. The space beiween the indicator side of the piston (5) and the cylinder (4) is now connected fo the compressor's low pressure P2. compressor’s discharge por fetes sneer las Vie2.B ee hep ot ‘ti-piston Hygraulic unit, 8. Piston Control valve 9. Spring Cylinder 10, Guide pin Piston 11. Indicator Piston rod Fig. 8. Low 5,4848-C-020E 6al7 TP 1997-02 ge High P1/P2 + high & Ata high P1/P2 (and thus also a high P4/Pm), the force At this piston (9) position, a link opens between high exerted on the smaller piston area exceeds the force _pressure and the indicator side of the hydraulic piston exer‘ed on the farger area on which the intermediate (5), Moreover. the piston (2) prasses the &ipiston to pressure acts, Stal-Maxi S80 Screw compressors the high 2; position via the piston rod (6). ‘AS 2 result, the piston moves to the position shown in Fig. 19. This change in the direction of the resultant force is atibutable to the differance between high pressure P1 and intermediate pressure Pi. ‘Bepiston Hydraulic unit Control valve Cylinder Piston Piston rod Radiat alaenenge pore 8, 3. 10, Wn Cylinder Piston Spring Guide pin Indicator Fig. 10. High 3 POEL EC OREO EEE EERCEEEE EERE REE REE RERE EEC EE LEER ERE EEE CE EE KSyr FHV IRHD?D roa POVIFVIVIVPPIOOIVG yy PVD yYP>OVPVVVG 7 Sabroe Refrigeration Stopping and starting ‘Whon the compressor stops, the spring (10) moves the piston (8) to the position that provides & low 6 ‘This helps to provide unfoading the next time the compressor is started, V1 = Optimum discharge, full load V2= Suction voiym, fulllead Va = Optimum discharge, patial load V4-= Suction volume, partial Inad Pressure A a). pwz |_| PMa P2 vt wl v2 v3 Ve Yejume Fig. 14 PV diagram, full load and partial ioad Fig, 11 shows that if optimum V1/V2 is provided at {ull oad, discharge opening must be delayed al partial load in ordar to provide a corresponding optimum qvsiva}. ‘The dlagram shows that when the compressor is operating at partial load, the intermediate pressure is affected in the seme Way as iis by an increased pressure ratio P4/P2, That isto say, when P1/Pr in- creases, the control system responds as shown in Fig. 10. ‘Tho builtin volume ratio thus adapts itself automatically to the prevailing operating conditions, and parial-oad efficiency is considerably higher than for a fived dis- charge port. StalMaxi S80 Screw compressors 4848-C-020E WH UP 1993-11da yrP PAID PPP VIIFVIFPO OPO PAHOA FOPIAD yPyYVIIIED yr? ’ eee Po Ste pay er ae “ig cocumart rs gn epi wand a TMS Uae Sea ene Stal-Maxi S80 4848-C-030E Screw compressors V2 UP 1993-12 Sabroe Refrigeration GENERAL, Intype S80 screw compressors, capacity is controlled using a slide valve located obliquely above the male rolor’s bore. When the axially rnovable slide is all the way in (towards the inlat side), the compressor opar- ates al maximum capacity. See Fig.1 Fig. 1 Location of position indicator at maximum capacity when the slide moves towards the discharge side, part of the gas flows back to the suction side, without being compressed, via a recirculation duct in the rotor ceasing. When the slide has moved as far as possible away from the suction sida, the compressor operates al minimum capacity. See Fig. 2 Piston Connected fo part A Connected to port B duct Compressor S81 S83 S85 S87 S89 le 220 260 300 340 380 Fig. 2. Location of position indicator at minimum capacity Capacity is increased and decreased steplesely between 100% and 10-20%. The ratio between slide position and capacity is linear. OPERATION The slide is connected to a hydraulic piston via a piston rod. A second piston rod Is also connected to the hy- draulc piston, and fs purpose is to visually indicate the slide position, The piston (double acting design} moves axially in response to the difference between the oil pump pressure and the suction pressure. Moreover, a epring that acts on the hydraulic piston makes il possible to unload the compressor when stopping. The piston is controlled by means of a four way solenoid valve. Recirculation Slide valve Visual position indicator Service valve Fig. 3 Capacity position sensor4848-C-030E Stal-Maxi S80 2b/2 Screw compressors TP 1996-12 Increase Seefig. 4 Solenoid valve SV15 is energized {upper solenoid, Ag. 7). Pressurized oil from the pump flows via conn. P10 conn. B on the solancid valve and continues to the side ‘ofthe hycraulie eyinder which is towards the slide valve, Oils drained trom the side of the hydraulic oylinder \which is towards the spring housing via conn, A to conn, Ton the solenoid valve and then to sustion pressure, Decrease Soo Fig. 5 Solencid valve SV16 is energized (lower solenoid, Fig. 7) Pressurized ol from the pump flows via conn. P fo conn, ‘Aon the solenoid valve and continues to the side of the hydraulic cyinder whic is towards the spring housing. Cll is drained from the side of the hydraulic cyfinder which is towards the slide valve via conn, Be cons. T on the solenoid valve and then to suction pressure Steady stata See Fig. 6 Both solenoids are de-energized. Both sides of the hydraulic cylindar are blacked. Unloaded starting ‘When the compressor is stopped, the capacity contro! piston must be returned to its minimum capacity posi- {ion before restarting can lake place. If this were nol, {he starting torque would be too high Consequently, solenoid SV16 (lower solenoid} must be energized for at east ten minutes atter stop, during which time the spring presses the hycraulic piston 10 its minimum position, In order fo reduce the unloading time on $85, §87 and S89, a check valve has been fitted to drain enclosed oil from the space around the capacity position sensor to the outlet conn. ‘See Manual Sheet “List of Parts" Service ‘When servicing, the hyciraulic oyfindar must be drained cf the enclosed pressurized all, Move the slide vaive to its minimum position, Energize SV16 whila the com pressor is being evacuated, If the slide valve has nat Teached its minimum position, energize SV15 as well, The rest ofthe oil in the spring housing is drained off via the service valve, See Fig, 3. It the coil is out of function, the solendid valve can be forced epen by pressing the inner part of the coli NOTE: When dismounting the spring housing, the utmost care must be taken since the unloading spring is preloaded. ‘Spare parts Compiste valve Coil 240 V/60 Hz, 1921 438-4 1921 470-4 220 Vi50 Hz 120 V/60 He, 19214382 1921 470.2 110 W/50 Hz 24 W/50-60 Hz 1921 438-3 1921 470-3 Compr. Orifice, conn.P Orifice conn. T S81 1921 499-402 mm 1921 489-:3.07.5 mm 983 1921 498-402 mm 1924 432.3.a1.5mm 885 1921 499-5.02.5 mm 1921 499-4 2 mn 887 1921 499-502. mm 1921 499-4 62 mm $99 None 1921 498-6 93.5 mn 4 Onings 3924 $284 708 a9.25%1.78 4 Screws 8921 2175 335 S8V15 increase Increase Decrease Steady state Py A <] Pry »5>9 PVYHIFIII,VIFIVIFOOEFIIDD d {i cosers trot oe copes at ove »? POPPI VHP FIZ VITOR DDD “ Sta Maxi $80 Screw compressors Sabroe Refrigeration 4848-N-G70E tala TP 1995-07 LUBRICATING OILS FOR SCREW COMPRESSORS Type S80 GENERAL Lubricating oils having relatively high viscosity must be used to ensure salistactory iubrication of type $80, screw compressors. = The optimal viscosity is 20 - $0 oSt, The minimury actual viscosity is 7 cSt. (Always remember that the viscosity drops when oil is mixed with halogenated hydroearoens). In addition to the minimum viscosity requirement, the oil must = Provide the required fluidity at the lowest evaporat- ing temperature encountered in the plant. — Provide sufficient oxidation stability (the oll must be moisture-tree whan added to the system}. = Provide sufficient chemical stability wnnan used to- gether with the refrigerant in question. — Mix satisfactorily with other olls used in the system. In addition, the extents to which different refrigerants dissolve in the oil must be known, so that the oif re~ turn system will function properly. ‘The recommended oils thal fulfil these requirements appear in Table 1. Refrigerant | Discharge | Discharge temperature | temperature lower than higher than | 90°C ro NB, (R717) | A 8 Oteooier | . ree | AN) |B it cooler 81 _ jo Nig (R717) A Liquid injection | Re | c Liguid infection Oiltype A = STAL No, 3914 1021 114 for 20-ire pail STAL No, 3914 1011 £44 for 25-ltre pail STAL No, 2914 1011 164 for 25ultre pail Gil type Olltype 1) Table 2 on the next page indicates how to choose the best type of oil However, il shouki bs noted that for R22 plants using oil of types B and C, the oll may form layers in the re {rigerant receiver under certain operating conditions and at ceriain oll concentrations. Diagram 1 shows the limits at which this occurs. The cil concentrations sot jorth in the diagram must not be exceeded, This means that the oil ratum systern must balance the oil carryover go that the maximum concentration will not be exceeded. For plants where different types of refrigeration com pressors are being used in parallel with the above ‘compressors, you must make certain that uncon- trolled mixing does not take place ifthe other types of ‘compressors require another type of oll, itis evident ‘that oll mixing may occur, the following must be ob- served = Allof the oils that are used must be mixabie without causing chemical reactions. = Pesiodic viscosity checks must be carried out Type of oil Type cf oll 8 3 Oil concantration % Diagram 44848-N-O70E 22 UP 1993-06 Stal-Maxi S80 Screw compressors Sabroe Refrigeration SELECTION OF OH. TYPES ‘The minimum actuat viscosity shall be 7 cSt Max actual viscosty during operation is 100 cSt, Increasing the viscosity up to 20.4 50 cSt will influence {Always remember that the viscosity drops when the compressor bearing fife in a positive direction. oll is mixed with halogenated hydrocarbons). Table 2 Refrig- | Type ef oil srant_| temperature is atways lower than 40°C. The incoming oll teinperature (to compresscr) must not be higher than 45°C (based on 40°C discharge ges superheating}.. ‘The most trequently used alternative. Has suliciant R22. B | viscosity al condensing temperature of up to 85°C and | incoming olf temperature (to compressor) up to 60°C ' (based on BO°C discharge gas superhaating). j |, Used for condensing temperature higher than $5%C and © | incoming of ternperature to compression of up to 70°C. __ Here, thre is some risk for excessively high viscosity L. when the compressor Is started ‘To be used only in situations where the condensing When the compressor is started, the viscosity ofthe oll rust be less than 300 cSt, sand this requires that the temperatures are minimum those set farth in Table 3 Dimension heating according to the viscosity of pure undissolved oil, Tables Type of oll Ollalone a fe. | A 16 8 10 c | 33 CELE EEE EOE EEL COE KE « CECER EEE OE ER EERE CELE EE EL CES CELE E CELEyr? yyy? VRUYVPPFPIFIOD d hauaaed emo Cocreve one es sea Eee ana hs Seat mera Mat Fie bide Betiparon He drouigct mat nate cop wit ue ube commis ce these VPIVIPEYIPIVI_IODD Stal-Maxi S80 4848-N-260aE Screw compressors wt TP 1995-02. Sabroe Refrigeration came 1. GENERAL 2.7 Clean the suction filter by washing it in a water- To prevent foreign particles from the refrigerating plant _sluble dagreasant, and then rinse it clean with hot from being drawn into the compressor whers they can water. Finally, blovrit thoroughly dry and clean with cause serious damage, the suction side of the com- compressed ait pressor has been provided with a suction filer. Hold the fitter cartridge up against a light to make The suction fikor housing is an integral part ofthe certain thatthe wire meshes in efter cartridge are compressor rotor casing. comoletely clean. trot, repeal the procedure. ‘The fiter cartidge consists of stainless steel wire mesh In connection with cleaning, check to see that there to which end plates have been soldered. fre no cracks in any of the soldered joints on the fiter ‘The fiter cartridge is secured by a holder and two cartridge compression springs. The filer prevents particles se the suston titer should be mounted . with new terger than 0.05 mm from passing gaskets (6). Mount a new O-ring (6) on the cover (1) 2, SERVICE INSTRUCTIONS and fit the holder, spring and cover The suction filter should be cleaned as follows: 2.9 Dry the compressor by evacuation and open the 2.4 Shut the valvas onthe discharge end suction sides 1S YaNOS. ofthe compressor unit and equalize the pressure 10 . the low-pressure side by opening the service valve rable 1 Paris st , mounted on the suction line tar] Gunny Manecinad | ascnsion | Wess [Link] this service valve when the pressure in the compressor has dropped to the plant's evaporating pressure, 2.3 Evacuate the remaining refrigerant frem the cor pressor, 2.4 Do nol disconnect or dismourit any flanged joints, fitings, valves or the like if the pressure in the com 7 pressor exceeds atmospheric pressure, Leave @ | ieereerery valve open te relieve the pressure. oj 2 98) 2100 628 © | +! Bind tange DN so | 6851 $908 505 2.5 Empty the compressor of ollthrough the compres-— 4g [yf casket qeavsmea tao) 005 0" draining valve, 2.6 Dismount cover (1), springs {2) and holder (8) ‘The suction fiter (4 ) with gaskets (5) can then be pulled straight oul, SONS LS vray , YRrryer) > RX SS oS @ (3) o f i ah ch eas a»vaF y » -) 2 he me * BERES 7 ERERE ibe - EE ~ if ~ HEY ~ o BYERS a) Fe Stal-Maxi SV60 4848-N-555cE Screw compressor units wi TP 1995-05 Sabroe Refrigeration OIL FILTER 1. GENERAL The oll filer consists of a fiter housing wih a remov- able insert containing 3 magnet intended to separate major metallic particles, and a fier cartridge. The fitcring grade of the of fiteris 825 > 200 avcording to. 180 4572. “The pressure drop across the fier is measured using a differential pressure pressostal that tips in response toa 12 bat pressure drop. See Manuat Shest lecirical ‘equipment for the electric function: “There are two oreen and wo red LEDs on the aleciric pressostal, The green LEDs are active when the indi- caloris in operation. The rad LEDs are active when the pressure drop exceeds 1.2 bar and the temperature exoeeds 20°C. ‘When the pressure drop exceeds 1 bar, the red button is used out on the visual ciffrential pressure incicator “The filer element must then be replaced in accordance with the following sat of service instructions 2, SERVICE INSTRUCTIONS 2.1 Close the vaives before and after ihe oil fiter. 2.2 Evacuale the refrigerant from the filter housing 2.3 Drain off the oil in the oil filter through the plug in ‘the bottom. 2.4 Remove the cover by loosening the nuts and pulling cover and titer insert from the housing. 2.5 Disassemble the filter by ioosening the nul at the ‘end of the insert. 2.6 Pullthe fiter cartridge from the magnet and clean the magnet. 2:7 Glegn the filler housing fram impurities, it any. 2.8 Assemble a new filter cartridge (1). 2.9 ‘Then assemble the insert and the cover with new ‘O-rings (2. 3, 4). 2.10 Dry the fer housing by evacuation. IMPORTANT: Since the life expectancias of the components in refrigeration system depend (among other things) on system cleanliness, preventing dirt and other contarnt rants from getting into the system during instaltation and servicing is of prime importance. 3, LIST OF PARTS Hem eon T Mo nub Man lwean Designation | Article umber Juan Weight f - jw 171 | iter carridge | ses2easso25! 1 lie | 2! Oring | 8921 5282 828 2 3 | Ong | 921 8282627! 1 ring. [ 3921 $282 5311 1 | El. pressostat | 39681471025! 1 6_| Visual indicat, | 3986 1471 024 t 7 | indicat, biock = 9966 1471 023 [10 mis get NPTE Fig. 1 OllfiterVOOR RVE ,arD » yey VV, ERG ’ ) yyy year ve aay ya 9 PREVI OE ye ’ Stop valve type ASB. §143-C-48E tale TKK 1991-08 ‘STOP VALVE Type ASB. GENERAL ‘This stop elve hes Been designed to satlty high demands on adaate ably te and funetionalreislley in refrigerating plants, i sais {he tequiraments of the Swedish Aefrigeration Standards and com- plies with tne requstions enforced io most other countries, ‘Tha vals can be delivered elated in Lloyals Register of Shipping, Bot Norske Veritas, Bursa Veritas and Germanisher Lloyd. DESCRIPTION “The vals fa fll How araa and alow flow rasan, “The veive body (1) ie made of steel, 6 choice of marerial caused by fhe et that the valve Is ermal weldod into the piping ever on the inmtllatin ete, The disk (3) bas a eplacesble senting ring (4) of {ation The disk nine in 2 sleeve (221, which protects the thes of re nem fora forelgn matter and ip Sonnactod tothe stem (vie # umber of Merdened steel rlias (22), The stem is made of stainless ‘Gael with a righly polished sursee, Tha rem seal is of talon where subsequent sghuen ng may be necessary, The valve is provided with «| beled beck seal (11) of teflon, which serves to afford sealing ‘between the stom end the cover (2) ofthe valve Lody, allowing the Hem eal {2 be removes for overhauling and replacement, if rovetsry, of the paket (71 ‘Thm conaction pipes are arranged for dnect welding to nipas with Gulside diameter: 219.1 ram, The hanévihes! (18) & mede of igat Slsy. Vai cover and dixmarsiing teol for the stem seahing are raise a optional accessories, APPLICATION ‘The tale pres testes 104.6 MPs. Permissible temperaure rope when usiig refrigerant » AOC 16+ 7509C. The valve complis, ‘ith the requirements aecorcing te AD Morkbiar 10 fe may be ued for afrigocants NH, R12, AZ2, R502 ond RISBA as Wella for at, cil ae other media which 60 ret arack tet, teflon fad Klinger 0 FITTING INSTRUCTIONS ‘The valve may be ured for both flow disetions and may be intalied ther hosleonnally or vertically. When the valve body is being ‘yaldee 10 a pipe, Mange ete, tha insart must be removed, Keep tht Invert in amanner atsuring adequate protection aguas, drt and cher impacts, Take particule core with the ster, which i sent ‘ive io saetching, searing ote, When the valve body hes been fies Tvelded oF Tangsd) and. fae been ensured that welding seg, dir, Ate, hes bean moved both from the valve body self and in the Tin esging wand from, the inert may be fied, Make sure that the ser i tet for 2 Rly open valve, Position the sealing ring in the ‘over ed tighten the earewsahternatahy. Never pint the wave str, PRESSURE DROP “Te resitaras fetor for the valve it 1.9 in the case of tlow aminst the disk anc 3.0 in the case of flow with the dick (irom Ata B86 Fig, 2), The ceaiance factor is valid for an inside diamecer of 207.3, mon on connecting pans, “The flow rosicanoe can be calculatad from the following Formule: where ® = Preseue drop Nim? P- (x ¥BEP w= velocity in pipe ns 2 P= Density ofthe median kgf? = Rasisance facor of the vale BN 200 Fig. t STOCKAGE AND FORM OF DELIVERY ‘The valve is intended to be welded into ahe piping system on the Intaliation site, and wile this Is being done the Insert wil have 42 bbe temoved in order not to get Gemaged, Fer this rsson, the vale willbe dolivered in two sation. “The valve body [s Gelivered separately, ready 10 be welded on the ‘nvtllation xt, The gasket surface fs protectad by means of 2 shest Of fibieboard wien ir serewnd 20 the body ‘Tha valve ingot, complate with its seal and screw, 1b dalivecest packed Ing mated eorrugstedboard case imackec with the type (leteice, site designation and drawing number. ‘ORDERING PROCEDURE Ta ondering the waive, ear to Table 1 below, which fits the oxder numpers for valve bodes and lnsarts, Thest order qumbers must sivaysbs queted, ‘Table 1, Order numbers for ASB 200 Cianifieation fYatve housing | Inver recioty LRandNV [BOR TT5A } 1910 255.8 Unciessified — ftses 116.8 | 19108558 ev sass tisc | isioass.c ot reas iso | 1910856. Valve coer 1095 107-F : Bararng ce 88898805143-C-48E Stop vaive type ASB 2/2 Kp 1982-09 MAINTENANCE jstions ior dismanciing and reassombly in the 298. Lf the stem s2ai leaks, #t will normally suffice to tighten the sland 113). If this measure proves inadequete, the gecket sould ba changed, (1 the valve can be left open ‘mile this is being cone, open ft fully so that the back-seal fing {17) seals between the cover (2) of the valve body and the stem 19]. Otherwise, the pressure over the disk must be lowered to atmospheric before the gland ir sorewed aff, The ‘gasket (7) can then be screwed out with the dismanti tool, The latter can be struck into the gasket to provid ‘008 grip. Make Sure that thers are no scratches, scorings or the like 1 the valve stem, There faust on no account be any sharp ‘edges ar burrs on i, When fitting the gasket, make sure that It Is not seratched ‘oF scored on th inner, cylindrical part, Lubricate the gas. ket with refigerating machinery oll a minute quantity of refrigerant stem may escane. A leak detec 1 the sealing ving on the disk Is damoged, # can elther be reversed or replaced by 3 new one, While this is being dona, ‘the valve must be completely relieved of pressure, A slightly damaged seat can be improved by rubbing with 1 piece of emery cloth attached to a cylindrical, flatended block. ‘Do not expose te stem Lo caraless treatment, Never paint thevalve nem, Vale body welgbt 35 kg lsat weight 303 ‘Tabie2 List of parts {com ory. No. | Description Order number 1 | Value body 1 | 1908 1158, 2 | cover 1 | et0 8384, 3 | Dik 1 | osr0 8528 4 | Seating ring 1 | 1685 117-18 5 | Gesket 1 | 3885 966-1 8 | Retainer 1 | 1888 607.6 7 | Gasket 1 | 1888 630-13, 8 | Ring 1 | 1887 205.2 9 | stem 1 | 888 104-2 10 | Inert 1 tase x87 tt | Back wat 1 | 1988 124-1 12 | Sleeve 1 | ist08631 13 | Gland 1 | 19106541 44 | Hexagon bolt 3 | 3921 2121 48a 15 | Hexagon belt | 1236712121540 36 | Hex lockingbot | 1 | 3924-2123 595 1 | Grub serew 1 [3621 2241 362 38 | Handwheel 1 | auz1 aszt B14 39) | Cup spring 2 [goat asizs12 20° | Cup snring 2 | 39zt 9512218 25 | Cup soring 2 | 3921 9612610 2 | Router 14 | 3922 1395 035, 2a | Pine plug 1 | 3951 3153.10 Dismanting too! 1889 349.6 Memin, Tomer, 25 Fig. 2 EL EE CAEL ee i woe Ce} Lege CLECLE CEE Cee Aoce i EEL EE ERE EEE EELSPPP VERIO DE ’ yYVYVIVERIVIPVARAIIGD » Pry, 3 vy? Pore tveras Stop valve Sabroe Refrigeration 5143-C-55a£ 4 TKK 1988-12 TYPE ASC STOP VALVE DN 50 GENERAL ‘This stop valve is designed for refrigeration plants ard heal pumps. lis to be welded to st2el pipes or flanges and itjoatures the following: + Unobstructed free-flow area that ensures iow flow resistance. + Lightweight valve body that faciiates handling and welding, Replaceable seat seal on disk (closing member) Back seat seal that perrnits stem seal to be ro- placed during operation, + Stem guard that prevents dit from gatting into the stem ihreads and causing them to bind. + Adapted for ISO pipe sizes in preference group 1 Low-temperature stung box availabie as an accessory. This valve is available classified by Lloyd's Rogister of Shipping and Det Norske Veritas, On request, itis also available classifiad by other societies. DESCRIPTION ‘The valve body (1) is made of stael pipe that is ta- pered down ai one and to facilitate welding of the seat ‘connection and flared at the side-connection side. A ffange ring used to attach the insert has been welded Io the shell, The connections are machined for direct fiting to pipes of the sizes set forth in group ll in ma nual sheat 5121-C-5. ‘The disk (7) is provided with a replaceable sealing fing (2) made of tefion, This disk, which runs in a uide in the cover (6) fs joined to the stem (8) via a threaded joint. One grub screw (15) prevent the stem and disk from corning unscrewed, Added closing force is provided due to the fact that the stem threads in the cover and on the disk have different pitches. As a re- ‘ull, jess closing force is needad on the handwhsel (19). The stem is made of stainless steel having a high finish, The stem seal consists of two O-rings (47) that make the valve easy to operate, For low-iempers- ture applications, the stuifing box ean be replaced with a losv-lemparature stung box. The valve is pro Vided with a back seal seal (4) made of tefon. This back seat seal closes when the vaive is opened all the way, I{provides @ seai between the stem anc! cover. This can be very useful when (for example) the ‘Grrings in the stuffing box (2) have to be replaced. ‘Avalve cover and stern axtension are available as op- tons PRESSURE DROP The resistance coefficient for the valva is 1.5 for low against the disk (from B to A in Fig. 9) and 2.9 for flow inthe same direction as the disk {A to 8). The resist- ance coefficient is spectied for connected pipe having an inside clameter of $4.5 mm. The valve's fiow resist ance can be calculated using the foliowing formule: tpnex wr Ap = Pressure drop in Nim? w= Velocity in pipe in mis p = Medium dansity in kgm? & = Valve's resistance coefficient§143-C-55aE 24 TKK 1988-12 APPLICATION LIMITS ‘This valve has been pressure-tested at 4.6 MPa, Temparatura limits: 40°C 10 130°C for standard version (with O-rings) 60°C 10 -150°C for refrigerants and with low-tem- perature sturfing box (teflon) ‘This valve complies with the requirements set forth in AD Merkbiatt W10. lean be used with the following refrigerants: NH, R12, R22, R134, R500, R502 and 81381. It can also be used with ar, oils anc other media thal do not al- tack steal, teflon, chioroprene rubber or Kiinger Sil 4400 (gland packing) MOUNTING INSTRUCTIONS Flow can proceed either way through this valve, and it ‘can be mounted either horizontally or vertically. The insert must be removed trom the valve body before it is welded to a pipe, tlango or the fike. Tha inser mast be kept where itis protected from moisture, dirt and other impurities. Be careful of the stern. itis vulner- able to scratches and impacts, After the valve body is in place (wekled or flanged) and you have made cet- tain that all waiding spatter, cir, etc. have been re moved trom bath the valve bedy and the fines running te and from, you can mount the insert. Make cartain that the stam is set to provide a fully open valve. Fi the seeing ring in place ia the valve body and mount the insert, Tighten the screws altemately. Never paint the valve stem, Table 1 Ordering numbers Stop valve Sabroe Refrigeration STORAGE AND FORM OF DELIVERY Due fo the fact that the insert must be dismounted dur- ing welding of the vaiva body, the two are delivered separately, On delivery, the vaive body is smeared with serew Compressor lubricating oil and packed in a sturdy plas- tic bag that is sealed to prevent rusting On delivery, the inseit is also smeared with screw ‘compressor lubricating oil and packed in a sturdy sealed plastic bag. The outer shipping container con- sists of a cardboard box on which tha type, size desig nation and drawing number are marked. In edition, the box is starrped with the manufacturing date and provided wih a label reading THIS SIDE UP. HOW TO PLACE AN ORDER To order this valve, see Table 1 which presents order- ing numbers for valve bodies, inserts and accesso- rigs. Always specify these numbers in your orcier. Classfficatian Valve body | Insert sosiely i f TRandNV | 1905 7EK 5 I 205 130-4 Unclassified | 1905 118.8 ‘Accessorias — Vel | 1905 200-8 Low-temperature stuffing box 1905 120-4 Stem extension "14885 008 | Regulating cone - 79052038 | Dismounting ool ‘orlow-temp — | 4889 249-D Gland packing Pee ee eer ede < ree cee CHEE EE EE EEC ELLE we CEE ES eee EE « ‘yoxvo?d weyers PUP VIVO VIVEP PEA IVIADE PROVO VORA HED EPPO Sabroe Refrigeration MAINTENANCE Instructions for disassembling and reassembling in the event of ieakage. If the stom seal leaks, the O-rings (17) must ba re- placed. Ifthe valve can be open whit they are being replaced, open it all the way so that the back seat seal (4) provides a seal between the stem (8) and the cover (6). Ifthe vaive cannot ba opan while the O- rings are boing repkacaxi, the pressure across the disk (7) must be lowerad to atmospheric pressure before unscrewing the stuffing box (8). The O-rings can then be removed easily, and new ones canbe fied. Check io see that there are no scratches or the like ‘on the stem, There must be absolutely no sharp burrs. Make certain thal thare are no defects on the sealing sings, and be careful not to damage them while they are being inserted, Smear these rings with screw com preesor lubricating oil. It must be easy to fit the stutf- ing box with rings onto the stern and slide it down, You should have a stuffing box ready for use before starting to work. When tha valve Is open, 2 very small armour of refigarant that has been dissolved in the oll can escape. However, any leakage indication that would actuate @ leaiedetector torch (for example} will Quickly vais, Stop valve ‘Table 2 List of parts item? Name ] O07) Ordering No | 1 | Valvebooy 71 | 1905 116-A7E 2 | Sealing ring | | 1885 117-22 3 | Gasket | 1 | 1886 347-8 4 | Back seal seal 11887 207-5 5 | Gasket 3921 5213 88 8 | Cover | 1905 181-1 7 | Disk | 1905 133-4 8 | Stem | 1905 140-2 2 | Stuffing box | 1908 199-1 11810 816-4 3021 1171 283 gu2t 2120 495 921 2123 368 3923 2123870 14 | Tension pin 12 | Hexagon bolt 18 | Looking sorew ! 10 | Holder | 14 * Looking screw | 45, Grub screw | 9921 2236 966 18 | Gland packing g92t 5239 954 47 | Orting 3821 5295 719 18 Locking washer | 5921 5415 156 19 | Handwhes! | 921 e821 05 20 | Cup spring | 8921 9512 B06 OD UNN enone 21 | Cup spring 3821 9612 807 §143-C-55aE Bal4 TKK 1991-10 Iv the stuffing box fs to function well, the rubber rings must be of the correct grade and size. We recom. mend that you keep several rings in reserve for the valve. Use only genuine STAL rings made of special symthetic rubber. If the disk sealing ring (2) Is dam- ‘aged, it can be tumec over or replaced with a new ‘one. in suich case, all pressure trust be released irom the valve before the insert Is removed. A lightly dam aged soat can be Improved by rubbing it with emery cloth stretched across the flal face of a cylindbica’ rub- bing bieck. ‘Always treat the stem gently, Never paint the stem, Prascure saatle| maintained oniy5143-C-55aE Stop vaive 4ala TKK 1989-02 Sabroe Refrigeration 960; [so] 2531 | e603 365 Fig. 4, Valve wath stem extension Fig. 3 Dimensional drawing a —T It Hea 310 life? Fig. Valve with valve cover ELEC CECE CEE CAEL CEE EOE CELE CE EERCER EE EEE EERSE EEK ECERE RE CECErr? + verre VR EVV PPV PRIAD “he carer ut [tate imperied i ati pany nor be uate Ine | Hl 4 1 y rPrOVIRVD VERE, IVP PIVG 5143-C-15kE 18 PGS 1995-10 STOP VALVES Type AVA5-20 GENERAL ‘The dasign of these valves is based on many year's experience, the aim being to provide an economical valve which could take the place of the earlier types §-500:A7-18 and S-500:B7-15. Besides the valves have bean provid with a sealing cover. By utilizing smodem manufacturing methods, a uniform, high qual- ity is obtained at a low price. The valves are made for connection to steel tubes. They are made of steel,and the valve body is surface-Ireated, The vaive slem seal is made of teflon, cover. Cover for the valve stem is delivered as standard, APPLICATIONS ‘The valves are designed for working pressures of up 10.3.5 MP2 and for temperatures between +150 and 70°C, They are suitable for all of the currently known refrigerants. ‘At high pressures and moderate temperatures, they ate also suitable for other mediums, that do not attack the vaive material, such as air, water, light hydraulic oils, certain vegetable oils, ethylene, etc ‘The valves should not ha mounted with the stern down order number, e.g. Valve 1885 411-E, Handwhes! 321 8822 801 WELDING SOME DISTINGUISHING FEATURES wards. fgg Robust construction SEPE Vole stomof stainless ster INTERCHANGEABILITY AND ORDER PROCEDURE E228 The stem sealing is designed so that the sliding sur- ‘The AVA-vaives are fully interchangeable for the ear- a t face of the stem always is protected against external ligr valves §-500:A and S-500:B concerning installa- E 5 damage. On the bigger valves, which ae intended! for tion dimensions and connections Bric 4 welding, the gasket is not fitted. The gasket is delivered £3 together with the valve on the stem under the valve: When ordering a valve with a handwheel, state the 3 i 4 i “The threads of the valve stem are protecied as far as. possible from dirt and impurities from the pipe system. ‘The stem threads have a very fine pitch, facitating fiowadjusiment. The bigger valves are also provided with a regulating cone. Handwheal and disassembly tools are obtainable as accessarias. Figure 1. When AVA 15-2 and AVA 20-2 are welded on the instalation site, the tation gasket must be removed. ‘When fiting, the steel washer must be placed under the teflon gasket. Coun, A Conn.B Figure 2. AVAS and 7o So zx a g 2 oe Table |, Techical data 2 # vawwe | order — | Flow | intended Friction Type | number | aia | tor pon Typeot | factor Connection pans (not melded inthe valve) AYA ime | dlmeneton | oonnection tip | ok 12 | Henowneet ter | Dy: amt alos Gonnestion A Connection & : : CT Feme Tea A ee gp fwenete [ae [aos ers ters| | samt gost ar pz [tees 411-8 |" 6a @ |fermie az | sos las {ors 8 | -aos1 g051 a7 | “3957 s00: 810 | zea [tgs 410-6 |" e8 g [VaNeTF | a2 | 103 [27s | ars 8 31953 3081 81D ea frais a5] & hen jos 24 |e) S| “saps 9001 nos = 2 2 [1886 [ost & [femue nos | 24 | 2a g 3951 3081 608 | 9951 5001 #96. 3 625 [1865 40 F VONPTE 3 | 26 | 24 ‘3951 3081 608 J] S 11 [ase 620-6 219/75 |Ferrute coupling | asieo | va | 40 | a _|1a85 887-4 3951 3091 621 | 3951 gout azi | 3953 3997 621 = qo. [1686 620-F tara Weld 3.020 | tay | ao | ao [18859874 | Welding connection to pipes | Welding connection te pives 8 21h, 3560 | 153 Eee Bextra BANPIF Taso | iar} «0 | xa 048 TOT BE0-1/ 80 g40-D | aus avec | oe [sr a7 |you7 470007179 687 F7Et| age 0-12 Tas 179-1 oe sane ws 1687 682] on0 aro [etn 6-8 Kw. © 1 yy Fave aFentecoig ues BSE Sinner vA EB MAINTENANCE, Directions for disassembling of AVA 15 and 20 Always be carefu: when dismantling a gasket, The Ifthe stem seal leaks, iis normally sufficient to tighten washer may be missing (because of improper mouint- the gland (4). Il this measure proves inadequate, the ing} or positioned on the wrong site of the gasket. It gasket (5) should be changed. Ifthe valve canbe left such is the case, the back seal can come ioose, and open while this is baing done, open il fully so thet the this will result in refrigerant |eakage. if this oours, you slem (2) seals against the back seal (6). must immediately stop screwing olf the gasket If not, the pressure in the valve must be lowered to Knock it off the stem using a suilable screw driver and atmospheric before the gland is screwed off. The gas-_pick out the pieces, Before mounting a new gasket (5) ket can then be screwed out vith the disassembly it should be oiled wah refrigerating machinery cil. tool, The toot should be struck into the gasket tosecure AVA Sand 7, These valves are not lo be disassembled. aa good orp. ‘The oompiele valve must bo changed,yrPvVHVD ? yr > PYITVIVPFIVA PRO RARDD “Te docuert uot nt spine ino ou 1 ’ VOPVIP DATTA IVG yr 1 Safety valve type AZB 40 5172-C-52aE daa Sabroe Refrigeration TPS 1997-10 SAFETY VALVE TYPE AZB 40 GENERAL This safety valve is of a simple and reliabie design. ‘The standard opening prassures are in accordance with the requirements of the Swedish Refrigeration Code and the Swerdish Pressure Vessel Cotle. See also manual sheet §17-N-1E. DESCRIPTION ‘The valve is of the so-called high-liting type, implying that ihe vaive disk is fitted with a sacondary pressure surface, so that full opaning is attained as soon as the preset opening pressure is reached. The valve Is set to opan at the pressures specified in Table 1. The valve is corapietaly leakproof at pressures specitiod in ‘Table 1 under sealing pressure. The valve is totally enclosed and is provided with & connection for a blow-off line. All parts age of black finished steel, except for the: valve disk and stern which are made of stainless steel ‘The valve seal is made of reinforaed PTFE. i Fo Broseniied Seb The minimara throughput area is 14 c1n?. APPLICATIONS ‘The valve applications are evident from Tables 2 and 3. Temperature range -00 10 +120°C. ‘The valve can be used for all media which do not atlsck black finished steel or PTFE Eeaees FITTING INSTRUCTIONS Connection A fits against welding flange 3951 3318 +804 for version A up fo and including F. Gonnoction A fits against DIN-lange 3951 3345 402 for versions G end H. For iting of two valves, special valve racks are avall- able for weicing into the pressure conriection, See manual sheet 517-N-1E. The safety valve must be con-nected abave the liquid jevel in the vessel. The valve seaiing must not be broken. FORM OF DELIVERY ‘The valve is delivered adjusted anci sealed. Gonnec- tion B is fitted with a counter tange (STAL or DIN}, Weight: 18.8 kg Pa = gauge 1 MPa = 10 kp/em?