Sabroe Kit Installation guide

Brand
Sabroe
Model
Kit
Type
Installation guide
Mounting instruction
008784 17 May 2011
Kit for reduction of oil carry-over - SMC 100 compressors
It is well-known that small concentrations of oil in the form of small droplets and mist above the oil sump in the
compressor housing will leave the compressor and be lost with the discharge gas to the high pressure system in a
refrigerant plant.
As an alternative to an external oil separator vessel an internal demister unit can be installed in the compressor
housing.
The demister unit can be attached to the inner surface of the compressor side covers and must be connected to
the breathing channel for the blow-by gas flowing from the oil sump to the suction gas channel of the compressor
block.
Fig. 1: Internal demister unit
In the demister unit the small oil droplets in the refrigerant gas will tend to hit a steel wire in the knit mesh and by
the force of gravity they will slowly collect at the bottom of the unit and flow back to the oil sump through a rubber
hose.
The demister unit with patent pending is designed for installation in all SMC 100 Mk 2-3-4 compressors and de-
pending on the number of compressor cylinders, a various number of demister units should be installed.
All parts required for the installation are contained in the kits.
The kits can be installed on side covers for water-cooled compressors only.
Johnson Controls Denmark ApS
Christian X's Vej 201 ∙ 8270 Højbjerg ∙ Denmark
Phone +45 87 36 70 00 ∙ Fax +45 87 36 70 05 ∙ www.sabroe.com
CVR No 19 05 61 71
Page 1 of 6
Contents of the demister kits
All parts needed for one internal breathing channel including attachment to one side cover:
Basic kit, Item no. 3184.713
Item No. Text Quantity
3142.174 Demister unit 1
1241.023 Drain hose, dia.13/6 x 150 mm 1
1345.158 Hose clamp 1
3142.176 Shim 40x70x1.5 2
1424.152 Set screw M6x20 4
1433.072 Locking nut M6 4
3142.175 Stud 19 mm w. collar 1
1331.549 O-ring 21.82x3.53 1
For the various compressor sizes a selection of complete kits have been made:
Complete kits, Item no.: SMC 104 SMC 106 SMC 108 TSMC 108
3184.714 3184.715 3184.716 3184.717
Item No. Text Qty. Qty. Qty. Qty.
3184.713 Basic kit 2 2 2 1
2353.189 Gasket for top/side cover 2 2 2 2
3142.177 Piston for unloading cylinder 2 3 4 3
1331.560 O-ring for piston 2 3 4 3
Complete kits, Item no.: SMC 112 SMC 116 TSMC 116
3184.718 3.184.719 3.184.720
Item no. Text Qty. Qty. Qty.
3184.713 Basic kit 4 4 3
2353.189 Gasket for top/side cover 4 4 4
3142.177 Piston for unloading cylinder 6 8 7
1331.560 O-ring for piston 6 8 7
Johnson Controls Denmark ApS
Christian X's Vej 201 ∙ 8270 Højbjerg ∙ Denmark
Phone +45 87 36 70 00 ∙ Fax +45 87 36 70 05 ∙ www.sabroe.com
CVR No 19 05 61 71
Page 2 of 6
Mounting instruction
1. Unpack the kit with all its contents.
Fig. 2
2. Prepare the compressor - equalized pressure and venting to the atmosphere.
3. Take off the side covers and place them on a plane surface with the inner surface up.
4. Check the fit of the demister unit against the cooling ribs of the cover. Use the shims to correct the axial
positioning. Be aware that the shims have an edge which is intended for support on the top of the ribs of
covers older than Mk4 and should point downwards on Mk4.
Fig. 3
Johnson Controls Denmark ApS
Christian X's Vej 201 ∙ 8270 Højbjerg ∙ Denmark
Phone +45 87 36 70 00 ∙ Fax +45 87 36 70 05 ∙ www.sabroe.com
CVR No 19 05 61 71
Page 3 of 6
5. Correct the shape of the cooling ribs, if necessary, using a grinding wheel.
Fig. 4
6. Drill 2 x 2 holes dia. 7 mm in the outermost ribs.
Fig. 5
7. Fit the demister unit with the 4 M6 bolts and the shims in the correct position pressing the connector flange
against the rib sides.
Fig. 6
Johnson Controls Denmark ApS
Christian X's Vej 201 ∙ 8270 Højbjerg ∙ Denmark
Phone +45 87 36 70 00 ∙ Fax +45 87 36 70 05 ∙ www.sabroe.com
CVR No 19 05 61 71
Page 4 of 6
8. Insert the bushings into the breathing holes in the compressor block until contact with the collar surface. It is
recommended to apply Loctite to the collar surface if the fit feels loose. Mount the O-ring in the end of the
collar.
Fig. 7
9. Press the cover against the counter surface of the compressor housing and tighten two of the cover bolts.
Fig. 8
10. Correct the positioning of the connector flange of the demister unit with a heavy lever arm through the open-
ing for the opposite side cover.
Fig. 9
Johnson Controls Denmark ApS
Christian X's Vej 201 ∙ 8270 Højbjerg ∙ Denmark
Phone +45 87 36 70 00 ∙ Fax +45 87 36 70 05 ∙ www.sabroe.com
CVR No 19 05 61 71
Page 5 of 6
11. Fasten the M6 screws for the demister unit with the correct torque and reinstall the side cover using a new
gasket from the kit.
12. Replace the unloading pistons with the new ones with O-ring. These are intended to be used only for un-
loading cylinders controlling cylinder pairs where demister units are to be installed. This is the case for all
cylinders in 1-stage compressors but only for the LP cylinders in 2-stage compressors.
The purpose of the additional O-ring is to reduce the flow of oil droplets to the internal refrigerant gas chan-
nel connected to the inlet of the compressor cylinders and hereby to further reduce the amount of oil leaving
the compressor.
After evacuation the compressor can be restarted and a considerable reduction of oil carry-over to the system will
be evident.
Tests under different operating conditions have proven a 50-80% reduction of oil blow-out.
Jens Lund Christensen
Technical Services
Direct no.: +45 87 36 77 42
Fax no.: +45 87 36 75 05
e-mail: [email protected]
Johnson Controls Denmark ApS
Christian X's Vej 201 ∙ 8270 Højbjerg ∙ Denmark
Phone +45 87 36 70 00 ∙ Fax +45 87 36 70 05 ∙ www.sabroe.com
CVR No 19 05 61 71
Page 6 of 6
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Sabroe Kit Installation guide

Brand
Sabroe
Model
Kit
Type
Installation guide
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