Sabroe Refrigeration A/S

Instruction Manual for
Reciprocating Compressor
97.07
0171-230-EN
BFO 3 - 4 - 5
99.05
Specification for
BFO 3 Ć 4 Ć 5
Piston compressor type BFO may be fur- manual even if they may not be part of your
nished with various equipment depending on particular unit.
function and requirements. In the following table the (x) indicates, which
of these variants are found on the unit as in-
Some of these variants are described in this dicated below.
Compressor type
Designation
Serial number
Refrigerant R717 ❑ R22 ❏ R134a ❏ _____ ❏
UNISAB II control system
Control system
Analogue control system
Air cooling
Compressor
cooling
Water cooling (top covers)
Drive type V-belts
Explosion-proof execution
Oil pump drive Gear-wheel drive
Equipment for parallel operation
Compressor used for air conditioning ( KP1 regulated)
0171-231-EN 1
Preface
The aim of this instruction manual is to this instruction manual to ensure reliable and
provide the operators with a thorough efficient operation of the plant as SABROE is
knowledge of the compressor and the unit, at unable to provide a guarantee against
the same time providing information about: damage occurring during the warranty period
where this is attributable to incorrect
S the function and maintenance of the
operation.
individual components;
S service schedules; To prevent accidents during dismantling and

S procedure for dismantling and assembly of compressors and components,
reassembling of the compressor. these should only be carried out by
authorized personnel.
The instruction manual also draws attention
96.06
to typical sources of errors which may occur
The contents of this instruction manual must
during operations. It states their cause and
not be copied or passed on to any
explains what should be done to rectify them.
0171-500-EN
unauthorized person without Sabroe’s
It is imperative that the operators familiarize permission.
themselves thoroughly with the contents of
In the space below you can enter the name and address of your local SABROE
REPRESENTATIVE :
SABROE REFRIGERATION A/S
P.O. Box 1810, DK–8270 Højbjerg Phone: +45 86 27 12 66

Chr. X’s Vej 201, Århus, Denmark Telefax: +45 86 27 44 74
2 0171-702-EN
Table of Contents
Specification for BFO 3 - 4 - 5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

Preface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Table of Contents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
First Aid for accidents with Ammonia . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
First aid for accidents with HFC/HCFC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Protecting the environment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Description of compressor BFO 3 - 4 - 5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Handling of the compressor, areas of application, safety equipment etc. . . . . . . . . . . . . . 13
Vibration data for compressors - all types . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Compressor data for reciprocating compressors BFO 3 - 4 - 5 . . . . . . . . . . . . . . . . . . . . . . 17
Operating limits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
R717 Operating limits for BFO 3-4-5 compressors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
R22 Operating limits for BFO 3-4-5 compressors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
R134a Operating limits for BFO 3-4-5 compressors . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
General operating instructions for BFO 3 - 4 - 5 reciprocating compressors . . . . . . . . . . 21
Starting up compressor and plant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Stopping and starting-up compressor during a short period of standstill . . . . . . . . . . . 21
Stopping plant for brief periods (until 2-3 days) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Stopping plant for lengthy periods (more than 2-3 days) . . . . . . . . . . . . . . . . . . . . . . . . 22
Automatic plants . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Pressure testing refrigeration plant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Pumping down refrigeration plant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Operating log . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Servicing the reciprocating compressor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Removing refrigerant from compressor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Lubricating oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Lubricating oil requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
General rules for use of lubricating oil in refrigeration compressors . . . . . . . . . . . . . . . 30
Instructions for choosing lubricating oil for refrigeration compressors . . . . . . . . . . . . . 30
Charging refrigeration compressor with lubricating oil . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Changing oil in refrigeration compressor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Charging the compressor with oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
Assessing the oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
Visual assessment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
Analytical evaluation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
Setting of pressures for SABROE compressor BFO 3 - 4 - 5 . . . . . . . . . . . . . . . . . . . . . . . 36
Expected discharge gas temperatures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
Servicing the refrigeration plant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
Maintenance of BFO reciprocating compressor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
1. The compressor is operational . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
0171-231-EN 3
2. The compressor is inoperative . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
Top covers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
Valve intermediate plate incl. suction and discharge valves . . . . . . . . . . . . . . . . . . . . . . 42
Connecting rod . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
Shaft seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
Crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
Main bearings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
Compressor lubricating system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
Oil pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
Oil filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
Suction filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
Stop valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
Capacity regulation for compressor BFO 4 and BFO 5 . . . . . . . . . . . . . . . . . . . . . . . . . . 52
Heating rods for oil heating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
Pressure gauges . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
Torque moments for screws and bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
Refrigeration Plant Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
Operational reliability . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
Pumping down the refrigeration plant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
Dismantling plant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
Tightness testing and pump-down of refrigeration plant . . . . . . . . . . . . . . . . . . . . . . . . . 60
Trouble-shooting on the Reciprocating Compressor Plant . . . . . . . . . . . . . . . . . . . . . . . . . . 61
Remedying malfunctions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
Selecting lubricating oil for SABROE compressors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
Alignment of unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102
Installation on vibration dampers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103
V-belt drive for BFO reciprocating compressors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104
Mounting of V-belts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105
Connections on BFO 3 - 4 - 5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106
Table on connections to BFO 3 - 4 - 5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107
Cooling of reciprocating compressor BFO 3 - 4 - 5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108
Water cooling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108
Air cooling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108
Ordering Spare Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109
Spare parts drawing for BFO 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0661-480
List of parts for BFO 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0661-486
Spare part list for BFO 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0661-489
Piping diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Order specific
Special wiring diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Order specific
Dimension sketch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Order specific
Cooling water diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Order specific
Foundation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Order specific
Vibration dampers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Order specific
Spare parts and tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Order specific
Diverse . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Order specific
4 0171-231-EN
First Aid for accidents with Ammonia
(Chemical formula: NH3 - refrigerant no.: R717)
General Inhalation
Ammonia is not a cumulative poison. It has a 1. Move affected personnel into fresh air im-
distinctive, pungent odour that even at very mediately, and loosen clothing restricting
low, harmless concentrations is detectable by breathing.
most persons. Since ammonia is self-alarm-
ing, it serves at its own warning agent, so 2. Call a doctor/ambulance with oxygen
that no person will voluntarily remain in con- equipment immediately
centrations which are hazardous. Since am-
monia is lighter than air, adequate ventilation 3. Keep the patient still and warmly wrapped
is the best means of preventing an accu- in blankets.
mulation.
4. If mouth and throat are burnt (freeze or
Experience has shown that ammonia is ex-
96.01
acid burn), let the conscious patient drink

tremely hard to ignite and under normal water, taking small mouthfuls.
conditions is a very stable compound. Under
extremely high, though limited concentra- 5. If conscious and the mouth is not burnt,
0170-008-EN
tions, ammonia can form ignitable mixtures give hot, sweet tea or coffee (never feed
with air and oxygen, and should be treated an unconscious person).
with respect.
6. Oxygen may be administered, but only
Basic rules for first aid when authorized by a doctor.
1. Call a doctor immediately.
7. If breathing fails, apply artificial respira-
2. Be prepared: Keep an irrigation bottle tion.
available, containing a sterile isotonic
(0.9%) NaCl-solution (salt water).
Eye injuries from liquid splashes or
3. A shower bath or water tank should be concentrated vapour
available near all bulk installations with
ammonia. 1. Force the eyelids open and rinse eyes im-
mediately for at least 30 minutes with the
4. When applying first aid, the persons as- salt water solution just mentioned
sisting should be duly protected to avoid
further injury. 2. Call a doctor immediately.
0178-225-EN 5
Skin burns from liquid splashes or 2. Call a doctor immediately.
concentrated vapour
1. Wash immediately with large quantities of 3. After washing, apply wet compresses
water and continue for at least 15 minutes, (wetted with a sterile isotonic (0.9%)
removing contaminated clothing carefully NaCl-solution (salt water)) to affected
while washing. areas until medical advice is available.
No plant can ever be said to be too safe.

Safety is a way of life.
6 0178-225-EN
First aid for accidents with HFC/HCFC
Refrigerant no.: R134a – R404A - R410A - R505A - R507 - R22, etc
General Inhalation
HFC/HCFC form colourless and invisible 1. Move affected person into fresh air im-
gasses which are heavier than air and smell mediately. Keep the patient still and warm
faintly of chloroform at high concentrations and loosen clothing restricting breathing.
only. They are non-toxic, non-inflammable, 2. If unconscious, call a doctor/ambulance
non-explosive and non-corrosive under nor- with oxygen equipment immediately.
mal operating conditions. When heated to
above approx. 300°C they break down into 3. Give artificial respiration until a doctor au-
toxic, acid gas components, which are thorizes other treatment.
strongly irritating and aggessive to nose,
eyes and skin and generally corrosive. Be- Eye injuries
sides the obvious risk of unnoticeable, heavy 1. Force eyelids open and rinse with a sterile
gases displacing the atmospheric oxygen, isotonic (0.9%) NaCl-solution (salt water)
inhalation of larger concentrations may have or pure running water continuously for 30
an accumulating, anaesthetic effect which minutes.
may not be immediately apparent. 24 hours
2. Contact a doctor, or get the patient to a
medical observation is, therefore, recom-
hospital immediately for medical advice.
mended.
Skin injuries – Freeze burns
Basic rules for first aid 1. Wash immediately with large quantities of
luke warm water to reheat the skin.
1. When moving affected persons from low- Continue for at least 15 minutes, removing
lying or poorly ventilated rooms where contaminated clothing carefully while
high gas concentrations are suspected, washing.
the rescuer must be wearing a lifeline, and
be under continuous observation from an 2. Treat exactly like heat burns and seek
assistant outside the room. medical advice.
3. Avoid direct contact with contaminated oil/

2. Adrenalin or similar heart stimuli must not refrigerant mixtures from electrically burnt-
be used. out hermetic compressors.
No plant can ever be said to be too safe.

Safety is a way of life.
0178-225-EN 7
Protecting the environment
Increasing industrialisation threatens our en- concentrations of refrigerant vapours are in-
vironment. It is therefore absolutely impera- haled they attack the human nerve system.
tive that we protect nature against pollution.
When halogenated gasses come into contact
with open flame or hot surfaces (over approx.
To this end, many countries have passed le-
300°C) they decompose to produce poiso-
gislation in an effort to reduce pollution and
nous chemicals, which have a very pungent
preserve the environment. These laws apply
odour, warning you of their presence.
to all fields of industry, including refrigeration,
and must be complied with. In high concentrations, R717 causes respira-
tory problems, and when ammonia vapour
Be especially careful with the following sub- and air mix 15 to 28 vol. %, the combination
stances: is explosive and can be ignited by an electric
96.01
spark or open flame.
S refrigerants
Oil vapour in the ammonia vapour increases
0170-009-EN
S cooling media (brines etc)
this risk significantly as the point of ignition
S lubricating oils.
falls below that of the mixture ratio stated.
Refrigerants usually have a natural boiling
Usually the strong smell of ammonia will
point which lies a good deal below 0°C. This
give ample warning of its presence before
means that liquid refrigerants can be extre-
concentrations become dangerous.
mely harmful if they come into contact with
skin or eyes. The following table shows the values for refri-
gerant content in air, measured in volume %.
High concentrations of refrigerant vapours Certain countries may, however, have an offi-
are suffocating when they displace air; if high cial limit which differs from those stated.
Halogenated refrigerants Ammonia
HFC HCFC
R134a R404A R407C R410A R507 R22 R717
Unit
TWA
Time weighted ave- vol.% 0,1 0,1 0,1 0,1 0,1 0,1 0,005
rage during a week
Warning smell vol.% 0,2 0,002
8 0178-225-EN
Further comments on refrigerants: Halogenated refrigerants must never be
S If released to the atmosphere, haloge- mixed. Nor must R717 ever be mixed with
nated refrigerants of the type HCFC halogenated refrigerants.
(e.g. R22) may cause a depletion of the
ozone layer in the stratosphere. The Purging a refrigeration plant
ozone layer protects the earth from the If it is necessary to purge air from a refrige-
ultraviolet rays of the sun. Refrigerants of ration plant, make sure you observe the follo-
the types HFC and HCFC are greenhouse wing:
gases with contribute to an intensification
of the greenhouse effect. They must, S Refrigerants must not be released to the
therefore, never be released to the atmo- atmosphere.
sphere. Use a separate compressor to
draw the refrigerant into the plant con- S When purging an R717 plant, use an ap-
denser/receiver or into separate refriger- proved air purger. The purged air must
ant cylinders. pass through an open container of water
so that any R717 refrigerant remaining
S Most halogenated refrigerants are mis- can be absorbed. The water mixture must
cible with oil. Oil drained from a refrigera- be sent to an authorized incinerating plant.
tion plant will often contain significant
amounts of refrigerant. Therefore, reduce S Halogenated refrigerants can not be ab-
the pressure in the vessel or compressor sorbed by water. An approved air purger
as much as possible before draining the must be fitted to the plant. This must be
oil. checked regularly using a leak detector.
S Ammonia is easily absorbed by water:

At 15°C, 1 litre of water can
Cooling media
absorb approx. 0,5 kg liquid Salt solutions (brines) of calcium chloride
ammonia (or approx. 700 litres (CaCl2) or sodium chloride (NaCl) are often
ammonia vapour). used.
S Even small amounts of ammonia in water In recent years alcohol, glycol and halogena-
(2-5 mg per litre) are enough to wreak ted compounds have been used in the brine
havoc with marine life if allowed to pollute production.
waterways and lakes.
In general, all brines must be considered as
S As ammonia is alkaline it will damage
harmful to nature and must be used with
plant life if released to the atmosphere in
caution. Be very careful when charging or
large quantities.
purging a refrigeration plant.
Refrigerant evacuated from a refrigerant
plant shall be charged into refrigerant cylin- Never empty brines down a sewer or into
ders intended for this specific refrigerant. the environment.
If the refrigerant is not to be reused, return it The brine must be collected in suitable con-
to the supplier or to an authorized incinerat- tainers, clearly marked with the contents, and
ing plant. sent to an approved incinerating plant.
0178-225-EN 9
Lubricating oils – alkyl benzene-based synthetic oil
Refrigeration compressors are lubricated by – polyalphaolefine-based synthetic oil

one of the following oil types, depending on
the refrigerant, plant type and operating con- – glycol-based synthetic oil.
ditions. When you change the oil in the compressor
or drain oil from the refrigeration plant’s ves-
– mineral oil sels, always collect the used oil in containers
marked “waste oil” and send them to an ap-
– semi-synthetic oil proved incinerating plant.
Note
This instruction provides only general information. The owner of the refrigeration
plant is responsible for ensuring that all by-laws are complied with.
10 0178-225-EN
Description of compressor
BFO 3 Ć 4 Ć 5
Fig. 1
97.02
T0177164_0 V1
0171-232-EN
The BFO compressor type is a multi-cylinder The intermediate plate is mounted between
reciprocating compressor comprising three top cover and compressor frame and is easy
sizes: BFO 3 with 2 cylinders and BFO 4 and to remove once the top cover has been dis-
5 with 4 cylinders. The BFO compressor is mantled.
specifically designed for refrigerants from the
The crankshaft is fitted in slide bearings, ab-
halocarbonic group, the HFC/HCFCs, but
sorbind both radial and axial forces. Oil pres-
ammonia may also be used. The type of re-
sure to the bearings are supplied from the
frigerant used in your particular unit can be
built-in gear-wheel oil pump of the compres-
seen from p. 1 of this manual. The above fig.
sor.
1 illustrates a 4-cylinder compressor.
At the shaft end the crankshaft is equipped
In the standard design the BFO compressors with a balanced shaft seal of the slide ring
are equipped with both suction and discharge type. It consists of a spring-loaded carbon
stop valve, built-in suction filters, oil pumps, ring rotating with the crankshaft and sealing
slide bearings and compressor belt pulley for against the shaft seal cover.
V-belt drive.
The 4-cylinder compressors, BFO 4 and BFO
5, are available with capacity regulation
The pistons work in cylinder linings, posi-
stages ranging from 100% down to 50%.
tioned in the compressor block with two cylin-
ders under each top cover. The compressor Capacity regulation is controlled by means of
valves are the so-called plate valves fitted on a solenoid valve, fitted in a special top cover
an intermediate plate. purpose-made for capacity regulation.
0171-231-EN 11
The compressor type can be determined by Similarly, the nameplate indicates the com-
the nameplate, located on the end face of the pressor’s serial number, which is also stamp-
compressor, facing away from the coupling/ ed into the compressor housing near the suc-
belt drive. The following illustration shows a tion chambers.
SABROE nameplate.
Whenever contacting SABROE about the
compressor, its serial number should be
SABROE stated.
AARHUS DENMARK
Type Refrigerant
Shop no Year
Max. speed r.p.m.
Swept volume m3/h
Working pressure bar
Test pressure bar
T0177093_2
12 0171-231-EN
Handling of the compressor, areas of application,
safety equipment etc.
Direction of rotation clearly marked with red paint. The weight of

In order to reduce the noise level from the the unit is stated on the package as well as in
electric motors these are often executed with the shipping documents.
specially shaped fan wings, thus determining During transportation and handling care
a particular direction of rotation. should be taken not to damage any of the
In case you yourself order a motor you components, pipe or wiring connections.
should take into consideration whether the Areas of application of the recipro-
motor is intended for direct coupling or for
cating compressors
belt drive of the compressor.
Compressor types:
The direction of rotation of the compressor BFO 3-4-5
for compressors CMO-TCMO and SMC- CMO-TCMO,
97.12
TSMC is indicated by an arrow cast into the SMC 100-TSMC 100 Mk3, S, L, E
compressor cover, near the shaft seal. SMC 180-TSMC 180,
On the BFO compressors the direction of HPO-HPC
0170-119-EN
rotation is not indicated by an arrow but is In view of preventing an unintended applica-

standard as illustrated by the following tion of the compressor, which could cause
sketch: injuries to the operating staff or lead to tech-
nical damage, the compressors may only be
applied for the following purposes:
The compressor may ONLY be used:

S As a refrigeration compressor with a num-
ber of revolutions and with operating limits
Seen towards shaft end
as indicated in this manual or according to
a written agreement with SABROE.
Handling of compressor and unit
S With the following refrigerants:
For lifting of the compressor the large models
R717 – R221 – R134a1 – R404A1 –
are equipped with a threaded hole for mount-
R410A1 – R5071 – R6001 – R600A1 –
ing of the lifting eye. As to the weight of the
R2901 – LPG1
compressor, see table on compressor data. 1) Exempted are the following compres-
Note: sors:
SMC-TSMC 100 E (only R717)
The compressor block alone may be lifted HPO and HPC (only R717 and R410A))
in the lifting eye. The same applies to the All other types of gas may only be
motor. used following a written approval from
SABROE.
The unit is lifted by catching the lifting eyes
welded onto the unit frame. These have been S As a heat pump:
0171-487-EN 13
– BFO 3-4-5 manual handle, to which there is free ac-
cess.
CMO - TCMO and SMC - TSMC may
be used with a max. discharge pressure S It must be able to stop any dangerous si-
of 25 bar. tuation, which may occur, as quickly as
possible without this leading to any further
– HPO – HPC may be used with a max.
danger.
discharge pressure of 40 bar.
S In an explosion-prone environment, pro- Combustion motors
vided the compressor is fitted with ap- If combustion motors are installed in rooms
proved explosion-proof equipment. containing refrigeration machinery or rooms
The compressor must NOT be used: where there are pipes and components con-
S For evacuating the refrigeration plant of air taining refrigerant, you must make sure that
and moisture, the combustion air for the motor is derived
from an area in which there is no refrigerant
S For putting the refrigeration plant under air
gas, in case of leakage.
pressure in view of a pressure testing,
S As an air compressor. Failure to do so will involve a risk of the lubri-
Emergency device cating oil from the combustion motor mixing
with the refrigerant; at worst, this may give
The compressor control system must be
rise to corrosion and damage the motor.
equipped with an emergency device.
In case the compressor is delivered with a Explosion-proof electrical execution
SABROE-control system this emergency de-
If the compressor is delivered in an explo-
vice is found as an integrated part of the con-
sion-proof electrical execution, this is stated
trol.
in the table on page 1 of this instruction
The emergency device must be executed in manual.
a way to make it stay in its stopped position,
following a stop instruction, until it is deliber- Likewise, the compressor will, besides the
ately set back again. It must not be possible SABROE name plate, be equipped with an
to block the emergency stop without a stop Ex-name plate like the one illustrated below.
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 pos-
sible to restart it.
Other demands to the emergency device:

S It must be possible to operate it by means
T2516273_0
of an easily recognizable and visible
14 0171-487-EN
The temperature of tangible surfaces close to the warning signs during operation
When a compressor is working, the surfaces are so hot that your skin may be burnt from 1
that are in contact with the warm discharge second’s touch or longer.
gas also get warm. However, the temperatu-
re depends on which refrigerants and under
which operating conditions the compressor
is working. 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 equip-

ped with yellow warning signs informing
you that pipes, vessels and machine parts
0171-487-EN 15
Vibration data for compressors Ć all types
Vibration data for SABROE screw compressor unit can - under normal circumstances -
sors comply with the following norm: be classified in Class III or IV according to
ISO 2372 group C the following table from ISO 2372. Recip.
compressor units can be classified in class
Depending on the laying of the foundation
IV, likewise under normal conditions.
and the size of the motor a screw compres-
Vibration severity ranges and examples of their application to small machines (Class I) medium size ma-
chines (Class II), large machines (Class III) and turbo machines (Class IV)
Examples of quality judgement

Ranges of vibration severity for separate classes of machines
ms-velocity V (in mm/s)

Range Class I Class II Class III Class IV
at the range limits
95.06
0.28
0.28
0.45
0.45 A
0170-115-EN
0.71
0.71 A
1.12
1.8
1.12 B A
1.8 B A
2.8
2.8 C B
4.5
4.5 C B
7.1
7.1 D C
11.2
11.2 D C
18 18
28
D
28 D
45
45
71
SABROE screw compressor unit: – Motor and compressor have not been
Group C, class III or IV aligned as described in the Instruction
SABROE recip. compressor unit: Manual.
Group C, class IV. – For screw compressors, if the compres-
sor runs at a wrong Vi ratio.
Pay attention to the following, however:
– The pipe connections have been
S On placing the unit on the vibration executed in a way that makes them force
dampers delivered by SABROE pull or push powers on the compressor
(additional) the vibrations against the unit or they may transfer vibrations to the
foundation are reduced by: unit, caused by natural vibrations or con-
nected machinery.
– 85-95% for screw compressor units
– The vibrations dampers have not been
– 80 % for recip. compressor units
fitted or loaded correctly as indicated on
S However, a higher vibration level may oc- the foundation drawing delivered
cur if: together with the order.
16 0178-250-EN
Compressor data for reciprocating compressors
BFO 3 Ć 4 Ć 5
Operating limits
SABROE prescribes certain operating limits These operating limits for R717, R22 and
within which compressor and any additional R134a as well as the main data of the com-
equipment should be operating. pressor are stated in the following tables and
diagrams.
Main data:
Num- Swept Compressor weight
Com- ber of Stroke Max/min. volume (incl. belt pulley,
Boring
pressor cylin- length rpm at 1450 excl. motor)
type ders rpm kg
mm mm R22-R134a R717 m3/h R22-R134a R717
BFO 3 2 55 49 1800/500 1450/700 20.27 38 37
97.02
BFO 4 4 55 49 1800/500 1450/700 40.54 77 70

BFO 5 4 70 55 1800/500 1450/700 73.60 105 103
0171-233-EN
Sound pressure level in dB(A) for BFO compressor and unit

Sound pressure level
Compressor type Compressor Air-cooled unit Water-cooled unit
dB(A) dB(A) dB(A)
BFO 3 70 76 70
BFO 4 69 75 69
BFO 5 73 78 73
The stated sound pressure levels are aver- During the sound pressure measuring the
age values measured in a closed room at a rpm was1,450.
distance of 1.5 m. from the source of noise. Similarly, the rpm of the fan on the air-cooled
unit amounted to 1,450.
0171-231-EN 17
R717
Operating limits
TC (° C)
for BFO 3-4-5
compressors
60
Condensing temperature
50
40
3
30
2
20
1
–30 –20 –10 0 10 20
T0177166_0 V1 Evaporating temperature TE (° C)
Area Description
1 Deep-freeze area
2 Normal cooling area
3 Air conditioning
Hatched External cooling such as water or air fan must be applied
Absolute operating limits:

Min. evaporating temperature = –30°C
Max. condensing temperature = 55°C
Max. discharge gas temperature = 120°C
Min. number of revolutions = 700 rpm
Max. number of revolutions = 1450 rpm
Max. suction gas superheating = 10 K
18 0171-231-EN
R22
Operating limits
TC (° C)
for BFO 3-4-5
compressors
60
50
40
30
1 2 3
20
–30 –20 –10 0 10 20

T0177166_0 V2
Evaporating temperature TE (° C)
Area Description
1 Deep-freeze area
3 Air conditioning
Hatched External cooling needed if suction gas superheating exceeds 20K

Cross-hatched External cooling such as water or air fan required

Max. discharge gas temperature = 140°C
Max. omdrejningstal = 1800 rpm
0171-231-EN 19
R134a
Operating limits
TC (° C)
for BFO 3-4-5
compressors
70
60
50
1 2 3
40
30
20
-30 -20 -10 0 10 20 30
T0177166_0 V3
Evaporating temperature TE (° C)
Area Description
1 Deep-freeze area
3 Air conditioning
Hatched External cooling such as water or air fan required

Max. discharge gastemperature = 140°C
Max. ambient temperature = 45°C
Max. number of revolutions = 1800 rpm
20 0171-231-EN
General operating instructions
for BFO 3 Ć 4 Ć 5 reciprocating compressors
Starting up compressor and plant S Carefully continue opening suction stop

valve to its full open position.
S The heating rod in the crankcase must be
energized at least 6-8 hours before start- S Open main valve in liquid line.
ing up the compressor in order to boil any
refrigerant out of the compressor oil. At S If the oil in the crankcase foams, or knock-
the same time, the suction check valve ing noises are heard from the compressor
must be open. because droplets of liquid are being fed in
with the suction gas, throttle suction stop
S Check oil level in crankcase. The oil level valve immediately.
must always be visible in the oil sight
glass. See section: Charging the compres- S The compressor is now operating.
sor with oil. Increase capacity stepwise, allowing the
compressor to adjust to new conditions
97.02
S Start condenser cooling, brine pumps, before switching to next stage.

fans at air coolers as well as any com- Check carefully whether oil is foaming and
pressor cooling device.
0171-234-EN
whether oil pressure is correct.
S Check correct setting of safety auto- S Check whether oil return from oil separa-
matics on compressor. tor is working. (Pay attention to any clog-
ging of filter and nozzle.)
S Open discharge stop valve at compressor.
The pipe should normally be warm.
S Set capacity regulator to minimum capa-
S Do not leave plant for first 15 minutes after
city.
start-up and never before it has stabilized.
S In order to avoid excessive pressure re-
duction in the compressor on start–up, the Stopping and starting-up com-
suction stop valve must be opened a few pressor during a short period of
turns, as there is otherwise a risk of oil
standstill
foaming in the crankcase.
Before stopping the compressor, its capacity
S Open all other stop valves except for the must be reduced to the lowest capacity stage
main valve in the liquid line and possible for a few minutes, before it stops.
by-pass valves serving other purposes.
During short periods of standstill, it is not
Note:In case the oil separator at standstill is necessary to shut off the suction stop valve
colder than the condenser, the valve in the and the discharge stop valve. The heating
oil return pipe must not be opened until rod must be energized.
the oil separator has warmed up.
Compressor start-up must always take place
S Start compressor motor and check suction at the lowest capacity stage, after which ca-
and oil pressures. pacity is increased at suitable intervals, in
0171-231-EN 21
order to avoid that a sudden excessive pres- Automatic plants
sure reduction in the evaporation system S Refrigeration plant should normally be put
causes liquid hammering in the compressor into operation as described in the Start-up
and oil foaming in the crankcase. section.Once started, switch over to auto-
matic operation.
Stopping plant for brief periods
S Special instructions for automatic plant in
(until 2-3 days) question should be followed to the letter.
S Shut off liquid supply to evaporators for a
S The following should be checked daily,
few minutes before stopping the plant.
even on automatic plants:
S Stop compressor and shut off suction and
– correct oil charging,
discharge stop valves. Close valve in oil
return. – automatic oil return,
S Stop condenser cooling, pumps, fans and – correct oil pressure,

any compressor cooling. – suction and condenser pressures,
S Cut off power supply to both master and discharge pipe temperature,
control currents. – correct setting of safety automatics.
Stopping plant for lengthy periods Pressure testing refrigeration plant

(more than 2-3 days) Before charging the plant with refrigerant, it
S Shut off main valve after receiver and must be pressure tested and pumped down.
pump down evaporators. If necessary, ad- Pressure test the plant with one of the follow-
just low-pressure cut-out on unit to a lower ing:
pressure during evacuation.
S dry air - pressurized cylinders containing
S Allow temperature in evaporators to rise, dry atmospheric air may be used - but
then repeat evacuation. never oxygen cylinders;
S When suction pressure has been reduced S air compressor for high pressure;
to slightly over atmospheric, stop com-
S nitrogen.
pressor. Shut off suction and discharge
stop valves and close off stop valve in oil Important:
return. The plant compressors must not be used
to pressurize the plant.Water or other
S Shut off condenser cooling. If there is a fluids must not be used for pressure test-
risk of freezing, draw off coolant. ing.
S Cut off power supply to master and control If nitrogen is used, it is important to place a
currents. reducing valve with a pressure gauge be-
tween the nitrogen cylinder and the plant.
S Inspect receiver, condenser and pressure
vessels as well as piping connections and During pressure testing, it is important to en-
apparatus for leakage. sure that pressure transducers and other
22 0171-231-EN
control equipment are not exposed to the When pressure testing, compile a pressure
testing pressure. The compressor stop test report containing the following:
valves must also be closed during pressure
S date of pressure testing,
testing.
S person carrying out the test,
Plant safety valves must normally be blanked
off during pressure testing, as their opening S comments.
pressure is lower than the testing pressure.
Important: Pumping down refrigeration plant

During this pressure testing, no person Following pressure testing, the refrigeration
should be allowed to be present in rooms plant must be evacuated in order to eliminate
housing plant parts or in the vicinity of the atmospheric air and moisture. Evacuation
plant outside the rooms. must be carried out on all types of refrigera-
tion plant, regardless of the type of refriger-
S The entire unit must be pressure tested in
ant with which the plant is to be charged.
accordance with the local regulations for
pressure testing. Observe that HCFC and HFC refrigerants
mix only minimally with water, and it is there-
S The test pressure must never exceed the
fore necessary to effect evacuation of such
disign pressure.
systems with particular care.
S If it is required that the compressor should
The boiling point of a fluid is defined as the
be pressure tested together with the unit
temperature at which the steam pressure
or with the plant, the testing pressure must
equals atmospheric pressure. For water, the
not exceed:
boiling point is 100°C. Lowering the pressure
For reciprocating compressors:
also lowers the boiling point of the water.
BFO: 25 bar
The table sets out the boiling point of water
S Please observe that manometers, pres-
at very low pressures:
sure controls, pressure transmitters and
other control equipment are not exposed At pressure
Boiling point
to testing pressure. of water °C mm Hg mbar
S Afterwards, reduce pressure to 10 bar for 5 6,63 8,80

a period of 24 hours - as an initial tight- 10 9,14 12,3
ness test - as a tightly sealed plant will
15 12,73 17,0
maintain this pressure throughout the peri-
od. 20 17,80 23,7
During the tightness test, it is permitted to For evacuation, use a vacuum pump which
enter the room and approach the plant. bleeds the plant of air and steam.
S By way of a second tightness test, ex- The vacuum pump must be able to lower the
amine all welds, flange joints etc. for leak- pressure to approx. 0.1 mm Hg (mercury col-
age by applying soapy water, while main- umn) and must be fitted with a gas ballast
taining the 10 bar pressure. valve. This valve should be used wherever
0171-231-EN 23
possible to prevent water vapours condens- S Evacuate to a pressure lower than 5 mm
ing in the vacuum pump. Hg.
Important: S Blow dry air or nitrogen into system to a

Never use the refrigeration compressor to pressure corresponding to atmospheric.
evacuate the plant. Never use OXYGEN cylinders.
For a satisfactorily performed evacuation, the
final pressure must be lower than 5 mm Hg. S Repeat evacuation to reduce pressure to
Attention is drawn to the fact that there may less than 5 mm Hg.
be a risk of any water left in the refrigeration
S Shut the vacuum pump off from refrigera-
plant freezing if ambient temperatures are
tion plant and check that the pressure
lower than 10°C. In such instances, it will be
does not rise for the next couple of hours.
necessary to supply heat to the component
If the system still contains water, this will
surroundings, as ice evaporates with difficul-
evaporate and cause the pressure to rise,
ty.
thereby indicating unsatisfactory evacua-
It is recommended to carry out evacuation as tion and necessitating a repetition of the
follows: procedure.
24 0171-231-EN
Operating log This operating log should be kept at regular
intervals, thus providing important informa-
In order to keep tabs on the operating state tion about the cause of any undesired
of the refrigeration plant, it is recommended changes in the operating state.
that an operating log be kept. (See following page)
Observation Measuring point Measurement unit
Time Date and time

Suction pressure • Compressor pressure gauge
°C or bar
• UNISAB II Control
Discharge pressure • Compressor pressure gauge
°C or bar
Oil pressure • Compressor pressure gauge
bar
Oil temperature • UNISAB II Control °C
Suction gas temp. • Thermometer in suction pipe

immediately °C
before compressor
Discharge gas temp. • Thermometer in discharge pipe
immediately after compressor but
°C
before oil separator
Oil level in • Oil level sight glass Must be visible in oil

compressor in compressor sight glass
Recharding of oil on • See section on oil Number of litres
compressor charging
Compressor motor’s • Electrical panel
consumption in amps.
• UNISAB II Amps
At the same time, attention should be paid to the following:

(tick these off in the log, if you wish)
S whether the compressor’s cooling system is functioning correctly,
S whether any unusual noises can be heard from the compressor,
S whether there are unusual vibrations in the compressor.
0171-231-EN 25
Servicing the reciprocating compressor
In order to ensure problem-free operation, it 2. The compressor will then stop on the low
is advisable to carry out regular servicing to pressure cut-out. This can be adjusted to
the refrigeration plant. In this section, stop compressor at a pressure lower than
SABROE indicates some periodic services normal.
fixed on the basis of the number of operating
3. Close discharge stop valve and other pip-
hours from the first start-up or following an
ing connections to compressor.
overhaul of the compressor.
4. On HFC and HCFC compressors, remove
The service schedules also depend on the
remaining refrigerant gas using a pump-
speed of the compressor. If the compressor
down compressor.
runs at less than 1200 rpm, SABROE permits
extended service intervals. However, the
compressor must always operate within the
speed recommended by SABROE. See De-
scription of compressor. Provided the com-
pressor operates within the specified pres-
99.05
sures and temperatures and the prescribed Evacuating pump
periodic services are performed, the com-
R22
0171-235-EN
pressor will have a long and efficient life.
S The following must therefore be checked S On the R717 compressor, adopt the fol-
daily: lowing method:
Operating pressure,
Connect the compressor to a sealed, empty
Operating temperatures,
vessel which in turn is connected to an open
Oil level and pressure,
tank containing water.
Abnormal noise and vibrations.
The actual operating conditions should be

entered in an operating log daily. See the Op-
erating log section.
Removing refrigerant from Water
compressor
R717
Before the compressor can be dismantled,
the refrigerant must be removed from the
The water will absorb the refrigerant, which
compressor. This can be done in the follow-
can then be dispatched for proper destruc-
ing ways:
tion. The moment the pressure is equalized,
1. Run compressor at lowest capacity stage the valve must be reclosed in order to pre-
and throttle suction stop valve slowly until vent water being sucked back into the com-
completely closed. pressor.
26 0171-235-EN
Note: supply ready-made spare-part sets, which
The following instructions apply to the it would be an advantage to have before
compressor only. Servicing of the refrig- carrying out the scheduled service.
eration plant is described in a separate In the event that the compressor cannot op-
section. Service the compressor motor ac- erate, start evacuation as described under pt.
cording to your own instructions. For the 3, and remember also to close the suction
various scheduled services, SABROE can stop valve.
0171-235-EN 27
Scheduled services
No. Operating Operating Activity

hours hours
< 1200 rpm > 1200 rpm
1.1 Clean suction filter.
1 75 50
1.2 Check tension of driving belts.
2.1 Check or change oil. When changing oil, clean oil

filter as well. See the following section:
Assessing the oil.
2.3 Check that the following function correctly:
2 300 200 Safety automatics
Heating rod
V-belt drive.
2.4 Retighten external piping connections.
2.5 Check oil return system from oil separator.
3.1 Check or change oil. When changing oil, clean oil filter
as well.
See the following section: Assessing the oil.
3 7500 5000
3.3 Check that the following function correctly:
Safety automaitcs
Heating rod
V-belt drive
Oil return system from oil separator
4.1 Check or change oil. When changing oil, clean oil fil-
ter, too. See section: Assessing the oil.
4.3 Check the following:
Oil cooling system
Water cooling system for any deposits and clogging
Safety automatics
4 15000 10000
Heating rod
V-belt drive
Oil return system from oil separator
Valves
Cylinders
Pistons, gudgeon pins and gudgeon pin bearings
Piston and oil scraper rings
Unloading valve
Seal for tightness
4.4 Change:
V-belts
28 0171-235-EN
Operating Operating
No. Hours Hours Activity
< 1200 rpm > 1200 rpm
5 22500 15000 5.1 Check V-belt drive
6.1 Change compressor oil,

Change oil filter cartridge,
Clean crankcase.
6.3 Check the following:
Oil cooling system
Water cooling system for any deposits and clogging
Safety automatics
6 30000 20000 Heating rod
V-belt drive
Valves
Cylinders
Pistons, gudgeon pins and gudgeon pin bearings
Piston and oil scraper rings
Unloading mechanism
Seal for tightness
Oil pump and drive
Check valves.
6.4 Change:
V-belts
Half-sections of bearing for connecting rod
7 37500 25000 As for service no. 5

10 60000 40000 Major overhaul; contact SABROE Refrigeration
Then repeat scheduled services from no. 3 inclusive.
0171-235-EN 29
Lubricating oil
Lubricating oil requirements The oil should therefore be purchased in con-

tainers corresponding to the quantity to be
Above all, the refrigerator oil must provide
used for a single, or at most, two top-ups.
satisfactory lubrication of the compressor,
The oil containers must be kept carefully
even at the relatively high temperatures oc-
sealed. If all the oil in a container is not used
curring during compression. It must be inca-
in one go, the container should be tightly
pable of coking at such high temperatures
sealed and stored in a warm place to prevent
and must not precipitate solid constituents
the absorption of moisture.
such as paraffin or wax at the lowest occur-
ring temperatures. The oil must not have any Note:
corrosive effect, whether alone or mixed with It is inadvisable to reuse oil which has
refrigerant. According to the oil companies been drained from a compressor or plant.
the oils mentioned in the Oil Recommenda- This oil will have absorbed moisture from
tion in this instruction manual comply with the air and may cause operating prob-
these conditions. See section on Choice of lems. Always switch off the power to the
lubricating oils. heating rod before draining off the oil.
If, after reading the above, any doubt exists
General rules for use of lubricating as to the type of oil which has been used in
your compressor, you are recommended to
oil in refrigeration compressors
contact SABROE, rather than risk charging
S Only fresh, clean refrigerator oil may be the compressor with unsuited oil.
charged. Oil draind from the evaporator
system in an ammonia plant must not
Instructions for choosing
be reused in the compressor.
S Use grade of oil originally prescribed for
lubricating oil for refrigeration
compressor. compressors
S As far as possible, avoid mixing different The instructions in Choice of lubricating oils
types of oil. Mixed oil is generally inferior offer more detailed guidelines for choosing
the lubricating oil best suited to each individ-
to the two original oils. Mixing various
ual case on the basis of the anticipated oper-
types of oil may give rise to formation of
ating conditions.
sludge, which will lodge in valves and fil-
ters.
Charging refrigeration compressor
S Should it be necessary to switch to anoth- with lubricating oil
er brand of oil, this must be done at the
If the reciprocating compressors are deliv-
same time as a complete change of oil in
ered with a special oil-charging valve on the
the compressor and draining off all oil
crankcase, refrigerator oil may be topped up
from the refrigeration plant is carried out. while the compressor is in operation.
S The refrigerator oil must be free of mois- The oil charging valve can be fitted at pos. H.
ture, which may give rise to operating mal- See section concerning the connections on
functions and attacks of corrosion. BFO 3-4-5.
30 0171-235-EN
Note: S Clean crankcase thoroughly, wiping with a
When charging for the first time, use an oil clean, dry linen cloth (not cotton waste).
pump; it goes without saying that the com- S Reassemble side covers.
pressor must not be started unless al-
ready charged with oil. S Reduce pressure in compressor crank-
S Reduce pressure in crankcase, e.g. by case to slightly above atmospheric by
throttling suction stop valve, until suction throttling suction stop valve while com-
pressure gauge shows a pressure slightly pressor is running at its lowest capacity
below atmospheric. stage. Alternatively, raise to slightly above
S Fill pipe connected to oil charging valve atmospheric pressure by stopping com-
with refrigerator oil and insert free end of pressor and closing suction stop valve.
pipe down into a vessel containing fresh Pressure in crankcase will then rise gradu-
refrigerator oil. ally.
S Open oil charging valve carefully, thereby S Oil in the crankcase can now be forced
causing external air pressure to force oil
out through connecting point F, which can
into crankcase.
be fitted with a drain valve while the com-
S Avoid getting air or other impurities pressor is at a standstill. See section on
sucked into the compressor. Connections on BFO 3-4-5.
Note:
In order to achieve a pressure below at- S Equalize pressure in compressor to atmo-
mospheric, it is sometimes necessary to spheric. See section on Environmental
reset the low-pressure cut-out so that the protection.
compressor can aspirate down to this S Clean oil filter.
pressure. Remember to reset the pressure
S Charge to correct level with fresh, clean
cut-out to its normal setting after charging
refrigerator oil according to SABROE’s oil
with oil.
recommendations.
Note:
Since halocarbon refrigerants such as S Connect heating cartridge.
R22 mix with refrigeration oils, there will S Connect vacuum pump to compressor and
always be a good portion of oil blended pump down to 5-7 mm Hg; close off con-
with the refrigerant in the plant. Often, nection.
therefore, it is necessary to refill with re-
Then open suction stop valve a few turns,
frigerator oil after starting up for the first
time and after charging with fresh refriger- filling compressor with refrigerant gas. In
ant. the case of R717, it will suffice to blast the
compressor through by carefully opening
For a while after the plant is started for the
first time, you should therefore keep an extra suction stop valve while the purge valve is
sharp eye on the oil level in the compressor. open. See section on Environmental pro-
tection, however. When smelling R717,
Changing oil in refrigeration close purge valve.
compressor S Open discharge stop valve and valve in oil
S Cut off power to heating rod. return line; the compressor is now ready
S Close compressor stop valves and valve for start-up as described in section: Gen-
in oil return line from oil separator, if any. eral operating instructions.
0171-235-EN 31
Charging the compressor with oil
Compressor Volume of oil The oil level must always be visible in the
in crankcase oil level sight glass. The below table illus-
Type Size
Litres trates, how many litres of oil a drop in the
3 1.5 oil level of 10 mm is approximately equal
BFO 4 2.6 to.
5 3.8
24 14
CMO 26 16
TCMO 28 18
4 13
104 26
SMC 100 106 28
TSMC 100 108 30
Mk 3 112 47
S-L-E
116 50 T0177162_0
SMC 180 186 80

TSMC 180 188 90 Compressor 10 millimeter
type size difference in
oil levels equals
The volume of oil stated in the table is the 3 ~0.2 litre of oil
amount which must always be present in the BFO 4 ~0.3 litre of oil
5
crankcase. ~0.4 litre of oil
As a rule, the compressor should be charged CMO/ 24
26 ~1 litre of oil
with oil after the plant is started for the first TCMO 28
time, as some of the oil – especially in an 104
SMC / 106 ~2 litres of oil
HCFC installation – will be absorbed by the
TSMC 108
refrigerant in the plant.
100
112
The following determinants decide the total S-L-E 116 ~6 litres of oil
volume of oil a refrigeration plant should con- SMC /
tain: TSMC 186
188 ~6 litres of oil
S type of refrigerant 180
S refrigerant charge (volume) Assessing the oil

S size of plant Refrigerator oil is a vital part of the compres-
sor as it not only lubricates and cools the
S temperature range in which refrigeration movable parts of the compressor, it also pre-
plant is to operate. vents abrasive particles from entering the
bearings.
The oil level must be checked with extreme
care, particularly when starting and charging An analysis of the oil can give important in-
with refrigerant. formation on how the compressor is running.
32 0171-235-EN
We would, therefore, advise that the oil anal- Analytical evaluation
yses be carried out at the intervals prescri-
Naturally, the oil sample can be analysed by
bed.
the oil company which supplies the oil.
As a special offer to our customers
An oil sample must be drawn off while the
SABROE has developed an analytical con-
compressor is in operation, which gives a
cept, in cooperation with Mobil Oil, which is
representative sample.
able to analyse all oil makes. This will mean
Before taking the sample clean the connect- a uniform reporting of the results.
ing point F which can be fitted with a drain The analysis allows the following to be deter-
valve. Drain off a little oil to prevent any im- mined:
purities, which may have accumulated in the S Whether or not the oil is still usable, if nec-
valve or the piping, from mixing with the essary after filtering.
sample.
S Whether solid particles possibly present in
the oil originate from the bearings or other
Visual assessment components exposed to wear and tear in
which case the compressor must be in-
If you pour the sample into a clean, transpar-
spected.
ent glass bottle or a test-tube and hold it up
to a clear light source, it will be easy to as- S Each report will include the corresponding
sess the quality. You can also compare the measuring results from the previous 3 oil
sample with the fresh oil of the same make analyses. In this way you will be able to
and grade. follow up on the state of both the oil and
the compressor from one analysis to the
An oil which you approve on the grounds of a next.
visual assessment must:
S be clear and shiny
Procedure
S not contain any visible particles
S A form set with a plastic sampling bottle
S feel viscous, smooth and greasy when a and a dispatching envelope can be re-
drop is rubbed between two fingers. quested from the local Sabroe Refrigera-
If you don’t feel that you can approve the oil tion representation.
by visual assessment, charge with new oil or
S The oil sample must be drained from the
send a sample to a laboratory for analysis.
cleaned oil drain valve into the sample
bottle. Screw the lid loosely on and let the
Warning bottle stand for a few hours to enable re-
If the oil sample is poured into a glass bottle, frigerant contained in the oil sample to
this must not be hermetically sealed until all
the refrigerant in the oil sample has evapora- evaporate before sending it to the labora-
ted. Refrigerant in the oil may produce ex- tory.
cess pressure in the bottle with subsequent
risks of explosion. Never fill a bottle up com- S Please follow the Sampling and Shipping
pletely. Do not send glass bottles through Instructions enclosed in the form set in
the postal service – use purpose-made plas- which the addresses of the laboratory in
tic bottles. Please see below.
Holland are also mentioned.
0171-235-EN 33
The analysis the results of the analyses approach these
The following table states some average values. In some cases the water content of
values that can be applied in practice. How- 100 ppm in HCFC plants may be too much
ever, you should be on the alert whenever and thus lead to Cu–plating in the shaft seal.
Limiting values
Sabroe Oil PAO 68 Sabroe Oil AP 68 Sabroe Oil A 100
Parameter Unit Method Target Target Target
Spec. Max. Min. Spec. Max. Min. 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 report report report
1500
Pentane Insolubles W% MM 490 – 0.05 – 0.05 – – 0.05 –
(5mm)
Oxidation abs/cm IR,1700-1720 – 5 – – 5 – – 5 –
/cm
Nitration abs/cm IR,1627-1637 – 5 – – 5 – – 5 –
/cm
Nitro Compounds abs/cm IR,1547-1557 – 0.5 – – 0.5 – – 0.5 –
/cm
Maximum values for metal content in the oil
Lead ppm ICP – 10 – – 10 – – 10 –

Copper ppm ICP – 10 – – 10 – – 10 –
Silicium ppm ICP – 25 – – 25 – – 25 –
Iron ppm ICP – 100 – – 100 – – 100 –
Chromium ppm ICP – 5 – – 5 – – 5 –
Aluminium ppm ICP – 10 – – 10 – – 10 –
Tin ppm ICP – 10 – – 10 – – 10 –
1): TAN (Total Acid Number) is only reported for non-ammonia- 2): SAN (Strong Acid Number) is only reported for non-ammo-
applications nia-applications
34 0171-235-EN
A report is drawn up for every sample re- through a 3 micron filter and back to the
ceived. This report indicates: unit. The system must be completely
closed, to prevent the oil being affected by
S Whether the oil can still be used – without moisture in the air.
taking any further action.
S Whether the oil is no longer fit for use.
S Whether the oil can be used after it has
been filtered through a very fine filter. The report will always be sent to the address
stated on the sample label included in the
If this is necessary, the oil must be form set. A copy will be sent to SABROE Re-
pumped directly from the compressor unit frigeration, so that we are in a position to ad-
vise you, if required.
0171-235-EN 35
Setting of pressures for SABROE compressor
BFO 3 Ć 4 Ć 5
R134a R22 R717

Refrigerant
Dimension bar bar bar
HP pressure cut-out 16 17 18
Set at a pressure with a saturating temp. of 5 ° C

LP pressure cut-out
(9 °F) lower than the lowest evaporating temperature
Blow-off to
Safety valve the atmosph. 19 20 21
97.02
on receiver and Blow-off
condenser to LP side 18 19 20
Balanced
execution
0171-241-EN
Oil differential pressure
pressure cut-out – breaker press.
(only BF 4 and BF 5) 0.5 0.5 0.5
Delay period of 120 sec.
Min. condensing pressure

(regulated at the cooling water 6-7 11-12 11-12
outlet of the condenser)
36 0171-231-EN
0170-105-EN 96.02
0172-133-EN
Expected discharge gas temperatures

Suction gas superheat ° C
HFC - HCFC
Condensing pressure bar


Condensing temp. ° C
R134a R22 R404A/R507 R717
Evaporating temperature Evaporating temperature Evaporating temperature Evaporating temperature
or or or or
intermediate temperature intermediate temperature intermediate temperature intermediate temperature
C° C° C° C°
+10 0 -10 -20 -30 +10 0 -10 -20 -30 0 -10 -20 -30 -40 +10 0 -10 -20 -30
20 5.7 38 41 43 48 55 8
8.2 37 48 61 76 91 11.0 40 42 46 53 62 7.6 53 71 91 110 131
25 6.6 44 45 48 52 59 9
9.5 47 57 69 84 101 12.5 44 47 51 58 67 9.1 65 83 102 121 142
30 7.7 49 50 53 58 11. 55
66 11.1 65 77 92 108 14.3 49 52 56 63 71 10.7 77 95 113 133 151
10 35 8.8 53 54 58 64 74 12.7 68 74 85 99 115 16.2 54 57 61 67 75 12.6 89 106 123 141 160
40 10.1 57 59 63 69 14
79 14.5 72 82 94 106 120 18.2 59 62 66 72 79 14.6 101 117 133 151 170
45 11.5 61 63 67 74 82 16.5 81 90 100 112 126 20.5 65 67 71 77 83 16.9 110 126 143 161 –
20 5.7 48 51 53 58 65 8
8.2 48 59 72 88 103 11.0 50 52 56 63 72 7.6 65 83 103 122 143
25 6.6 54 55 58 62 69 9
9.5 57 68 80 95 110 12.5 54 57 61 68 77 9.1 77 95 114 132 153
20 30 7.7 59 60 63 68 11
76 11.1 65 76 88 102 117 14.3 59 62 66 73 81 10.7 89 106 125 142 162
35 8.8 63 64 68 74 12
84 12.7 73 84 96 109 123 16.2 64 67 71 77 85 12.6 100 116 134 152 –
40 10.1 67 69 73 79 14
89 14.5 82 92 103 115 128 18.2 69 72 76 82 89 14.6 111 127 144 162 –
45 11.5 71 73 77 84 16
92 16.5 90 98 109 121 133 20.5 75 77 81 87 93 16.9 121 136 154 171 –
20 5.7 58 61 63 68 75 8
8.2 59 70 83 97 113 11.0 60 62 66 73 82 7.6 78 96 115 134 153
25 6.6 64 65 68 72 79 9
9.5 69 78 91 105 120 12.5 64 67 71 78 87 9.1 90 106 126 144 163
30 7.7 69 70 73 78 11
86 11.1 75 86 98 111 125 14.3 69 72 76 83 91 10.7 102 118 136 154 –
30
35 8.8 73 74 78 84 12
94 12.7 84 95 106 118 131 16.2 74 76 81 87 95 12.6 112 128 146 163 –
40 10.1 77 79 83 89 14
99 14.5 92 101 111 123 135 18.2 79 82 86 92 99 14.6 123 138 155 – –
45 11.5 81 83 87 94 102 16.5
16 99 108 117 128 139 20.5 85 87 91 97 103 16.9 132 148 165 – –
Discharge gas temp.° C Discharge gas temp.° C Discharge gas temp.° C Discharge gas temp.° C
37
Servicing the refrigeration plant
During both start-up and operation it must be S the condenser pressure is not excessively
made sure that the plant is working correctly. high, and
Compressor and condenser must be able to

work satisfactorily, safety devices must be S the plant otherwise works as it is sup-
intact and the evaporator must function under posed to.
load - that is to say:
The service instructions outline some general
S the desired temperatures are observed,
guidelines for servicing the refrigeration
S the oil pressure and discharge pipe plant, with some references to the instruction
temperature on the compressor are manual. The service instructions should
correct, therefore be read and followed carefully.
97.07
Check Interval Activity
0171-470-EN
Condensing pressure Excessively high pressure may be
due to:
• reduced cooling effect
Pressure • air in the condenser.
and temp. Too low condenser pressure im-
Daily
plies a risk of restricting the refri-
gerant supply to the evaporator.
Discharge pipe temperature Normal discharge pipe tempera-

ture acc. to instructions.
Filter in Accumulated dirt causes reduced

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

(on HFC/HCFC installations) with a sight-glass featuring mois-
ture indicator; if the indicator col-
Dehumidi- our switches from green to yellow,
fier When
there is moisture in the refrige-
needed
rant.
Change the drying filter regularly.
38 0178-250-EN
Check Interval Activity
Refrigerant charge Inadequate charge results in re-

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

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

When tional on the evaporator being
Evapora- needed kept free of ice. Defrost as and
tor when required.
Oil draining (ammonia plant) Periodically Check evaporator, intermediate

cooler, receiver, etc. for oil accu-
mulation. Exercise caution; use a
gas mask.
0178-250-EN 39
Maintenance of BFO reciprocating compressor
General Adjust the low-pressure control so that the

When the compressor requires maintenance, compressor stops at a suction pressure of
it is important to follow the instructions given approx. 0.1 bar.
below. In order to make sure that the com- Throttle the suction stop valve very slowly.
pressor is working correctly, the gauge mea- Keep an eye on the suction pressure gauge.
surements and screw torques must be strictly
adhered to. The suction pressure must be lowered slowly
enough to give the refrigerant dissolved in
Before opening the compressor, it is expedi- the oil time to escape without the oil foaming.
ent to ensure that you have spares of those This is of great importance in compressors
seals and gaskets to be stripped down or dis- running on HFC/HCFC. An ammonia com-
mantled. An O-ring which has been exposed pressor is strong enough to have the pres-
sure reduced somewhat more quickly without
97.02
to oil and heat for any length of time may
have expanded so much as to prevent it from any oil foaming.
being refitted.
Once the pressure is down to approx. 0.1
0171-239-EN
bar, stop the compressor and perform the
All seals and gaskets used are resistant to
oil, HFC/HCFC and ammonia. All O-rings are following steps in the order specified:
made of neoprene rubber. S Close suction stop valve.
In the following sections and paragraphs ref- S Cut off power to compressor motor.
erence is made to position numbers on the
assembly drawings at the end of this manual. S Close discharge stop valve.
S Drain off last remains of refrigerant gas.

However, for BFO 5 the position numbers
may deviate from those of BFO 3 and 4. In S Having ensured that power to compressor
such cases reference is made to the draw- motor cannot be inadvertently connected,
ings for BFO 3 and 4. the compressor is ready for opening.
Consequently, remove all fuses to the electric

Pump-down motor.
Before opening up the compressor for in-
spection, the pressure inside must be low- 2. The compressor is inoperative
ered to slightly above atmospheric. This can S Leave heating rod in crankcase connected
be done in the following way, depending on for a couple of hours before the compres-
whether the compressor is operational or de- sor is due to be opened in order to heat up
fective. oil. Warm oil does not contain as much
refrigerant.
1. The compressor is operational S Suction stop valve must be open while

heating rod is connected.
Run the compressor at minimum capacity at
normal operating temperature. S Keep discharge stop valve closed.
40 0171-231-EN
S Close suction stop valve and disconnect Top covers
heating rod. The top cover is divided into a suction and a
pressure chamber.
S Equalize the pressure in the compressor.
The BF5 compressor series is fitted with a
built-in safety valve, fitted in the top cover.
S Once pressure has been equalized to at-
This safety valve opens at a prescribed pres-
mospheric, the compressor is ready for
sure as stated in the table on Pressure set-
opening. Remember to make sure that
tings and connects discharge side to suction
power cannot be connected inadvertently
side.
and start the motor.
Dismounting of top cover
Consequently, remove all fuses to the electric Dismount top cover pos. 16 (17) by removing
motor. screws pos. 18 and pos. 19.
Mounting of top cover
Dismantling and assembly
Before mounting top cover pos. 16 (17)
The following sections describe the individual check gasket pos. 7 of any damage. Clean
components. When dismantling and assem- and lubricate surface with refrigerator oil.
bling, parts should generally be fitted in the
same position from which they were taken, Mount top cover pos. 16 (17) and screws
and should therefore be marked as they are pos. 18 and 19.
removed. Further they should be thoroughly Tighten screws cross-wise with the torque
cleaned, checked and lubricated prior to be- moment indicated in instruction: Torque mo-
ing reassembled. ments for screws and bolts.
0171-231-EN 41
Valve intermediate plate incl. S Check that the intermediate plate is posi-
suction and discharge valves tioned correctly before fitting top cover.
The valves are plate valves, consisting of an Note:

intermediate plate, pos. 6, upon which suc- Normally, the tip of the intermediate plate
tion and discharge valve plates are mounted. must be facing the oil pump. Only in the
The intermediate plate is positioned right un- case of compressors with specially fitted
der the top cover. When top cover has been device for unloaded start is the intermedi-
dismantled, this intermediate plate becomes ate plate rotated 180°, hence the tip facing
visible and can be removed. the shaft seal end of the compressor.
S Insert screws pos. 18 and pos. 19 and

Usually, the intermediate plate is delivered
tighten cross-wise with a torque moment
with suction and discharge valve plates as
as indicated in instruction on Torque mo-
one spare part, including complete gaskets.
ments for screws and bolts.
See fig. 1.
S After app. 24 hours’ operation screws and
Fig. 1
top cover should be retightened.
Refitting of valve intermediate plate:

S Provided that intermediate plate pos. 6 is
undamaged it can be refitted with new
suction and discharge valve plates, pos. 8
and pos. 10.
S Suction valve plate and spring plate can

be dismantled without the use of any
tools.
S Dismantle discharge valve pos. 10 by re-

T0177165_0 V4
moving hexagon screws, pos. 13, secured
by means of a lock washer.
Mounting
S On refitting the discharge valve make sure
S Without causing any damage clean all ga- that the discharge valve plate does not get
sket surfaces thoroughly of any gasket re- stuck between valve intermediate plate
mains. and hexagon screw.
S Lubricate the new gaskets pos. 5 and pos. S During renovation of the intermediate pla-
7 in refrigerator oil and check that the ga- te incl. suction and discharge valves, re-
skets are facing correctly in relation to the member to replace all valve and spring
holes for the fixing screws. plates.
42 0171-231-EN
Connecting rod S Following dismantling of base plate, the
connecting rods become visible.
The connecting rod consists of 2 parts, accu-
rately fitted and kept together by two bolts.
S Dismantle connecting rod screws pos. 26
Extracting piston and connecting rod: and remove half sections of bearing. Now
S Empty the compressor of oil and refrige- push connecting rods upwards and out of
rant. the bearings of the crankshaft.
Dismantle all pipe and V-belt connections to S On compressor types BFO 3 and BFO 4
the motor. the pistons are extracted from the top.
Next, dismantle the compressor from the
base frame and place it on a worktable of a S On BFO 5 compressors the crankshaft
suitable size. must be dismantled as the pistons must
be extracted from the bottom. See fig. 2.
S Dismantle top covers
See also instruction on the removal of the
S Dismantle valve plates and gaskets. crankshaft.
Fig. 2
BFO 5 BFO 3Ć4 T0177165_0 V8
The pistons are manufactured in an alumini- must be fitted on the connecting rod. See the
um alloy and equipped with a piston ring, following paragraphs.
pos. 32 (33: BFO 5), and a scraper ring,
S Mount piston and connecting rod in the
pos. 31 (32: BFO 5).
same way as they were dismounted. See
also mounting of crankshaft.
The connecting rod are made of drop-forged
aluminium. S Guide the connecting rod into place on
crankshaft by hand.
Mounting of connecting rod S Mount the bottom part of the connecting
Before mounting connecting rod in the com- rods and tighten with screws pos. 26.
pressor block the piston with the piston rings Tighten screws with a torque moment as
0171-231-EN 43
indicated in Torque moments for screws and measure the ring opening. This
and bolts. should measure between 0.20 and
0.35mm.
S When connecting rods have been moun-
ted and assembled with the correct torque S First fit scraper ring pos. 31, next com-
moment, they must be able to move axial- pression ring pos. 32 on the piston.
ly on the bearing journals. See fig. 3.
S Check the free movement of the rings in
S The crankshaft must be easy to rotate.
the grooves. The play between rings and
S In order to avoid damage of piston rings the side of the grooves should be between
during mounting it is recommended to use 0.01 and 0.03mm.
a tool that squeezes the rings tightly round
the piston and then push the piston into Fig. 4
the cylinder. A few drops of refrigerator oil
in the cylinder facilitates this procedure. 0.20-0.35
10
Fig. 3
0.01-0.03
T0177165_0 V17
Assembling and dismantling of piston

and connecting rod
Use the following procedure on assembling
T0177165_0 V7 piston and connecting rod:
S Fit one of the Seeger circlip rings pos. 30
Mounting of piston rings in the piston
in the bore for the piston pin.
Before mounting the piston rings in the piston
their fit in the cylinder lining should be S Guide connecting rod into place in piston
checked by measuring the ring opening. and position the piston pin.
See fig. 4.
S Fit the other Seeger circlip ring.
S Insert each piston ring in the cylinder at a
distance of app. 10mm from cylinder top Carry out dismantling in reverse order.
44 0171-231-EN
Shaft seal The shaft seal parts are pressure lubricated
with oil from the oil pump. This oil forms a
62
thin lubricating film round the rotating parts.
67 A slight seeping of oil may occur, especially
64 during the start-up of new compressors and
during standstill.
This does not necessarily mean that the shaft
seal is leaky. But if the amount of seeping oil
rises – or if it continues at the same speed –
the shaft seal must be replaced.
115
63
Dismounting and dismantling of
61 65 66
shaft seal
Having depressurized the gas in the com-
pressor and safeguarded the motor against
T0177165_0 V3 any inadvertent start up, dismantle V-belt and
key.
The shaft seal is of the slide ring type and its
S Remove shaft seal cover by removing
purpose is to create a firm sealing along the
screws pos. 67.
crankshaft between the interior of the com-
pressor and the atmosphere. The shaft seal S Guide ring pos. 62, O-ring pos. 63, and
consists of two units: slide ring pos. 64 will now be forced out of
spring pos. 61.
S The stationary part, consisting of shaft
seal cover pos. 66 og sealing pos. 115. Assembling and mounting of shaft seal
The shaft seal cover is made of fine-grai- Following a thorough cleaning of the crank-
ned cast iron with lapped contact surface. shaft check that it is without any scratches,
bruises or wear marks. Lubricate the crank-
S The dynamic part, rotating around the shaft and the shaft seal parts thoroughly with
crankshaft. the same type of oil as used in the com-
The dynamic part consists of compression pressor.
spring pos. 61 with guide ring pos. 62, Remounting of the shaft seal is carried out in
O-ring pos. 63, and a lapped slide ring of reverse order to the above.
special carbon pos. 64.
S Mounting of the dynamic part is carried
Note: out without any tools. The parts are pus-
It is recommended to be very careful with hed against the crankshaft until spring
the lapped slide surfaces as even the pos. 61 is compressed.
slightest scratches or any other damage to S Mount shaft seal cover pos. 66. Make sure
the slide faces will result in leaks. that the bore in the cover does not touch
the crankshaft.
In order to obtain a proper tightness on re-
placement the entire shaft seal incl. spring S Fasten the cover with screws pos. 67,
pos. 61, guide ring pos. 62, O-ring pos. 63, which are tightened with the moment ind-
slide ring pos. 64 and shaft seal cover pos. icated in Torque moments for screws and
66 must be replaced. bolts.
0171-231-EN 45
Crankshaft
The crankshaft is made of heat-treated SG-
cast iron of excellent strength and wear prop-
erties. The bearing journals are superfinish-
treated and oil channels have been bored for
all lubricating points.
By means of borings in the counterweights
the crankshaft is dynamically balanced with
regard to the forces of 1st and 2nd order.
Dismantling of crankshaft
T0177165_0 V6
S Evacuate the compressor of oil and refri-
Reassembling of crankshaft
gerant and safeguard against any inadver- The crankshaft is reassembled in the reverse
tent start up. Remove fuses, if any. order to the dismantling. Note the following,
however:
S Dismount top cover and valve plate.
S In the case of BFO 3 compressors con-
S The bottom plate dismantled, the connec- necting rods and pistons must be inserted
ting rods become visible. in the block before the crankshaft is moun-
ted.
S Dismantle connecting rod screws pos.
S Push the crankshaft into the rear bearing,
26/27 and take out half sections of bea- then mount the main bearing cover.
ring.
S Mount oil pump after inserting the Woo-
druff key in the crankshaft pump end (BFO
S Push connecting rods upwards and out of
4 and 5).
the crankshaft bearings.
S Mount shaft seal and shaft seal cover.
S Dismount oil pump as described in a se- S Push connecting rods into place in their
parate section. In the case of compressors crankshaft journals and lubricate with a
BFO 4 and 5 the oil pump is driven by few drops of oil. After the lower connecting
means of a key which is now removed. rod bearings have been mounted and
screws pos. 26/27 tightened with the cor-
S Dismantle shaft seal cover and shaft seal. rect torque moment acc. to the instruction
manual it must be possible to move con-
S By supporting the crankshaft it is possible necting rods axially on their bearing jour-
to dismount bearing cover from shaft seal. nals. See fig. 3.
S The crankshaft can now carefully be pul- S The crankshaft must be easy to turn.
led out of the shaft seal end of the com- S If this is so, remount bottom plate pos. 2
pressor block. with gasket pos. 3. The oil bore of the bot-
tom plate must fit the oil bore in the com-
S Make sure that none of the connecting pressor block.
rods slides out of the cylinders and gets S Remount valve plate and top cover.
damaged. S Top up with fresh refrigerator oil.
46 0171-231-EN
Main bearings
The crankshaft rotates in two main bearing wear-resistant bearing metal has been em-
covers equipped with large bearing bushings. bedded in the main bearing cover next to the
A finely machined slide bearing material of shaft seal.
Fig. 1 Fig. 2
Rear main bearing cover Main bearing cover at shaft seal

T0177165_0 V5
Rear main bearing cover Main bearing cover at shaft seal

S After dismantling of the oil pump the bea- S After dismantling of shaft seal the main
bearing cover pos. 58 can be pulled out.
ring flange pos. 39 is accessible and can
See instruction concerning dismantling of
be pulled straight off. See instruction con-
shaft seal.
cerning the mounting of the oil pump.
S Remove screws pos. 59 before dismount-
ing of main bearing cover.
S The crankshaft is now positioned in the
S Give the bearing surfaces a thorough
main bearing only and must not be turned. cleaning and lubricate with a few drops of
oil.
S Check that the bearing is clean and lubri- S Check gasket surfaces and fit new gasket
cate it with a few drops of refrigerator oil pos. 57.
before remounting. S Push main bearing cover pos. 58 incl. the
fitted main bearing across the crankshaft
S Check flange gasket, pos. 38. and fit it so that the oil channel in the shaft
seal chamber faces upwards – see fig. 3.
In this way the oil cannot return to the
S The oil channel of the bearing flange and
crankcase via the oil and ring channels
gasket must fit in with the oil channel of till after the shaft seal chamber has been
the compressor block. In case the chan- completely filled.
nels do not fit, the oil flow from the oil
S Fasten bearing cover with screws pos. 59
pump is cut off and the compressor will and tighten with the torque moment as de-
break down shortly. scribed in Torque moments for screws and
bolts.
S The oil pump must be mounted as descri- S Fit shaft seal as described in a separate
bed in a separate section. instruction.
0171-231-EN 47
Compressor lubricating system
Fig. 3
ÈÈÈÈ
ÈÈÈÈÈÈÈÈ È
ÈÈÈ
ÈÈÈÈÈÈÈ
È
È
ÁÁÁÁÁ
ÁÁÁÁÁ •
48
T0177165_0 V1
The oil pump is a highly efficient gearwheel and the bore in the crankcase. Lubrication of
pump, driven directly by the crankshaft but cylinder walls and piston pins is done by
independent of its direction of rotation. splash lubrication.
The oil is sucked from the crankcase through On BFO 4 and 5 compressors oil filter pos.
the oil filter with magnet insert pos. 48. From 48 is built into the oil draining screw. This
here the oil is supplied under pressure to the makes it easy to reach.
individual bearings and to the shaft seal On a BFO 3 compressor dismantle bottom
through bores in the crankshaft. plate pos. 2 before extracting the oil filter.
The return flow from the shaft seal chamber Clean the oil filter in a suitable dissolvent and
cannot take place until this is completely blow clean with compressed air. See also
filled up. The oil returns via the ring channel instruction concerning oil filter.
48 0171-231-EN
Oil pump
47 45 39
OBEN
42
46
44
41
40
T0177165_0 V2
Dismantling of oil pump Mounting of oil pump

Having evacuated the compressor of both oil Mounting of the oil pump is done in reverse
and refrigerant as well as made sure it does order. Note the following, however:
not start up inadvertently, proceed as follows: S After mounting of pump housing pos. 41,
gearwheel pos. 42 and steel balls pos. 40,
S Dismantle screws pos. 47, end cover pos.
lubricate with clean refrigerator oil.
46 and gasket pos. 45.
S Pull out the now accessible pump plate S Push pump plate pos. 44 with shaft pin
pos. 44, and in which shaft pin pos 43 for pos. 43 into place so that shaft pin pos.
the upper gearwheel has been pressed in. 43 makes up the bearing for the upper
S Gearwheel pos. 42, pump housing pos. 41 gearwheel while resting in the bore for the
incl. the four steel balls pos. 40 are now rear bearing flange.
visible and can be dismantled. S Now mount end cover pos. 46 together
with gasket pos. 45.
In order to ensure the working of the pump
it is absolutely essential that the embed-
ded inscription ”OBEN” on the end cover
faces upwards.
S Fit screws pos. 47 and tighten cross-wise
with the torque moment prescribed in Tor-
que moments for screws and bolts. This is
very important in order to avoid warping
the rear bearing cover.
0171-231-EN 49
Oil filter
All the oil to the compressor lubricating sys- On the BFO 4 and 5 compressors the oil filter
tem is filtered through an oil filter, fitted in the is built into the draining screw and hence
crankcase. The filtered oil also passes one easy to reach.
magnetic filter in which any small iron par-
ticles may be caught before the oil flows to On BFO 3 remove bottom plate pos. 2 to
the oil pump. make it possible to clean the oil filter.
pos. 48
BFO 3
BFO 4 pos. 48
BFO 5
T0177165_0 V9
Cleaning of oil filter

The oil filter should be cleaned at regular in- This is a consequence of the tiny dirt par-
tervals. See section on Servicing the com- ticles that will be coming from the plant dur-
pressor. Please, note in this connection that ing its first operating period.
often the filter must be cleaned already after Clean the oil filter in a suitable dissolvent and
a brief operating period following the initial blow clean with pressurized air before refit-
start-up. ting.
50 0171-231-EN
Suction filter On cleaning the filter dismantle suction stop
valve pos. 34 by removing screws pos. 35.
Between suction stop valve pos. 34 and com-
The cone-shaped filter pos. 33 and gaskets
pressor a fine-meshed filter has been fitted.
pos. 21 can now be removed without the use
The purpose of this filter is to prevent that
of any tools.
impurities from the plant are conveyed with
the gas flow into the compressor. Clean the filter in a suitable dissolvent and
blow clean with compressed air.
Clean the suction filter at regular intervals as The BFO 3 compressor is further equipped
stated in the section on Servicing the recipro- with built-in suction filters, which are cleaned
cating compressor. after dismantling of top cover and valve plate.
21
33
21
T0177165_0 V10
0171-231-EN 51
Stop valves Function
Suction and discharge stop valves are used Capacity regulation is obtained when the
to cut off the compressor from the plant. solenoid valve, fitted in the top cover, closes
the admission of gas to the two cylinders,
They are closed tightly by manual tightening.
positioned under the same top cover. This
Hence, it is not advisable to use any tools in
makes the inlet pressure to the cylinder drop
order to close the valve as this would just
to zero bar. At the same time the compressor
lead to overloading of the valve parts.
capacity is reduced to 50%. However, a little
The valve spindle is fitted with a mainten- gas will be flowing through the closed sole-
ance-free gasket that needs no replacement. noid valve, hereby ensuring the necessary
Further, the valve is fitted with a backseal- cooling and lubrication of the cylinders.
ing, which is brought into operation when the
This capacity regulation permits a certain re-
valve is completely open and the valve cone
duction in power consumption.
screwed back towards the cylinder head
(anticlockwise rotation). The solenoid valve can be manoeuvered
Note: either by means of a manual switch or
In case the compressor is operating, the through a pressure control or thermostat.
valve cone should not be screwed com- With a dead coil the connection to the suction
pletely back against the cylinder head as side remains open and the compressor
any safety pressure controls connected to works at 100% capacity. With an energized
the valve housing will hereby be blocked. coil the connection to the suction gas side is
cut off. The compressor works at 50% capac-
Capacity regulation for ity.
compressor BFO 4 and BFO 5 Note:

The BFO 4 and BFO 5 four-cylinder com- Stop the compressor and check that the
pressors can be delivered with a system for solenoid valve works correctly. At a cur-
stage-wise capacity regulation, from 100% to rent impulse to the solenoid valve the
50%. characteristic valve stroke must be heard!
100% capacity 50% kapacitet:

no current on current conducting
solenoid valve solenoid valve
T0177165_0 V11
52 0171-231-EN
Service instruction A wrongly mounted valve plate will block the
gas connections and lead to inadmissible
On mounting the special top cover for capac- pressure rises as well as breakdown of the
ity regulation make sure that the valve plate compressor.
is mounted correctly.
The coil of the solenoid valve is replaced by
loosening the top screw so that the coil – in a
The tip of the valve plate must face the dead state – can be removed without first
compressor oil pump. having to depressurize the compressor.
Unloaded start Normal operation

Solenoid valve active Solenoid valve inactive
NonĆreturn valve closed NonĆreturn valve open
Suction side Discharge side Suction side Discharge side
T0177165_0 V14
Start unloading
At a star-delta start of electric motors it is When the electric motor has reached its max.
often considered necessary to limit the com- rpm, a switch takes place from star to delta
pression work of the machine at the starting start. The solenoid valve is closed and the
moment in order to reduce the starting torque compressor now works under normal condi-
of the electric motor. tions.
Usually, a solenoid valve is used in a by-pass
arrangement which, in the starting-up phase,
short-cirucits the discharge side to the suc- In a few cases a delaying relay must be
tion side of the compressor. At the same used, keeping the solenoid valve open until
time, a non-return valve must be fitted in the the motor has reached its max. number of
discharge line to the condenser preventing revolutions. The delaying relay is set to a
the return flow of discharge gas to the com- delay of 1–2 sec. after a switch from star to
pressor. delta has taken place.
0171-231-EN 53
In the case of BFO 4 and 5 compressors a On the BFO 3 compressors the by-pass de-
solenoid valve with a by-pass arrangement is vice is fitted under the valve flanges and be-
included in the delivery as an integrated part tween the suction and discharge stop valves.
of the compressor. Fit the non-return valve in the discharge line
after the compressor.
BFO 3 Check that the solenoid valve is fitted with
the flow arrow pointing from the high pres-
sure to the low pressure side.
A wrongly fitted valve or a leaky valve will
lead to overheating and breakdown of the
compressor.
T0177165_0 V12
C D B A
A: Unloading housing with bypass

B: Connection for thermostat T0177165_0 V13
C: Solenoid valve start unloading
D: Connection for oil return and low pressure control
In order to protect the compressor against Set the thermostat to break at 140°C + 6%.
too strong heating up a thermostat must be
fitted in the gas flow on the compressor dis-
charge side at point B. This thermostat is
part of the safety circuit of the compressor.
54 0171-231-EN
Heating rods for oil heating
The BFO 4 and 5 compressors are delivered Further, the danger exists that the oil, during
in a standard execution with built-in heating start-up of the compressor, foams so vigor-
rod in the crankcase. For BFO 3 compres- ously that the lubricating pressure is gone.
sors the heating rod can be delivered togeth-
er with the order. Before start-up the heating rod should be
switched on for at least 6-8 hours.
The purpose of the heating rod is to keep the
oil in the crankcase warm even during stand- Note:
still of the compressor. This ensures a low The heating rod must not be on if the oil
content of refrigerant in the oil. level in the vessel is below minimum in the
sight glass. While the compressor is oper-
Too much refrigerant in the oil makes it lose ating, it is usually off. Further, remember
its lubricating properties. This may lead to to switch off the heating rod if the com-
damage of the movable parts in the compres- pressor crankcase is opened for inspec-
sor. tion.
97.01
0171-236-EN
E
D F
A B
T0177165_0 V15
Compres- Effect Voltage A B C D E F

sor type Watt Volt mm mm mm (”) mm mm mm
BF3 60 220-240 65 155 M22x1,5 30 52 Ø 12.5
BF4-BF5 80 220-240 65 155 M22x1,5 30 52 Ø 12.5
0171-231-EN 55
Pressure gauges
The analog instrumentation on the compres- temperature under which the instrument will
sor includes two pressure gauges: one that be functioning.
measures the discharge pressure on the
compressor and one combined suction and Example:
oil pressure gauge. These pressure gauges If the mid–compensation range is to be
are filled with glycerine, which both attenu- moved from 20°C to 10°C, equalization must
ates the deflections of the indicators and lu- be performed at 10°C. When the screw is
bricates the gauge works. then retightened, the middle of the com-
pensation range will have been moved down
However, a fluctuating ambient temperature to 10°C. The total stretch of the compensa-
has an influence on the volume of the glycer- tion range remains unchanged.
ine (warm glycerine takes up more space
The middle of the compensation range.
than cold glycerine), which can affect the Tighten the balancing screw at this temperature
measuring accuracy of the gauge.
10°C
Furthermore, it is essential that no excess -10°C 50°C
95.06
pressure can possibly occur in the gauge
20°C
housing, as this involves a risk of explosion 0°C 60°C
0170-161-EN
of the housing.
30°C
+10°C 70°C
Both these considerations have been effec-
tively solved in the gauges by a combination T0177086_0
of internal temperature compensation and

the so-called blow-out safety device which is Cleaning and refilling glycerine-
fitted in the back plate of the pressure gauge
filled gauges
housing.
S Remove blow-out disk and temperature
compensator from back of housing.
Adjustment to other temperature
ranges: S Wash gauge interior with warm water and
allow to dry carefully.
A balancing screw on the rear of the instru-
ment is firmly tightened at a temperature of S Fill gauge housing with fresh glycerine un-
20°C – the normal ambient temperature. til it flows out of bleeder hole.
Note:The glycerine must be absolutely wa-

If ambient temperatures change considerably
terfree.
thus requiring a general shift in the com-
pensation range, slacken the balancing S Refit compensator and blow-out disk in
screw for approx. 1 minute, then retighten. gauge housing and cover centrehole in
This must be done at the average operating blow-out disk with a piece of tape.
56 0171-231-EN
Note: Compensator
Glycerine should be refilled at a room tem-
perature of 20°C; when mounted, and the +20°C
compensator must be its normal shape as

shown at the top of the following drawing. -10°C
Balancing screw
S Clean gauge exterior with warm water.
+60°C
S Remove tape from centrehole.
T0177086_0 Blow-out
S Refit gauge.
0171-231-EN 57
Torque moments for screws and bolts
On mounting screws and bolts must be tightened with the moments as indicated below.
3 4 5
BFO Thread moment Thread moment Thread moment
mm Nm mm Nm mm Nm
Cylinder cover M10 51 M10 51 M10 51
Bottom plate M8 34 M8 34 M8 34
Cover for oil pump M8 34 M8 34 M8 34
Suction and discharge M10 51 M10 51 M10 51
valve
97.02
Front bearing flange M8 34 M10 51 M10 51
Shaft seal cover M5 8,5 M8 34 M8 34
0171-237-EN
Cover f. suction – – M8 34 M8 34
chamber
Connecting rod screws M6 15 M6 15 M8 29
58 0171-231-EN
Refrigeration Plant Maintenance
Operational reliability bled of refrigerant. Adjust any constant-

pressure valves to bring evaporator pres-
The prime causes of operating malfunctions
sure down to atmospheric.
to the plant are:
1. Incorrect control of liquid supply to the 3. Start up the compressor. Adjust regulat-
evaporator. ing system to lower suction pressure.
2. Moisture in the plant. 4. Keep a close eye on the suction pres-

sure gauge! When the suction pressure is
3. Air in the plant. equal to atmospheric, stop the compres-
sor and quickly shut off the discharge stop
4. Anti-freezing liquid is missing.
valve. Shut off any stop valve in the oil re-
5. Congestion due to metal shavings and turn line.
94.05
dirt.
If the receiver has an extra stop valve in
6. Congestion due to iron oxides. the feed line, this can be closed; practical-
0171-464-EN
ly the entire refrigerant charge will then

7. Congestion due to copper oxides. remain shut off in the receiver.
8. Inadequate refrigerant charge. Note:
Below, some information is given about ways The receiver must not be overfilled! There
of keeping contaminants out of the refrigera- should be a minimum gas volume of 5%.
ting system and at the same time facilitating 5. A slight overpressure should normally re-
day-to-day supervision of the refrigeration main in the piping system - this safe-
plant. guards the system against the penetration
of air and moisture.
Pumping down the refrigeration
6. Before dismantling parts, the operator
plant
should put a gas mask on.
Before dismantling any parts of the refrigera-
tion plant for inspection or repair, pump-down
must be carried out.
Dismantling plant
In order to prevent moisture penetrating into
1. Open suction and discharge stop valves the refrigeration plant during any repair work,
on compressor. it is advisable to follow the rules below:
2. Close liquid stop valve after condenser or 1. No component should be opened un-
receiver so that liquid refrigerant can be necessarily.
collected in the tank. Any solenoid valves
in the liquid line should be opened by 2. When dismantling the system, the pres-
force, adjusting the thermostat to its low- sure in the system should be a little higher
est position so that the liquid line can be than atmospheric.
0171-702-EN 59
3. Note: Tightness testing and pump-down
If the piping system is colder than the sur- of refrigeration plant
roundings, there is a considerable risk of
Before charging refrigerant into that part of
damp precipitation (condensation) on cold
the refrigeration plant which has been
plant parts. Plant components to be dis-
opened, this should be pressure-tested as
mantled must be warmer than the ambi-
described in the section entitled Pressure
ent temperature.
testing.
4. No two points in the system should be Afterwards, pump down in order to eliminate
opened at the same time. air and moisture. In this regard, consult the
section on Evacuation.
5. Plug, close or at least cover opening with
Otherwise, follow the instructions given in the
oiled paper or suchlike.
separate instruction manual on plant compo-
6. Be aware of the possibility of filters nents.
being very moist. 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.
60 0171-702-EN
TroubleĆshooting on the Reciprocating Compressor
Plant
Operating condition lefthand column, the error being briefly de-

scribed in the next column. The third column
Experience shows that pressure and temper-
states code numbers for the possible causes
ature variations in a refrigeration circuit can
of the error.
provide information about the operating con-
dition of the refrigeration plant. The code numbers refer to the subsequent
chart.
In particular, suction and condenser pres-
sures as well as the temperatures of suction The section entitled Remedying malfunctions
and discharge gases may provide important states how to remedy the observed error.
information as to the operating conditions
See the following example for the correct
of the plant.
procedure.
91.05
It often takes only very slight modifications to

variable pressures and temperatures to pro- Example
duce considerable changes in operating con- Observed error: discharge pipe temperature
0170-335-EN
ditions. too low - error code 15.
Using the following troubleshooting chart, it is Cause codes:

possible to ascertain the cause of and reme- 26 (Liquid in suction line)
dy for any operating disturbance. 32 (Too much coolant/air to condenser)
39 (Expansion valve produces too little su-
Using the trouble-shooting chart perheating)
In the following chart, each individual error Any explanatory comments will be stated in
option is indicated by a code number in the the section that follows.
0171-231-EN 61
Error
code Observed error Cause code
1 Compressor fails to start 1, 2, 3, 4, 5, 6, 7, 9, 10, 12, 14.
2 Compressor starts and stops too often 9, 10, 11, 13, 21, 22, 23, 24, 32, 34, 35, 36, 37,
40, 41, 43, 44, 51, 52, 54, 56, 59.
3 Compressor starts but stops again immediately 3, 5, 6, 9, 10, 11, 12, 13, 14, 15, 17, 18, 41,
42, 49, 50, 55, 61.
4 Compressor operates continuously 8, 21, 22, 24, 41, 46, 52, 53, 56, 60.
5 Abnormal noise from compressor 16, 17, 18, 19, 26, 48, 49, 50, 51, 52, 53, 54, 56,
57, 58.
6 Insufficient capacity on compressor 13, 15, 17, 18, 20, 21, 22, 23, 24, 32, 34, 35, 36,
37, 40, 41, 44, 45, 46, 49, 50, 51, 52, 53, 56, 60.
7 Liquid stroke in compressor during start up 16, 18, 26, 37, 38, 39, 44, 56, 61.
8 Liquid stroke in compressor during operation 21, 23, 26, 37, 39.
9 Excessive condenser pressure 9, 25, 28, 29, 30, 31, 33.

10 Too low condenser pressure 22, 32, 51, 52, 54, 60.
11 Excessive suction pressure 13, 17, 26, 34, 39, 52, 53, 54, 5,. 60.
12 Too low suction pressure 11, 13, 20, 21, 22, 23, 32, 35, 36, 37, 40, 41, 42,
44, 45, 56, 59.
13 Too low oil pressure 12, 15, 17, 18, 26, 49, 50, 55.
14 Excessive discharge pipe temperature 11, 21, 22, 23, 28, 29, 30, 31, 33, 34, 35, 36, 37,
40, 41, 46, 52, 54.
15 Too low discharge pipe temperature 26, 32, 39.
16 Excessive oil temperature 33, 34, 35, 36, 37, 40, 50, 52.
17 Oil level in crankcase falling 16, 18, 20, 26, 51, 57, 58.
18 Oil foaming vigorously in crankcase 16, 26, 39, 61.
19 Crankcase sweating or frosting up 16, 18, 26, 37, 39.
20 Capacity regulating oscillating 13, 15, 16, 17, 18, 49, 55, 56.
21 Impossible to bleed plant 10, 43, 51, 52, 53, 54, 60.
62 0171-231-EN
Code Case Code Case
1 No power - master switch not cut in 34 External pressure equalization on

2 Blown fuses - loose wiring or expansion valve closed
connections 35 Expansion valve partly clogged by
3 Electrical voltage too low ice, dirt, wax
4 No control current 36 Expansion valve has lost charge
5 Motor protection device activated 37 Expansion valve sensor misplaced
6 Control current circuit open 38 Expansion valve is leaky
7 Pump/fan not started 39 Expansion valve provides too little
8 Welded contracts in motor protection superheating
9 High-pressure cut-out has cut 40 Expansion valve produces excessive
superheating
10 Low-pressure cut-out has cut
41 Filters in liquid/suction line clogged
11 Low-pressure cut-out differential too
42 Solenoid valve in liquid/suction line
small
closed
12 Oil pressure cut-out has cut
13 Capacity regulator incorrectly set 43 Solenoid valve leaky
14 Defrosting timer breaks current 44 Evaporator iced up or clogged
15 Oil charge insufficient 45 Cooling air being recirculated
16 Compressor capacity too high (short-circuited)
during start-up 46 Excessive load on plant
17 Oil pressure too low (adjust oil pres- 47 Refrigerant collecting in cold con-
sure regulating valve) denser (close off by-pass)
18 Oil foaming in crankcase 48 Coupling misaligned or loose bolts
19 Oil overcharge 49 Oil pump defective
20 Poor oil return - oil in evaporators 50 Bearings worn out or defective
51 Defective piston rings or worn
21 Restricted supply of refrigerant
cylinder
22 Refrigerant charge insufficient
52 Discharge valves defective or leaky
23 Refrigerant vapour in liquid line
53 Suction valves defective or leaky
24 Leaky refrigeration plant
25 Refrigerant overcharge 54 Compressor by-pass open - leaky
26 Liquid in suction line safety valve
27 At low temperature operation, de- 55 Compressor oil filter clogged
gree of charge in evaporators rises 56 Capacity regulator defective
28 Insufficient coolant/air to condenser 57 Solenoid valve in oil return clogged/
29 Temperature of coolant/air too high defective
30 Non-condensable gases in 58 Filter in oil return clogged
condenser 59 Compressor capacity too high
31 Condenser needs cleaning 60 Compressor capacity too low
32 Too much coolant/air to condenser 61 Heating element in crankcase
33 Water valve closed defective
0171-231-EN 63
Remedying malfunctions
1. Compressor fails to start
1.6 Control current circuit open owing Pinpoint open switch and
to activated: remedy cause of
pressure cut-outs interruption.
thermostats
motor protection device
defrosting timer
1.9 High-pressure cut-out has cut Reset pressure cut-out and investigate cause
of high condenser pressure.
1.10 Low-pressure cut-out has cut Compressor cannot start before suction pres-
sure has risen above set point for pressure
cut-out restarting.
1.12 Oil-pressure cut-out has cut Compressor starts at reset.

Check oil level. If oil
foams in crankcase, see section 18.
2. Compressor starts and stops too often
2.9 High-pressure cut-out cuts at High condenser pressure - see section 9.

high pressure
Check condenser cooling and adjust pressure
cut-out to correct breaking pressure -
see table Pressure and temperature settings.
Replace defective pressure cut-out.
2.10 Low-pressure cut-out cuts at too Low suction pressure - see section 12.
low suction pressure.
If low-pressure cut-out is set too high, adjust
pressure cut-out.
2.11 Low-pressure cut-out differential is Increase differential pressure - see also special
too small between stopping and instructions.
starting
2.13 Compressor capacity too high Check operating conditions and, if need be,
reduce capacity.
2.41 Filter in suction line clogged Check suction filters on compressor.
2.43 Solenoid valve in liquid line does Check direction of flow.

not close tight.
Replace defective valve.
2.52 discharge valves on compressor At compressor stop, pressure equalizes rela-

are leaky. tively quickly between suction and discharge
side
Clean or change discharge valves.
64 0171-231-EN
3. Compressor starts but stops again immediately
3.5 Motor protection cuts Look for cause of overloading.

If star-delta start, set starting time to minimum.
3.10 Low-pressure cut-out has cut Open any suction stop valve which is closed.
3.12 Defective oil-pressure cut-out Replace cut-out - see special instructions.
3.15 Oil charge insufficient Top up with oil and investigate cause of oil
shortage.
3.18 Oil pressure failing owing to for- Reduce capacity. See sections 17 and 18.
mation of foam in oil.
4. Compressor operates continuously
4.10 Thermostat or low-pressure Adjust operating points.

cut-out does not cut at too low
temperature/pressure
4.21 Restricted supply of refrigerant to Remove dirt in filters and check function of ex-
evaporator. Compressor working pansion device as per special instructions.
at too low suction pressure.
4.22 Refrigerant charge unsufficient Top up with refrigerant of correct type.
0171-231-EN 65
5. Abnormal noise from compressor
5.16 Compressor capacity too high du- Reduce capacity.

ring start-up
5.17 Oil pressure too low See section 13.
5.26 Liquid refrigerant in suction line Liquid stroke. See points 7 and 8.
Adjust expansion or float valves.
5.48 Incorrect alignment of motor and Check alignment as per special instructions.
compressor
Loose bolts in coupling Tighten with torque wrench
5.50 Worn or defective bearings Overhaul or replace.
5.51 Too much oil circulating Check oil level.

5.53 through the plant, resulting in too
5.57 Solenoid valve, filter or jets in oil return system
low oil level in
5.58 compressor may be clogged. Leaky suction valve ring
plates, piston rings and worn-out cylinder may
also produce such oil consumption.
5.56 Capacity regulation oscillating Low oil pressure - see section 13.
owing to failing oil pressure
6. Too little capacity on compressor
6.15 Insufficient oil charge Top up with fresh oil of same type and make.
6.44 Iced-up evaporator Defrost evaporator; adjust defrosting time if

required.
6.49 Defective oil pump and hence fail- Repair or replace oil pump
ing oil pressure
6.56 Defective capacity regulating sys- Cause is most often failure in oil pressure or
tem refrigerant in oil; see section 4.5.
66 0171-231-EN
7. Liquid stroke in compressor during start-up
Liquid stroke in the compressor should not occur, as in the worst instance this can
cause rupture to the valve ring plates and damage to the inbuilt relief devices. Fur-
thermore, it can result in damage to the connecting rod bearings and cylinders if the
coolant degreases the faces and impairs the lubricating capacity of the oil.
7.18 Adsorption of (H)CFC refrigerant Reduce compressor capacity or start with

in oil throttled suction stop valve.
Sudden reduction in pressure Follow instructions in section 18.
across the oil sump (suction pres-
sure) produces foaming
7.26 Refrigerant has condensed in suc- Heating element in crankcase should be con-
tion line or crankcase nected for 6-8 hours before starting, so that
refrigerant dissolved in oil can be boiled out
before starting compressor up.
Suction line has free fall towards Start with throttled suction stop valve - stop
compressor when hammering is heard.
Liquid separator should be mounted in suction
pipe.
8. Liquid stroke in compressor during operation
8.23 Refrigerant gas in liquid line Expansion valve is oscillating.
8.39 Superheating of expansion valve Adjust superheating, which should normally be

is set too low 5-8°C.
0171-231-EN 67
9. Excessive condenser pressure
In the event of abnormally high pressures in the refrigeration system, there is a risk of
damage to the compressor. At very high pressures (see pressure testing), the risk of
the components in the refrigeration plant exploding can constitute a threat to life.
Abnormally high pressures can occur in the case of:
- extreme heating of plant parts (fire, solar radiation or other abnormal heating);
- volumetric expansion of fluids in sealed-off premises.
9.25 Overfilling with refrigerant Refrigerant fills condenser and reduces its ef-
fective area.
Draw off coolant.
9.28 Insufficient condenser cooling, Regulate water/air supply or reduce compres-

e.g. if cooling water fails, fan/ sor capacity, if called for. Check condenser as
coling water pump clogs, soiling, per instructions for same.
scaling or fouling of heat-transmit-
ting surfaces
9.30 Presence of non-condensable Blow air out at condenser. Follow instructions
gases (especially air) in conden- for condenser.
ser.
10. Too low condenser pressure
10.32 Excessive condenser cooling Regulate condenser cooling.
10.51 Defective piston rings or worn cy- Replace worn parts. See compressor instruc-
linders tions.
10.52 Discharge valves are defective or See compressor instructions. Check valve ring
leaky plates and piston rings.
10.54 Bypass between high-pressure Check compressor for internal leakage by per-
side and suction side of compres- forming pressure-drop test.
sor
See compressor instructions.
10.60 Compressor lacks capacity. Check whether compressor capacity corre-

sponds to load on plant. Reduce condenser
cooling.
68 0171-231-EN
11. Excessive suction pressure
11.26 Error in setting of liquid regulation Liquid refrigerant in suction line.

valve
Adjust, repair or replace expansion valve.
11.53 Leaky suction valves See compressor instructions. Remove cylinder

covers; check valve plates. Renew if needed.
11.54 Open by-pass between suction si- Check system for any by-pass detectable as a
de and high-pressure side of com- warm connection.
pressor. Safety valve leaky, or
opens prematurely. Adjust or repair leaky valves.
11.60 Compressor lacks capacity. Regulate compressor capacity.

Check whether all cylinders are operating.
Check function of capacity regulator.
12. Too low suction pressure

Abnormally low pressure in the refrigeration plant will increase the compression ratio
of the compressor with a subsequent risk of damage to the compressor.
The danger of air being sucked into the refrigeration plant also increases at abnor-
mally low pressure.
12.20 Oil in evaporator Draw off oil.
12.22 Refrigerant charge on plant insuffi- Check refrigerant charge.

cient
Charge plant with refrigerant.
Bubbles in liquid line sight glass
and possibly a warm liquid line Find and seal any leak.
12.35 Freezing-up of expansion valve Thaw out expansion valve with hot, wet cloths.
(HFC/HCFC plant)
Replace dessicant in drying filter.
12.36 Thermostatic expansion valve has Valve fails to open - change valve.
lost charge
12.40 Excessive superheating of suc- Regulate expansion valves to higher capacity.

tion gas
0171-231-EN 69
12.41 Filter in liquid line clogged Check and clean filter in liquid line.
12.42 Solenoid valve in liquid line fails to Coil may have blown. Control signal lacking.
open
12.59 Compressor has excessive capa- Reduce compressor capacity.

city
Check capacity regulating system.
13. Oil temperature too low
13.15 Too little oil in compressor Top up compressor with oil and investigate
cause of oil consumption.
13.18 Oil foams in compressor See point 18.
13.49 Oil pump defective Repair or replace.
13.50 Bearings worn Repair or replace.
13.55 Oil filter clogged Change filter cartridge
14. Excessive discharge pipe temperature
If, after approx. 1 hour’s operation, the discharge pipe temperature is more than
10°C higher than indicated in the table, the error may be due i.a. to:
14.21 Excessive suction temperature as Check refrigerant charge

result of reduced refrigerant sup-
ply to evaporator (extensive su-
perheating) owing to insufficient
refrigerant charge.
14.22 Excessive suction temperature as Check thermostatic expansion valves

result of reduced refrigerant sup-
ply to evaporator (extensive su-
perheating) owing to incorrectly
adjusted liquid regulating valves
14.52 Leaky discharge valves Leaking in discharge valves gives rise to gen-
eration of heat.
Change defective valves.
14.54 Open by-pass between high and Localize by-pass and remedy any leakages.
low-pressure side of compressor,
e.g. leaky safety valve
70 0171-231-EN
15. Too low discharge pipe temperature
15.26 Low suction temperature as result Adjust liquid regulating valve. Increase super-
of overflow of liquid refrigerant heating.
from evaporator
16. Excessive oil temperature
During operation, the heat of the compressor crankcase must be 40-70°C. When
working with R717 and R22, it may be necessary to supply the compressor with oil
cooling.
See point 14.
17. Oil level in crankcase falling
Where HFC/HCFC refrigerants are used, there will be some blending of refrigerant
and oil during the initial operating period. It may therefore prove necessary to top up
the oil after initial start-up of the plant.
Note:
The oil level must always be visible in the oil level sight glass on the compressor.
17.20 Filter in solenoid valve or jet in oil Oil return pipe must be warm during opera-
return line clogged tions. Clean filter.
17.26 Liquid in suction line and crank- Examine evaporator system and check super
case may cause foaming in oil heating of suction gas.
and thus increase oil consumption
17.51 Worn-out piston rings or cylinders Renew piston rings and, if need be, renew pis-
tons and cylinder linings.
17.57 Solenoid valve in oil return line de- Coil in solenoid valve defective.
fective - Replace coil.
- Electrical control signal lacking.
0171-231-EN 71
18. Heavy oil foaming in crankcase
18.26 Liquid in suction line See 17.26.
18.61 Too much refrigerant dissolved in - Before starting compressor, heating element
oil must have been on for at least 8 hours in
order to boil refrigerant out of oil. During
start-up phase, capacity should be con-
nected at a slow rate to prevent sudden drop
in pressure on suction side with resultant
foaming.
- Under normal operating conditions, com-
pressor should operate under as stable
pressure conditions as possible.
19. Crankcase sweating or frosting up
19.26 Liquid in suction line See 17.26.
19.37 Expansion valve sensor misplaced Check positioning of expansion valve sensor -
cf. instructions for expansion valve.
19.39 Liquid regulating valve or float val- Increase superheating on thermostatic expan-
ve producing too much liquid sion valve.
20. Capacity regulation oscillating
20.18 Oil foaming in crankcase See point 18.
21. Impossible to bleed plant
21.43 Solenoid valve leaky Pinpoint and seal leak, or change leaky com-
ponent.
21.51 Defective piston rings Check and replace any defective parts.
21.52 Defective discharge valves Check and replace any defective parts.
21.53 Defective suction valves Check and replace any defective parts.
72 0171-231-EN
Selecting lubricating oil for SABROE compressors
During the past few years YORK Lubricating oils with relatively high viscosities
Refrigeration has experienced a number of must be used to ensure satisfactory lubrica-
problems with mineral oils, particularly in tion of refrigeration compressors.
R717 plants. The problems can be divided
To obtain the best lubrication, the oil must:
into two groups:
S Provide the required fluidity at the lowest
a: The oil changes viscosity evaporating temperature encountered in
b: The oil decomposes (becomes very black) the plant and at the highest permissible
temperatures in the compressors.
The problems have been seen with several
S Provide acceptable fluidity at start-up.
mineral oil brands, often occuring within a
few operating hours and resulting in severe S Provide sufficient oxidation stability (the oil
consequences for both compressor and must be moisture-free when added to the
system).
plants.
S Provide sufficient chemical stability when
99.02
Following the careful investigation undertak- used together with the particular refriger-
en by YORK Refrigeration during the past ant.
few years, it has been decided to introduce a In addition, the extent to which different re-
0170-151-EN
range of synthetic oils which can fulfil the de- frigerants dissolve in the oil must be deter-
mands of modern refrigeration plants. mined, so that the oil return systems, etc. can
be designed to function properly.
Mineral oils may continue to be used in re-
frigeration plants, providing the lubricating Stratification
quality is carefully monitored. For modern, It should be noted that in certain plants, par-
high capacity refrigeration plants, where long ticularly with HFC and HCFC refrigerants, the
lifetime for both lubricants and moving parts oil may stratify into layers in the refrigerant
is expected, YORK Refrigeration recom- receivers and evaporators at certain operat-
mends the choice of synthetic lubricating oils. ing conditions and at particular oil concentra-
tions.
The application areas and specifications for
these synthetic oils can be found in the fol- The Oil recommendation diagrams for
lowing pages. Installers and/or users are at SABROE compressors for HFC and HCFC
liberty to choose either YORK Refrigeration’s will indicate the limits for Sabroe oils at which
own or alternative oil brands which fulfil the this stratification occurs. The oil concentra-
necessary specifications. tions stated in these diagrams must not be
exceeded. This will enable suitable oil rectifi-
General cation/return systems to be designed to bal-
This recommendation only deals with the lu- ance with the compressor oil ”carry-over” so
brication of the compressor. The perfor- that the maximum concentration is not ex-
mance of the lubricant in the plant (receiver, ceeded.
evaporator, etc.) must, however, also be tak- For area A in the diagrams, the max oil con-
en into consideration. centration in liquid phase must not exceed
0170-151-EN 73
2%. For the other area, the max. oil con- In the oil recommendation diagrams for each
centration must not exceed 5%. For area B: refrigerant and compressor type, it is pos-
please contact YORK Refrigeration. sible to determine the code number for the
oil best suited to the operating conditions.
Plants with several different compressor With this code number, it is possible to se-
types/makes lect the correct Sabroe oil for the application.
In plants comprising several different inter- The marked area on each side of the sepa-
connected compressor types and makes, it is rating line in the diagram shows the zone
strongly recommended that all compressors where both oils are useable.
should use the same type of oil. This is es-
sential where automatic oil return systems Oil types and oil companies
are employed. As a result of the large number of oil compa-
nies world-wide that deals in oil for refrigera-
If it is intended to change the oil from one tion plants, it is impossible for YORK
type to another, please refer to the Oil chang- Refrigeration to test the many different
ing on SABROE compressors later in this brands of oil on the market. It is our experi-
publication. ence, however, that some oil brands during
use can change character and thus no longer
Selecting the lubricating oil fit the specifications given by the companies
There are a number of operating diagrams at delivery. We have thus experienced
for the selection of lubricating oils for Sabroe changes in the specifications as well as in
compressors operating with various refriger- the formula and performance without having
ants. Once the general conditions concern- had any information about this from the oil
ing the lubrication of the compressor and oil company. This makes it very difficult for
type in the plant have been considered, the YORK Refrigeration to give a general ap-
specific plant conditions must be taken proval of the various oil brands.
into consideration.
Use the Oil recommendation diagrams to se- For this reason YORK Refrigeration has, in
lect the appropriate oil code number. cooperation with a large recognised oil com-
pany, developed a series of three oils which
The oil code number consists of letters des- cover most purposes. YORK Refrigeration
ignating the oil type together with the Sabroe has however, also listed a limited number of
viscosity grade number. oils which can be supplied through YORK
Refrigeration. The typical data of these oils
Code can be found in the Data Sheet for Sabroe
Oil types
design Oils. We suggest you to use these Sabroe
M Mineral oil oils, which are delivered in 20 litre pails and
Synthetic oil based on 208 litre drums and can be ordered using the
A
Alkylbenzene
parts no. listed in the List of Oils.
Synthetic oils based on
PAO
Polyalphaolefin
AP Mixture of A and PAO-oils It is of course possible to use similar oils from
E Synthetic ester-based lubricants other oil companies, and in this connection,
74 0170-151-EN
the Data Sheet for Sabroe Oils may be help- Screw compressors:
ful. The oil temperature before injection in
the compressor, but after the oil cooler
Please note, however, that YORK
Refrigeration has not tested any other oils Max. permitted oil temperature = set-
than our own brand, and hence we cannot ting point for alarm
answer for the quality, the stability or the suit- Min. permitted oil temperature = set-
ability of other oils for any purposes. The oil ting point for alarm
company in question is thus solely responsi- • Condensing pressure
ble for the quality and suitability of the oil de- • Evaporating pressure
livered, and if any problems are experienced
S Oil viscosity in the compressor during
with these oils in the compressors or in the
operation and under the influence of:
refrigeration plant, the oil supplier should be
contacted directly. • Refrigerant type and solubility of refrig-
erant in the oil
When choosing oils from other oil compa-
• Operating temperatures
nies, please pay particular attention to the
oil’s effectiveness in the compressor and the • Vapour pressure in the oil reservoir
refrigeration plant as a whole. Reciprocating compressor: Suction
pressure and oil temperature in the
Pay particular attention to the following as- crankcase.
pects:
Screw compressor: Discharge pressure
S Oil type and gas temperature.
S Refrigerant type S Compatibility with the neoprene O-rings:

the aniline point gives an indication of how
S Compressor type
the O-ring material reacts to the oil.
S Miscibility between refrigerant and oil At an aniline point less than approximately
S Operating data for the compressor 100°C the material tends to swell, and at
• Discharge gas temperature an aniline point higher than approximately
• Oil temperatures: 120°C it tends to shrink.
Reciprocating compressors:
For this reason it is not recommended to
Normal oil temp. in the crankcase change oil type from M oil to PAO oil as a
50-60 °C leakage may occur if the O-rings are not
Max. permitted oil temperature = Set- changed. YORK Refrigeration therefore
ting point for alarm recommends using the Sabroe AP68 oil
Min. permitted oil temperatures = set- as it reduces the risk of leaks considerably
ting point for alarm - if fitted in this case.
0170-151-EN 75
YORK Refrigeration can supply a calculation YORK Refrigeration is aware, however, that
showing the operating data on request. several customers have been using mineral
oils for many years without problems. Those
Attention is drawn to the following viscosity customers who wish to continue using miner-
limits during operation: al oils in existing, as well as new, compres-
sors can do so, providing the compressor
S Optimum viscosity range
type and operating conditions are similar to
(to be designed for) = 20 to 50 cSt
the existing ones (excepting the HPC and
S Max. permissible viscosity =100 cSt HPO series compressors).
S Min. permissible viscosity =10 cSt
(only applicable to HCFC and HFC under YORK Refrigeration has therefore decided to
cartain operating conditions: 7cSt)
market a brand of mineral oil which has been
S Max. permissible viscosity during the tested and found to be suitable for most gen-
starting of the compressor = 500 cSt eral refrigerating purposes.
Maximum refrigerant concentration in the oil
at running condition: 25% - also if viscosity If another brand of mineral oil is chosen, the
requirements are met. specifications in the data sheet in this recom-
mendation should be followed as a guideline.
Use of mineral oil
Lately we have experienced a number of
Mineral oil can be used in refrigerating
problems with mineral oil, particularly in R717
plants, providing the lubricating quality is
plants. The problems can be divided into two
carefully monitored. For modern, high capac-
groups:
ity refrigeration plants, in which a long life-
a: The oil changes viscosity within a few time for both lubricant and moving parts is
operating hours. expected, YORK Refrigeration recommends
b: The oil decomposes (becomes very using synthetic lubricating oils.
black) within a few operating hours.
A benefit of using the synthetic lubricant oil is
The problems have been seen with several
a much lower oil carry-over to the plant and
oil brands and have resulted in severe con-
longer intervals between oil changes.
sequences for both compressors and plants.
A better fluidity at lower temperatures also
gives an easier drainage at the cold parts of
When using mineral oil, it is thus important
the plant.
that the plant is monitored very closely, that
oil samples are taken regularly (every
1-2,000 hours) and that the condition/colour
How to use the oil recommendation dia-
of the oil is checked on a weekly basis.
grams:
YORK Refrigeration therefore recom- To determine the code number, first refer to
mends only to use M oil at moderate oper- the Oil recommendation diagram for the re-
ating conditions - cf. the attached oil rec- frigerant and compressor type and then plot
ommendation diagrams. the proposed operating conditions.
76 0170-151-EN
Example (recip. compressors): the example above, a oil code number E5
Refrigerant: R134a can be selected.
Condensing temp. TC +35°C
Evaporating temp. TE –3°C Code no Area no
1 2
Please observe !
E5 Y
Plants may operate at different conditions
from time to time, for example at different E9 Y
evaporating temperatures due to plant
In plants which incorporate both screw and
variations or at different condensing tem-
reciprocating compressors and where the
peratures due to seasonal changes.
recommendations indicate the use of differ-
By plotting TC and TE in the oil recom-
ent oil types, please contact YORK
mendation diagram, this example would
Refrigeration for advice.
require a No 1 oil. If, however, TE
changes at certain times, e.g. from –3 to Changing oil on Sabroe compressors
+7°C, a No 2 oil should be utilised. But, as
The oil should never be changed to another
+7°C is inside the marked area, the No 1
type without consulting the oil supplier. Nor is
oil can be utilised also at this TE.
it advisable to ”top up” compressors with an
R134a other oil than the one already used for the
ÎÎ
TC
particular plant and compressor.
°F °C
158 70
140 60 ÎÎ
ÎÎ 2
Mixing different oils may result in operating
problems in the refrigerant plant and damage
122 50
ÎÎ
ÎÎ
to the compressors. Incompatibility between
• •
104 40
the different oil types may degrade the lubri-
86 30
68 20 1 ÎÎ
ÎÎ
cating properties or may cause oil residues to
form in the compressor or oil separator or in
50 10
the plant. These oil residues can block filters
32 0
and damage the moving parts in the com-
14 -10
pressor.
-4 -20
-22 -30 Furthermore, changing the oil from one type

-60 -50 -40 -30 -20 -10 0 10 20 30 ° C
or make to another should only be undertak-
TE
-76 -58 -40 -22 -4 14 32 50 68 86 ° F en in connection with a careful procedure in-
Evaporating temperature
volving the drainage and thorough evacua-
By referring to the Oil recommendation table tion of the refrigeration plant. Information on
placed at the bottom of each oil recommen- a suitable procedure can be obtained from
dation diagram, it is possible to select the YORK Refrigeration as well as from a num-
code number for the appropriate oil type. In ber of oil companies.
0170-151-EN 77
It is imperative that oil is only used from the Oil drums should, ideally, be ”racked” and
original container and that both the make and mounted with a proper barrel tap to ensure
type complies with the specification for the an effective airtight seal.
plant.
Oil changing intervals
Ensure that the original container is sealed A list of the recommended intervals for
during storage to prevent moisture from the changing the oil can be found in the com-
air being absorbed into the oil - many oils, pressor instruction manual. These are pro-
particulary the polyolester oils, are extremely vided for guidance only. The actual interval
hygroscopic. Consequently, it is recom- between oil changes will often be determined
mended that the oil is only purchased in con- by a variety of operating parameters within
tainers corresponding to the amount to be the plant.
used on each occasion.
It is strongly recommended to monitor the
If the oil is only partially used, make sure that quality of the oil by carrying out oil analyses
it is effectively re-sealed in the original con- with regular intervals. This will also give a
tainer and that it is stored in a warm, dry good indication of the condition of the plant.
place. Ideally with nitrogen blanking of the oil The service can be supplied by YORK
to keep the water content below 50 ppm. Refrigeration or the oil suppliers.
Oil recommendation diagram symbols:

YĂ : In case of a new plant. Very suitable.
lĂ : In case you wish to change from mineral oil
A : Max oil concentration in liquid phase at: TE: 2% W
B : Max oil concentration in liquid phase: contact YORK Refrigeration
C : Min suction temperature –50°C: at TE< –50°C superheating must be introduced.
* : Dry expansion systems only. Flooded systems to be considered individually: contact YORK Refrigeration
ÑÑ
ÜÜ
SH : Suction gas superheat, K (Kelvin)
ÜÜ
: Zone in which both oils are useable
: Calculation must be performed using COMP1
78 0170-151-EN
Data sheet for listed Sabroe oils
Typical data for lubricating oils for Sabroe compressors
Sabroe Viscosity Viscosity Spec. Flash p. Pour p. Anilin Acid no.

code cSt cSt Index grav. at COC °C °C mg
40°C 100°C 15°C °C point KOH/g
M1 63 6.4 14 0.91 202 –36 81 0.02
A3 97 8.1 13 0.86 206 –32 78 0.05
AP1 64 9.3 121 0.858 195 –51 121 0.04
PAO3 66 10.1 136 0.835 266 <–45 138 0.03
PAO5 94 13.7 147 0.838 255 <–45 144 0.03
PAO9 208 25 149 0.846 260 <–39 154 0.03
E3
Due to the big difference between polyolester-based lubricants from various suppliers, it is
E5
not possible to present typical data for these oils. When using another oil brand than the one
E9 recommended by YORK Refrigeration, please contact the oil supplier to select the correct
oil type.
E11
The listed data are typical values and are intended as a guideline only when selecting a similar
oil from a different oil company. Data equivalence alone does not necessarily qualify the oil for
use in YORK Refrigeration’s Sabroe compressors.
0170-151-EN 79
List of part numbers for available Sabroe oils
Part no.
Oil brand Oil code no.
20 litre pail 208 litre pail
Mobil Gargoyle Arctic 300 M 1 (M68) 1231-264 1231-296
Sabroe Oil A100 A 3 (A100) 1231-263 1231-262
Sabroe Oil AP68 AP 1 (AP68) 1231-257 1231-260
Sabroe Oil PAO68 PAO 3 (P68) 1231-256 1231-259
Mobil Gargoyle Arctic SHC 228 PAO 5 (P100) 1231-282 1231-283
Mobil Gargoyle Arctic SHC 230 PAO 9 (P220) 1231-284 1231-285
Mobil EAL Arctic 68 E 3 (E68) 1231-272 1231-273
Mobil EAL Arctic 100 E 5 (E100) 1231-274 1231-275
Mobil EAL Arctic 220 E 9 (E220) 1231-279
Sabroe H oil E11 (E370) 3914 1512 954 1) 9415 0008 000
1) 18.9 litre pail (5 US gallons)
The oils recommended by the former Stal Refrigeration correspond to the following oils:
Stal Refrigeration oil type Sabroe oil
A Mobil Gargoyle Arctic 300 – M1 (M68)

B Sabroe Oil PAO 68 – PAO 3 (PAO 68)
C Mobil Gargoyle Arctic SHC 230 – PAO 9 (PAO 220)
H Sabroe H oil – E 11 (E 370)
80 0170-151-EN
R717 TC
one-stage
°F °C
reciprocating
122 50
compressors
104 40
86 30
68 20 1
50 10
32 0
Code no Area no 14 -10

1
-4 -20
PAO 3 Y
-22 -30
AP 1 l/Y -60 -50 -40 -30 -20 -10 0 10 20 °C
TE
M1 See note -76 -58 -40 -22 -4 14 32 50 68 °F
Note: YORK Refrigeration recommends that the use of M oils is restricted to moderately loaded compressors and
that the oil quality is monitored carefully via regular oil analyses.
Y : In case of a new plant. Very suitable.
0170-151-EN 81
R717
two-stage
°C
reciprocating
50
compressors
40
30
2K)dmM:YKE2Ă)dY)7E(0)dlM:Y(EKĂĂdKe:YMyreciproatngqTjM
20
10
-10
-20
-30
-60 -50 -40 -30 -20 -10 0 10 20 °C
82 0170-151-EN
R717 TC
HPO and HPC
°F °C
reciprocating
176 80
compressors
158 70
140 60
1
122 50
104 40
86 30
68 20
50 10
Code no Area no
1 32 0
PAO 5 Y -30 -20 -10 0 10 20 30 40 50 °C
TE
-22 -4 14 32 50 68 86 104 122 °F
Please observe: PAO 5 oil is the only oil which can be used in the HPO and HPC compressors.
0170-151-EN 83
R22 TC Contact YORK Refrigeration
one-stage
°F °C
reciprocating 2
122 50
compressors
104 40
86 30
1
68 20
50 10
32 0
14 -10 A
Code no Area no -4 -20
1
-22 -30
A3 Y
-60 -50 -40 -30 -20 -10 0 10 20 °C
TE
-76 -58 -40 -22 -4 14 32 50 68 ° F
C Evaporating temperature

84 0170-151-EN
R22 TC
two-stage
°F °C
reciprocating
122 50
compressors
104 40
86 30 1
A
68 20
50 10
32 0
14 -10

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

0170-151-EN 85
R134a
TC
ÑÑ
°F °C
one-stage
ÑÑ
158 70
reciprocating
ÑÑ
140 60 2
compressors
122 50
ÑÑ
ÑÑ
ÑÑ
104 40
86
68
30
20 1
ÑÑ
ÑÑ
50 10
32 0
14 -10
Code no Area no
-4 -20
1 2
-22 -30
E5 Y
E9 Y
-60 -50 -40 -30 -20 -10 0 10 20 30 ° C
TE
-76 -58 -40 -22 -4 14 32 50 68 86 ° F
ÑÑ
YĂ:
ÑÑ :
In case of a new plant. Very suitable.
Zone in which both oils are useable
86 0170-151-EN
R134a TC
two-stage °F °C
reciprocating 158 70
compressors 140 60
122 50
1
Condensing temperature 104 40
86 30
68 20
50 10
32 0
14 -10
-4 -20
Code no Area no
-22 -30
1
-40 -40
E5 Y
-70 -60 -50 -40 -30 -20 -10 0 10 20 30 °C
TE
-94 -76 -58 -40 -22 -4 14 32 50 68 86 ° F
0170-151-EN 87
R407C TC
one-stage
°F °C
reciprocating
122 50
compressors
104 40
86 30
68 20
1
50 10
32 0
14 -10
B
1
-22 -30
E3 Y -60 -50 -40 -30 -20 -10 0 10 20 °C
TE
-76 -58 -40 -22 -4 14 32 50 68 °F
YĂ: In case of a new plant. Very suitable.

88 0170-151-EN
R407C TC
two-stage
°F °C
reciprocating
122 50
compressors
104 40
86 30 1
68 20 B
50 10
32 0
14 -10

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

0170-151-EN 89
R404A TC
one-stage
°F °C
reciprocating
compressors
122 50 ÑÑÑ
ÑÑÑ
104 40
ÑÑÑ
ÑÑÑ
2
ÑÑÑ
86 30
68 20 ÑÑÑ
ÑÑÑ
50 10 1
ÑÑÑ
32 0
Code no Area no 14 -10
1 2
-4 -20
E3 Y
-22 -30
E5 Y -60 -50 -40 -30 -20 -10 0 10 20 °C
TE
-76 -58 -40 -22 -4 14 32 50 68 °F
ÑÑ
ÑÑ
: Zone in which both oils are useble
90 0170-151-EN
R404A TC
two-stage
°F °C
reciprocating
122 50
compressors
104 40
86 30
1
68 20
50 10
32 0
14 -10

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

0170-151-EN 91
R410A TC
HPO og HPC
°F °C
reciprocating
122 60
compressors
50
104
40
86
30
68 20
10 1
50
0
32
A
-10
14
-20
Code no Area no -4
-30
1
-22 -40
E5 Y
-60 -50 -40 -30 -20 -10 0 10 20 30 40 50

TE
-76 -58 -40 -22 -4 14 32 50 68 °F

A : Max oil concentration in liquid phase at: TE: 2%
92 0170-151-EN
R507 TC
one-stage
°F °C
reciprocating
122 50
compressors
104 40
Condensing temperature 86 30
68 20
1
50 10
32 0
14 -10

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

C : Min suction temperature –50°C: at TE< –50°C superheating must
most be introduced.
0170-151-EN 93
R507 TC
two-stage
°F °C
reciprocating
122 50
compressors
104 40
86 30
1
68 20
50 10
32 0
14 -10

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

94 0170-151-EN
R717 TC
Screw compressors °F
ÜÜÜÜÜÜÜÜ
°C
122 50
ÜÜÜÜÜÜÜÜ
ÜÜÜÜÜÜÜÜ
104 40
ÜÜÜÜÜÜÜÜ
ÜÜÜÜÜÜÜÜ
ÜÜÜÜÜÜÜÜ
86 30
68 20
ÜÜÜÜÜÜÜÜ
ÜÜÜÜÜÜÜÜ
1
50
32
10
0
ÜÜÜÜÜÜÜÜ
14 -10
Code no Area no
1 -4 -20
PAO 3 Y
-22 -30
AP 1 l/Y 20 °C
-60 -50 -40 -30 -20 -10 0 10
TE
M1 See note -76 -58 -40 -22 -4 14 32 50 68 °F
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
ÜÜ
C :
ÜÜ :
Min suction temperature –50°C: at TE< –50°C superheating must be introduced.
Calculation must be performed using COMP1.
0170-151-EN 95
R22 TC
ÜÜÜÜÜÜ
ÚÚÚÚÚÚÚÚÚÚÚ
ÔÔÔÔÔÔÔÔÔÔÔ
ÒÒÒÒÒÒÒÒÒÒÒ
ÔÔÔÔÔÔÔÔÔÔ
SH25
Screw compressors °F °C
ÜÜÜÜÜÜ
ÔÔÔÔÔÔÔÔÔÔÔ
ÔÔÔÔÔÔÔÔÔÔ
ŠŠŠŠŠŠŠŠŠŠ
ÜÜÜÜÜÜ
122 50
2
104 40
ÜÜÜÜÜÜ
ÜÜÜÜÜÜ
Condensing temperature SH20
ÜÜÜÜÜÜ
86 30 SH5
68 20
ÜÜÜÜÜÜ
ÜÜÜÜÜÜ 1
SH10
50 10
ÜÜÜÜÜÜ
ÒÒÒÒÒÒÒÒ
32 0 ÒÒÒÒÒÒÒÒ
A
ÒÒÒÒÒÒÒÒ
Code no Area no
14 -10
ÒÒÒÒÒÒÒÒ
ÒÒÒÒÒÒÒÒ
ÒÒÒÒÒÒÒÒ
1 2* SH20
-4 -20
A3 Y
-22 -30
PAO 5 Y -60 -50 -40 -30 -20 -10 0 10 20 °C
TE
-76 -58 -40 -22 -4 14 32 50 68 °F
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.

* : Dry expansion systems only. Flooded systems to be considered individually: contact YORK Refrigeration
Ü
96 0170-151-EN
R134a TC
Screw compressors °F °C
ÜÜÜÜÜÜÜÜÜ
ÏÏÏÏÏÏÏÏ
ÒÒÒÒÒÒÒÒÒÒÒ SH30
158 70
ÜÜÜÜÜÜÜÜÜ
ÏÏÏÏÏÏÏÏ
ÚÚÚÚÚÚÚÚÚÚ
ÜÜÜÜÜÜÜÜÜ
ŠŠŠŠŠŠŠŠ
ÜÜÜÜÜÜÜÜÜ
ŠŠŠŠŠŠŠŠ
140 60 SH20
122 50
ÜÜÜÜÜÜÜÜÜ
ŠŠŠŠŠŠŠŠ
ÑÑÑÑÑÑ
ÜÜÜÜÜÜÜÜÜ
Condensing temperature 104 40 ÚÚÚÚÚÚÚÚÚÚ
ŠŠŠŠŠŠŠŠ
ÑÑÑÑÑÑ
ÜÜÜÜÜÜÜÜÜ
ŠŠŠŠŠŠŠŠ
ÑÑÑÑÑÑ
2 SH10
ÜÜÜÜÜÜÜÜÜ
ŠŠŠŠŠŠŠŠ
ÑÑÑÑÑÑ
ŠŠŠŠŠŠŠŠ
ÑÑÑÑÑÑ
86 30
SH5
68 20
ÑÑÑÑÑÑ
ÒÒÒÒÒÒÒ
ÑÑÑÑÑÑ
ÒÒÒÒÒÒÒ1
ÒÒÒÒÒÒÒ
50 10
Code no Area no
32 0
ÒÒÒÒÒÒÒ
ÒÒÒÒÒÒÒ
ÒÒÒÒÒÒÒ
(See note) 14 -10
1 2 SH20
E5 Y -4 -20
E9 Y -50 -40 -30 -20 -10 0 10 20 30 °C
TE
-58 -40 -22 -4 14 32 50 68 86 ° F
Note: For the compressors type ”S”, ”Rotatune”, ”SAB 81”, ”SAB 83”, and ”SAB 85” only Sabroe oil H is approved.
(SH) as stated in the diagram. See Oil types and oil companies in this section. Due to the ongoing development
of lubrication oils, please contact YORK Refrigeration for an update on the requirement for superheat.
ÑÑ
ÜÜ
0170-151-EN 97
R404A TC
Screw compressors
ÜÜÜÜÜÜÜ
ÖÖÖÖÖÖ
°F °C
ÜÜÜÜÜÜÜ
ÖÖÖÖÖÖ
SH15
104 40
ÜÜÜÜÜÜÜ
ÑÑÑÑÑÑÑ
ÜÜÜÜÜÜÜ ÖÖÖÖÖÖ
86 30
ÑÑÑÑÑÑÑ
ÜÜÜÜÜÜÜ
ÑÑÑÑÑÑÑ 3 SH10
2 (3)
ÜÜÜÜÜÜÜ
ÑÑÑÑÑÑÑ
68 20
50 10
ÜÜÜÜÜÜÜ
ÑÑÑÑÑÑÑ
ÖÖÖÖÖÖÖ
ÜÜÜÜÜÜÜ ÖÖÖ
32 0 ÑÑÑÑÑÑÑ
ÖÖÖÖÖÖÖÖÖÖ
ÑÑÑÑÑÑÑ
ÖÖÖÖÖÖÖ 1
(2)
14 -10
ÑÑÑÑÑÑÑ
ÖÖÖÖÖÖÖ
ÖÖÖÖÖÖÖ
B
ÖÖÖÖÖÖÖ
Code no Area no
(See note) -4 -20
ÖÖÖÖÖÖÖ
1 2 3 SH15
E3 Y -22 -30
E5 Y -70 -60 -50 -40 -30 -20 -10 0 10 °C
E9 Y TE
-94 -76 -58 -40 -22 -4 14 32 50 °F

ÑÑ
ÑÑ
ÜÜ
ÜÜ : Calculation must be performed using COMP1
98 0170-151-EN
R407C TC
Screw compressors
°F
122
°C
50 ŠŠŠŠŠŠŠŠŠ
ÜÜÜÜÜÜÜ ÚÚÚÚÚ
ŠŠŠŠŠŠŠŠŠ
ŠŠŠŠŠŠŠŠŠ
SH10
ŠŠŠŠŠŠŠŠŠ
ÜÜÜÜÜÜÜ
104 40
SH5
ÜÜÜÜÜÜÜ
ÑÑÑÑÑÑÑÑÑ
Condensing temperature 2
86 30
ÜÜÜÜÜÜÜ
ÑÑÑÑÑÑÑÑÑ
ÜÜÜÜÜÜÜ
ÑÑÑÑÑÑÑÑÑ
68 20
50 10
ÜÜÜÜÜÜÜ
ÑÑÑÑÑÑÑÑÑ
ÑÑÑÑÑÑÑÑÑ
ŠŠŠŠŠ 1
32 0
B
14 -10
ŠŠŠŠŠ
ŠŠŠŠŠ
ŠŠŠŠŠ
(See note) SH5
1 2
-22 -30
E3 Y -70 -60 -50 -40 -30 -20 -10 0 10 20 °C
E9 Y TE
-94 -76 -58 -40 -22 -4 14 32 50 68 ° F
ÑÑ
ÜÜ
0170-151-EN 99
R507 TC
Screw compressors
ÜÜÜÜÜÜÜ
ÑÑÑÑÑÑÑÑÑ
ŠŠŠŠŠ
°F °C
104 40
ÜÜÜÜÜÜÜ
ÑÑÑÑÑÑÑÑÑ
ÜÜÜÜÜÜÜ ŠŠŠŠŠ
ÑÑÑÑÑÑÑÑÑ
ŠŠŠŠŠ 2
ÜÜÜÜÜÜÜ
ÑÑÑÑÑÑÑÑÑ
ŠŠŠŠŠ
86 30 SH5
ÜÜÜÜÜÜÜ
ÑÑÑÑÑÑÑÑÑ
ÜÜÜÜÜÜÜ ŠŠŠŠŠ
ÑÑÑÑÑÑÑÑÑ
ŠŠŠŠŠŠŠŠŠŠŠ
68 20
50 10
ÜÜÜÜÜÜÜ
ÜÜÜÜÜÜÜ
1 SH5
ÏÏÏÏÏÏ
32 0
SH15
ÏÏÏÏÏÏ
ÏÏÏÏÏÏ
14 -10

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

Ñ
Ü
100 0170-151-EN
List of major oil companies
The oil from the companies listed below are NOT tested by YORK Refrigeration and are there-
fore NOT approved by YORK Refrigeration either. The following list reflects the information pro-
vided by the companies themselves. The assessment of durability and suitability of specific oils
for specific purposes are entirely at the companies’ own discretion. Oils tested and approved by
YORK Refrigeration can be found in the ”List of part numbers for available Sabroe oils”.
Oil Oil Types

Company M A PAO AP E
Aral
• •
Avia
•
BP
• • • •
Castrol
• • • •
Chevron (UK: Gulf Oil)
• • •
CPI Engineering Services
• • •
DEA
• • • •
Elf / Lub Marine 1
• • •
Esso/Exxon
• • •
Fina
• • •
Fuchs
• • • •
Hydro-Texaco
• • • •
ICI
•
Kuwait Petroleum (Q8)
• •
Mobil
• • • • •
Petro-Canada
•
Shell
• • • •
Statoil
• •
Sun Oil
• •
0170-151-EN 101
Notes:
102 0170-151-EN
Alignment of unit
Installation on vibration dampers
1
A1
A2
H Hmax
2
97.02
A1
0171-243-DA
A2
T0177040_0
The vibration dampers supplied are marked Industrial Marine-

with a code, for instance LM6-60. LM6 indi- type 1 type 2
cates the size; 60 indicates the rubber hard-
Flexion min 1,0 min 3,0
ness and is therefore an expression of bear- max 2,0 max 5,0
A1-A2
ing and damping ability.
Height adjustment H = H+12 with disks
max
supplied as shown
When using vibration dampers, the machine
room floor is assumed to have the necessary
The flexion of a damper is adjusted by in-
bearing stregth and to be level enough to en-
creasing or decreasing the load in relation to
able adjustment of the vibration dampers to
the other supports. The foot can be raised by
be made within the adjusting measurements
screwing the adjusting rod down or inserting
stated on the drawing submitted.
more disks between damper and foot (marine
design), thereby increasing load and hence
In order for the individual vibration damper to also the flexion.
cushion properly, a sufficient load must be
imposed. Measure A1 and H in an unloaded Once the installation has cooled down, check
and A2 in a loaded set-up, as shown in draw- during operation that the flexion of the damp-
ing T0177040. ers is still correct!
0171-231-EN 103
Installing directly on foundation Perform this check with the bolts loosened. If
slip occurs at one or more resting surfaces,
When installing a unit directly on a concrete
shim up before tightening. If unaligned, there
foundation, the foundation should be cast in
is a risk of stresses occurring in the compres-
accordance with the foundation drawings dis-
sor frame, which will damage the bearings.
patched.
When the foundation has been cast - with the Alignment of motor with base frame
holes shown for foundation bolts - and has Check the contact faces of the motor against
set, place the unit in position, allowing it to the base frame in the same way as for the
rest on beams levelled at a suitable height so compressor.
that the foundation plates are recessed
slightly into the foundation. Stresses from piping connections
In order to prevent stress being transmitted
Check that the foundation plates are right
from piping connections between unit and
next to the base frame. This can be achieved
plant, pipes must be laid so as not to gener-
by binding them to the resting surfaces of the
ate compressive stresses or tensile strains in
base frame with steel flex.
the event of expansions or contractions due
The concrete cast down around the founda- to temperature changes. Steel piping ex-
tion bolts should contain only a small amount pands approx. 1 mm per metre per 100°C.
of water, so that it can be well tamped around We can recommend that piping be laid as
the bolts. Low water content produces no shown in example 2 of the sketch. Example 1
contraction of the setting concrete. demonstrates too rigid pipe laying.
10-14 days should be allowed to elapse be-

fore removing the beams and tightening the
nuts for the foundation bolts. > 1.5 m
Before that, however, remove the steel flex

and check that there is no space between the
base frame and the foundation plates. If
there is, place shims between the plates be- 1 2
fore tightening.
Alignment of compressor with base

frame T0177057_0
Check that the entire footing of the compres- Final alignment of compressor and motor can
sor makes full contact against the milled-off be performed once all piping has been con-
faces of the base frame. nected to the unit.
104 0171-231-EN
VĆbelt drive for BFO reciprocating compressors
In case your SABROE compressor is belt driven, use drive belts with belt profiles like the ones
indicated in the following table.
Compres- Motor Compressor belt pulley Number of Center

sor type diametre Number of belts x revolutions distance
diam. profile x length at 50 Hz C
BFO mm mm mm (1/min) mm
90 875 730 234

110 875 920 220
1 133 165 1 x 13/8 x 900 1130 215
165 1180 1380 331
190 1200 1590 321
90 1060 710 328
97.02
110 1105 890 335

2 133 165 2 x 13/8 x 1120 1130 326
165 1180 1420 331
0171-238-EN
190 1200 1630 321

140 1482 915 465
170 3 x SPA x 1507 1125 455
3 210
210 1582 1420 461
230 1607 1580 458
140 1282 915 364
170 3 x SPA x 1307 1125 354
4 210
210 1382 1420 361
230 1382 1580 345
170 1582 1050 476
210 4 x SPA x 1607 1300 458
5 230
230 1657 1450 467
240 1657 1530 459
Fig. 1 C
T0177165_0 V16
0171-231-EN 105
Mounting of V-belts belts in between the pulleys by hand. The
S Before mounting of V-belts the pulley belts should be equally tight and an even
tracks should be thoroughly cleaned of oil pressure by hand only lower them 3 to 5
or dirt as well as checked for any grooves mm.
and bruises. S Let the transmission run for a couple of
S Move the motor sufficiently to allow the minutes, then check the degree of tight-
belts to be fitted without having to apply ness.
force. S It is important to inspect the tightening at
Never force the belts over the pulleys as regular intervals as indicated in the sec-
the power transmitting fibres can be dam- tion: Servicing the reciprocating compres-
aged and the life of the belts considerably sor.
reduced. S On replacing worn V-belts the whole set
S After fitting of the V-belts compressor and must be replaced.
motor are once more pulled apart and
S One set of V-belts must always be within
aligned by means of a straightedge as il-
the same tolerance group.
lustrated in fig. 1. The tracks must be flush
with one another and the shafts complete- S Never use belt grease.
ly parallel.
Remember:
S In order to obtain the best possible operat- The protecting guard should always be
ing conditions the belt tension must be mounted whenever the belt drive is oper-
correct. This is checked by pressing the ating.
106 0171-231-EN
Connections on BFO 3 Ć 4 Ć 5
L B1 B DV
B1
DV A
B/L
SV
SV
A1 A1 C/E
C/E D K
97.02
D/D1/H H
D1
K
G F
0171-240-EN
F/G
BFO3 BFO4
T0177164_0 V2 T0177164_0 V3
B1
DV
L
SV
D
A
D1
A1
H
J C/E
F K
BFO5
T0177164_0 V4
See table on the following page.
0171-231-EN 107
Table on connections to BFO 3 - 4 - 5
Pos Description BFO3 BFO4 BFO5

Dim Dim Dim
R22 R717 R22 R717 R22 R717
SV Suction stop valve*, pipe dia. 28L / 11/8”L Ø30 x 24S 35L / 11/8”L Ø38x32S 35L/11/8”L(2x) Ø38x32S(2x)
DV Press. stop valve*, pipe dia. 22L / 7/8”L Ø25 x 20S 28L / 11/8”L Ø30x24S 35L / 11/8”L Ø38 x 32S
A Connection to suction side, 1/ ” NPTF Ø6 V 1/ ” NPTF Ø6 V 1/ ” NPTF Ø6 V
8 8 8
cannot be closed
A1 Connection to suction side, 7/ ” UNF Ø6 V 7/ ” UNF Ø6 V 7/ ” UNF Ø6 V
16 16 16
can be closed
B Connection to ddischarge side, 1/ ” NPTF Ø6 V 1/ ” NPTF Ø6 V 1/ ” NPTF Ø6 V
8 8 8
cannot be closed
B1 Connection to discharge side, 7/ ” UNF Ø6 V 7/ ” UNF Ø6 V 7/ ” UNF Ø6 V
16 16 16
can be closed
C Pressure control for oil 1/ ” NPTF Ø6 V 1/ ” NPTF Ø6 V 1/ ” NPTF Ø6 V
8 8 8
differential pressure
D Pressure control for low oil pres- 1/ ” NPTF Ø10 V 7/ ” UNF Ø6 V 7/ ” UNF Ø6 V
8 16 16
sure
D1 Oil return from oil separator 1/ ” NPTF Ø10 V 1/ ” NPTF Ø10V 1/ ” NPTF Ø10 V
8 8 8
E Connect. for measuring oil press. 1/ ” NPTF Ø6 V 7/ ” UNF Ø6 V 7/ ” UNF Ø6 V
8 16 16
F Plug for oil evacuation M22 x 1,5 M22 x 1,5 M22 x 1,5 M22 x 1,5 M22 x 1,5 M22 x 1,5
G Connection for oil heat. rod M22 x 1,5 M22 x 1,5 – M22 x 1,5 – M22 x 1,5
H Connection for oil filling 1/ ” NPTF Ø10 V M22 x 1,5 M22 x 1,5 M22 x 1,5 M22 x 1,5
8
J Heating rod – – M22 x 1,5 – M22 x 1,5 –
K Connection for common oil/gas – Ø35 Ø35 Ø35 Ø35 Ø35 Ø35
compensation
L Connection for warm discharge 1/ ” NPTF 1/ ” NPTF 1/ ” NPTF 1/ ” NPTF 1/ ” NPTF 1/ ” NPTF
8 8 8 8 8 8
gas thermostat
L = bronze connection If nothing else is mentioned the measures

S = welding connection are in mm.
V = cutting ring connection
* = can be turned 180°
108 0171-231-EN
Cooling of reciprocating compressor
BFO 3 Ć 4 Ć 5
Water cooling A solenoid valve must be fitted in the inlet

It is possible to cool the compressors by ap- pipe to the water system of the compressor
plying water on the top covers. which shuts off the water flow in the cool-
ing system whenever the compressor is idle.
The need for cooling depends on the operat-
ing conditions and the type of refrigerant
used. Water cooling is especially necessary Technical data for the water cooling
when the compressor is working at very high system:
compression temperatures (above 140°C). – All connections are with an R 1/2” thread.
This may be the case in deep freeze areas
with a large discharge gas superheating. – Max. water flow:
^ 40 litres per minute.
If the compressor is working with ammonia,
– Max. pressure loss in the cooling system:
97.02
R717, water-cooling may also prove neces-

^ 0,15 bar.
sary. Please, see Operating limits diagrams.
– Max. permissible water pressure: 10 bar.
0171-242-EN
Water-cooling is achieved by replacing the

top covers with special top covers with con- The minimum water flow should be large
nections for cooling water. enough to prevent the max. permissible dis-
The water-cooled top covers are available for charge gas temperature from exceeding
BFO 3-4-5. As for BFO 4-5 it is further pos- 140°C.
sible to get water-cooled top covers where
space is left for a solenoid valve for capacity
regulation. Air cooling
Connect the water covers as shown in fig. 1. For air-cooling a special fan motor can be
Fig. 1 > delivered designed for operation at high am-
bient temperatures.
The following table indicates the technical
specifications of the motor.
The motor is also available for other voltage
<
and frequency values.
Motor Nominal Max. power Permissible Fan Phase

type effect consumption Power ambient shift
diameter
temperature
AD 1,65/ 3-fase
1176-4 360 W 0,95A 220/380V +80 °C 420 mm +35 °
60 Hz
0171-231-EN 109
Ordering Spare Parts
When placing an order for spare parts, ber. If you are in any doubt, add the spare
please state the following: part no. too.
1. Shop No. 3. Forwarding instructions

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

Sabroe Refrigeration A/S

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Sabroe Refrigeration A/S

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Sabroe Refrigeration A/S

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What are the different types of cooling that can be used for the compressor?

What are the different types of cooling that can be used for the compressor?

What information should be provided when ordering spare parts?

What information should be provided when ordering spare parts?

Instruction Manual for

Drive type V-belts

Oil pump drive Gear-wheel drive

Equipment for parallel operation

Compressor used for air conditioning ( KP1 regulated)

S service schedules; To prevent accidents during dismantling and

SABROE REFRIGERATION A/S

P.O. Box 1810, DK–8270 Højbjerg Phone: +45 86 27 12 66

Specification for BFO 3 - 4 - 5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

acid burn), let the conscious patient drink

No plant can ever be said to be too safe.

3. Avoid direct contact with contaminated oil/

No plant can ever be said to be too safe.

Halogenated refrigerants Ammonia

R134a R404A R407C R410A R507 R22 R717

Warning smell vol.% 0,2 0,002

S Ammonia is easily absorbed by water:

Refrigeration compressors are lubricated by – polyalphaolefine-based synthetic oil

Direction of rotation clearly marked with red paint. The weight of

rotation is not indicated by an arrow but is In view of preventing an unintended applica-

The compressor may ONLY be used:

Other demands to the emergency device:

Consequently, the compressors will be equip-

Examples of quality judgement

ms-velocity V (in mm/s)

BFO 4 4 55 49 1800/500 1450/700 40.54 77 70

Sound pressure level in dB(A) for BFO compressor and unit

–30 –20 –10 0 10 20

T0177166_0 V1 Evaporating temperature TE (° C)

2 Normal cooling area

Hatched External cooling such as water or air fan must be applied

Absolute operating limits:

–30 –20 –10 0 10 20

2 Normal cooling area

Hatched External cooling needed if suction gas superheating exceeds 20K

Absolute operating limits:

-30 -20 -10 0 10 20 30

2 Normal cooling area

Hatched External cooling such as water or air fan required

Absolute operating limits:

Starting up compressor and plant S Carefully continue opening suction stop

S Start condenser cooling, brine pumps, before switching to next stage.

whether oil pressure is correct.

S Stop condenser cooling, pumps, fans and – correct oil pressure,

Stopping plant for lengthy periods Pressure testing refrigeration plant

Important: Pumping down refrigeration plant

S Afterwards, reduce pressure to 10 bar for 5 6,63 8,80

Important: S Blow dry air or nitrogen into system to a

Observation Measuring point Measurement unit

Time Date and time

Suction gas temp. • Thermometer in suction pipe

Oil level in • Oil level sight glass Must be visible in oil

At the same time, attention should be paid to the following:

S whether the compressor’s cooling system is functioning correctly,

S whether any unusual noises can be heard from the compressor,

S whether there are unusual vibrations in the compressor.