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

Mounting instruction 22 June 2011

008938 (replaces 0171-980)

Mounting of new type of capacity rod on SAB 202 screw compressors

As described in Technical Information 2002/11 a new measuring system with a new capacity rod for SAB 202 screw
compressors was introduced in February 2002.

Fig. 1

This mounting instruction describes in detail how to disassemble and assemble the compressor in order to mount
the new capacity rod.
The capacity rod is available in different lengths and is used for indicating the positions of the capacity slide and Vi
slide on type L or S compressors.
When mounting the capacity rod, it is recommended to use one of the following alteration sets. The sets consist of
the mentioned parts, which must be replaced in order for the capacity rod to be mounted. The following alteration
sets are available. The position numbers are shown in Appendix 1.

Alteration sets

Indication of capacity slide position, SAB 202 L

Alteration sets, complete Part. no. 3084.652

Pos. 350 Position transmitter SA96DX Part. no. 1373.295
Pos. 64 Dowty ring Part. no. 1331.427
Pos. 356 Aluminium pipe, 320 mm Part. no. 1116.037
Pos. 60 Cover for capacity cylinder Part. no. 3013.206
Pos. 63 Cylinder screw M6 x 25 Part. no. 1413.342
Pos. 207A1 Piston rod, 202 L Part. no. 3043.256
Pos. 210 Pointed screw M6 x 10 (quantity: 2) Part. no. 1413.231
Pos. 61 O-ring, ø142.47 x 3.53 Part. no. 1331.096
Pos. 203 O-ring, ø40.87 x 3.53 Part. no. 1331.064
Pos. 204 Sealing ring, ø 150 Part. no. 1332.133

Page 1 of 12
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

Indication of capacity slide position, SAB 202 S

Alteration sets, complete Part. no. 3084.653

Pos. 350 Position transmitter SA96DX Part. no. 1373.296
Pos. 64 Dowty ring Part. no. 1331.427
Pos. 356 Aluminium pipe, 320 mm Part. no. 1116.037
Pos. 60 Cover for capacity cylinder Part. no. 3013.206
Pos. 63 Cylinder screw M6 x 25 Part. no. 1413.342
Pos. 207A2 Piston rod, 202 S Part. no. 3043.257
Pos. 210 Pointed screw M6 x 10 (quantity: 2) Part. no. 1413.231
Pos. 61 O-ring, ø142.47 x 3.53 Part. no. 1331.096
Pos. 203 O-ring, ø40.87 x 3.53 Part. no. 1331.064
Pos. 204 Sealing ring, ø 150 Part. no. 1332.133

Indication of capacity slide position, SAB 202 L (automatic Vi only)

Alteration sets, complete Part. no. 3084.654

Pos. 410 Position transmitter SA96DX Part. no. 1373.297
Pos. 411 Dowty ring Part. no. 1331.427
Pos. 412 Cylinder srew M6 x 25 Part. no. 1413.342
Pos. 416 Aluminium pipe, 143 mm Part. no. 1116.039
Pos. 380 Cover for slide stop Part. no. 3013.435
Pos. 381 O-ring, ø101.19 x 3.53 Part. no. 1331.083
Pos. 190-2 Slide stop, complete, 202 L Part. no. 3043.258
Pos. 371 Sealing ring, OD70 mm Part. no. 1332.126
Pos. 372 Retainer for aluminium pipe Part. no. 3045.070
The parts to be replaced when dismantling the capacity slide are mentioned below.

Indication of capacity slide position, SAB 202 S (automatic Vi only)

Alteration sets, complete Part. no. 3084.655

Pos. 410 Position transmitter SA96DX Part. no. 1373.301
Pos. 411 Dowty ring Part. no. 1331.427
Pos. 412 Cylinder srew M6 x 25 Part. no. 1413.342
Pos. 416 Aluminium pipe, 143 mm Part. no. 1116.039
Pos. 380 Cover for slide stop Part. no. 3013.435
Pos. 381 O-ring, ø101.19 x 3.53 Part. no. 1331.083
Pos. 190-1 Slide stop, complete, 202 S Part. no. 3043.259
Pos. 371 Sealing ring, OD70 mm Part. no. 1332.126
Pos. 372 Retainer for aluminium pipe Part. no. 3045.070
The parts to be replaced when dismantling the capacity slide are mentioned below.

Page 2 of 12
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

Parts to be replaced
The following list states the parts to be replaced, ie the parts witch are not going to be reused. The position numbers
are shown in Appendix 2.

Indication of capacity slide position, SAB 202 S and L

Pos. 350 Position transmitter Part. no. 3448.004
Pos. 351 Sight glass Part. no. 3045.047/048
Pos. 221 Indicator disc Part. no. 3045.001
Pos. 223 M4 x 10 screw Part. no. 1413.319
Pos. 224 Gasket, ø105 Part. no. 2356.155
Pos. 226 Locking washer, ø15 Part. no. 1437.054
Pos. 227 Locking washer, ø8 Part. no. 1437.060
Pos. 60 Cover for capacity cylinder Part. no. 3013.197
Pos. 70 Housing for capacity indicator Part. no. 3045.002
Pos. 71 M6 x 30 screw Part. no. 1413.343
Pos. 72 End ring Part. no. 3045.003
Pos. 73 M6 x 50 screw Part. no. 1413.347
Pos. 74 O-ring Part. no. 1331.081
Pos. 75 Sight glass for capacity indicator Part. no. 3045.050/049
Pos. 207A1 Piston rod, 202 L Part. no. 3043.140
Pos. 207A2 Piston rod, 202 S Part. no. 3043.141
Pos. 207B Bushing Part. no. 3045.046
Pos. 210 Spindle for capacity indication Part. no. 3045.059
Pos. 216 Magnetic coupling Part. no. 3045.061
Pos. 217 O-ring Part. no. 1331.146

Page 3 of 12
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

Indication of Vi slide position, SAB 202 S and L

Pos. 410 Position transmitter Part. no. 3448.004
Pos. 411 Driver Part. no. 3044.020
Pos. 412 M4 x 5 screw Part. no. 1413.211
Pos. 413 Clamping pin 1.5 x 12 Part. no. 1446.010
Pos. 400 Transmitter housing Part. no. 3044.064
Pos. 401 M6 x 80 screw Part. no. 1413.307
Pos. 402 End ring Part. no. 3045.009
Pos. 403 M4 x 10 screw Part. no. 1413.319
Pos. 405 Magnetic coupling Part. no. 3045.062
Pos. 371 Sealing ring Part. no. 1332.126
Pos. 372 Pin retainer Part. no. 3044.035
Pos. 380 Cover for slide stop Part. no. 3013.196
Pos. 386 Cylindrical pin, ø6 x 16 Part. no. 1445.076
Pos. 390 Spindle for automatic Vi Part. no. 3044.063
Pos. 393 Ball bearing Part. no. 1511.012
Pos. 395 Driving disc Part. no. 3044.021
Pos. 396 M4 x 12 screw Part. no. 1413.318
Pos. 190-1 Slide stop, 202 S Part. no. 3043.131
Pos. 190-2 Slide stop, 202 L Part. no. 3043.130

Page 4 of 12
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

Dismantling and mounting

When the pressure in the compressor has been reduced to atmospheric pressure and the compressor has been
secured against unintentional start-up as stated in the instruction manual, proceed as described below.

Indication of capacity slide position

In case the Vi regulation of the compressor is automatic and the new capacity rod is to be mounted, see the section
Indication of Vi slide position below.

Dismantling of capacity slide system

• Dismantle electric plug on existing capacity rod.
• Dismantle piping connection to cover, pos. 60.
• During manual Vi regulation it is advantageous to unscrew Vi slide as far as possible by turning spindle,
pos. 180, clockwise. This will loosen spring, pos. 191, see Fig. 2.

MAN. VI
181
185
184 ..
182
... .
183
. .. ...
.. .
180
188
187
196 . .
198

197 186 195 189 191

Fig. 2

• Dismantle complete capacity indicator by unscrewing two diagonally positioned cylinder screws, pos. 62.
Mount threaded spindles no. 22 and nuts no. 9.2 from tools kit, see Fig. 3.

Page 5 of 12
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

60 62

9.2 22

Fig. 3

• Remove remaining screws, pos. 62. By loosening nuts no. 9.2, the large spring, pos. 191, will loosen cover,
pos. 60, via capacity slide, pos. 200, and piston. Pull cover straight out to avoid damaging spindle, pos. 210.
Watch out! There may be oil behind the cover, pos. 60.
• It is now possible to remove complete capacity slide with piston, pos. 201/202, from cylinder.
• Remove cap screw, pos. 311, and clamp device, pos. 312, to dismantle piston rod, pos. 207A, and slide,
pos. 200. Do not reuse piston rod, pos. 207A.
• Spirolox ring, pos. 207D, and steel ball, pos. 207E, act as a kind of non-return valve. In case of an emergency
stop this non-return valve ensures that the capacity slide moves quickly to its minimum position as the oil
is emptied through the non-return valve.
• Mount Spirolox ring and steel ball on new capacity rod in pos. 207A1/A2.
• In case sealing ring, pos. 204, has been damaged, it must be replaced. This is done by removing slotted
nut, pos. 206, and locking plate, pos. 208, and then dismantle outer and inner rings of piston. Pay attention
to O-ring, pos. 203. Pos. 204 and 203 are part of the alteration set.
• Tape bearings, pos. 209, are fitted on the capacity slide end surface. They can be positioned loosely in the
capacity slide groove. Pos. 209 is part of the alteration set.

Page 6 of 12
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

Mounting of capacity slide system

See Appendix 1.
Assemble complete capacity slide on work bench as described below:
• Tighten screw, pos. 311, with clamp, pos. 312, to 300 Nm.
• Fit tape bearings, pos. 209, correctly in capacity slide, pos. 200.
• Fit steel ball, pos. 207E, and Spirolox ring, pos. 207D, on new piston rod, pos. 207A.
• Mount aluminium pipe, pos. 356, in piston rod so that it is level with the end of the rod as illustrated in
Appendix 1.
• Tighten pointed screws, pos. 210. Secure screws with Loctite 243.
• Mount piston parts, pos. 201 and 202, on piston rod, pos. 207A. Tighten slotted nut, pos. 206, and secure
locking plate, pos. 208. Remember that the opening of the sealing ring, pos. 204, must face the capacity
slide. Do not forget O-ring, pos. 203.
• Mount spring, pos. 191, and position complete capacity slide in thrust cover while guiding it carefully into
place until the spring starts resisting.
• Mount threaded spindles no. 22 in cylinder end surface. Position new cover, pos. 60, on threaded spindles.
See Fig. 3.
By tightening the nuts no. 9.2, the cover is pressed against the capacity slide, and the entire system is
pressed against the spring.
Be careful not to damage sealing ring, pos. 204, while inserting it in cylinder.
• Tighten two of the cylinder screws, pos. 62. Dismantle the two threaded spindles and nuts and replace them
with the two remaining screws, pos. 62.
• Mount and tighten sensor pocket, part of pos. 350. Remember Seeger ring, pos 64.
• Mount position transmitter, pos. 350, and tighten screws, pos. 63.
• In case of manual Vi regulation, adjust Vi to original position. See section Dismounting.
• Mount electric plug. See section Adjusting capacity measuring system.
• Mount piping connections to cover, pos 60.

Indication of Vi slide position

The following instructions must only be used in connection with automatic regulation of the Vi slide.
The new capacity rod is easily mounted by disassembling and assembling the compressor from both ends as de-
scribed in the following with reference to Appendices 1 and 2.

Dismantling of Vi slide
• First dismantle electrical connection to position transmitter, pos. 410. See Appendix 2.
• Dismantle piping connection to cover, pos. 380.
• After dismantling of screws, pos. 382, remove cover, pos. 380. Cover is not to be reused.

Page 7 of 12
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

Disassemble the compressor from the opposite end as described previously in section Indication of capacity slide
position.
• Dismantle electric plug on existing capacity rod.
• Dismantle piping connections to cover, pos. 60.
• Dismantle complete capacity indicator by unscrewing of two diagonally positioned cylinder screws, pos. 62.
Mount threaded spindles no. 22 and nuts no. 9.2 from tools kit, see Fig. 3.
• Remove remaining screws, pos. 62. By loosening of nuts no. 9.2, the large spring, pos. 191, will loosen
cover, pos. 60, via capacity slide, pos. 200, and piston. Pull cover straight out to avoid damaging spindle,
pos. 210.
Watch out! There may be oil behind the cover, pos. 60.
• It is now possible to remove complete capacity slide with piston, pos. 201/202, from cylinder.
• Dismount threaded plug and Dowty ring, pos. 24/25. Push Vi slide into compressor manually so that cylinder
screw, pos. 192, can be dismounted through the hole where treaded plug and Dowty ring, pos. 24/25, were
previously mounted.
• Remove Vi slide, pos. 190, through opposite end of compressor block. Vi slide must be replaced with new
slide from alteration set.

Mounting of Vi slide
Mount the following parts on the Vi slide, pos. 190, before positioning it in the compressor:
• On delivery spring cup A is mounted in slide stop, pos. 190, and cannot be dismantled.
• Mount aluminium pipe, pos. 416, and tighten retainer for aluminium pipe, pos. 372, and cylinder screws,
pos. 385.
• Mount Vi slide, pos. 190, in compressor as illustrated in Appendix 1. Turn slide so that it is possible to mount
and tighten cylinder screw, pos. 192, through the hole where threaded plug, pos. 24, and Dowty ring, pos.
25, are to be mounted.
• Mount spring, pos. 191, and position complete capacity slide in thrust cover while guiding it carefully into
place until the spring starts resisting.
• Take care not to damage sealing ring, pos. 204, while inserting it in cylinder. Mount threaded spindles
no. 22 in cylinder end surface. Position new cover, pos. 60, on threaded spindles. See Fig. 3.
By tightening the nuts no. 9.2, the cover is pressed against the capacity slide and the entire system is pressed
against the spring.
• Tighten two of the cylinder screws, pos. 62. Dismantle the two threaded spindles and nuts and replace them
with the two remaining screws, pos. 62.
• Mount and tighten sensor pocket, part of pos. 350, and remember Seeger ring, pos 64.
• Mount position transmitter, pos. 350, and tighten screws, pos. 63.
• Mount electric plug. See section Adjusting capacity measuring system.
• Mount piping connections to cover, pos 60.
At the opposite end of the compressor mount the Vi slide as follows:

Page 8 of 12
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

• On the new cover for slide stop, pos 380, mount sealing ring, pos. 371, with opening facing outwards as
illustrated in the drawing.
• Mount attachment for sealing ring, pos. 384, and tighten screws, pos. 387.
• Position cover for slide stop, pos 380, in compressor, and tighten screws, pos. 382. Remember O-ring, pos.
381.
• Mount sensor pocket, pos. 415, and sealing ring, pos. 411.
• Mount position transmitter, pos. 410, and tighten screws, pos. 412.
• Mount electric plug. The same electric plug can be used for the new capacity rod. It is however recommended
to check that the wiring connections comply with Fig. 4.

Capacity Slide UNISAB II

1 = OUT 4--20mA Termina l 31

2 = SUPPLY+24V DC Termina l 29
3 = COMMON -- Termina l 30
= GND Not to be used

Vi Slide UNISAB II

1 = OUT 4--20mA Termina l 34

2 = SUPPLY+24V DC Termina l 32
3 = COMMON -- Termina l 33
= GND Not to be used

Fig. 4

• Mount piping connections to cover, pos. 380.

Page 9 of 12
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

Adjusting capacity measuring system

The capacity transmitter is fitted with a single calibration button surrounded by a green and a red LED as shown in
Fig. 5.

LED--Position Calibration LED--Working

(Green ) pu sh bu tt on (Red )

Normally no t visible.
Remove cover for
calibration

Fig. 5

During normal operation the red LED is flashing slowly. The green LED will be constantly on when the transmitter is
in 100% position. It will flash quickly when the transmitter is in 0% position.
Calibration is carried out as follows:
Note: Make sure that UNISAB II is not in alarm.
1. Apply supply voltage for a minimum of five minutes before calibration.
2. Press the calibration button for five seconds to get the transmitter in calibration mode. The red LED will
change from normal flash to OFF.
3. Decrease the capacity to its minimum and then press the calibration button once. The red LED will turn ON
immediately. After ten seconds the red LED will turn OFF again, indicating that it is ready for 100% calibra-
tion.
4. Increase the capacity to its maximum and then push the calibration button twice. The red LED will start
flashing quickly. After ten seconds the red LED will change to normal flash rate indicating that the calibration
has been completed.
5. The calibration will be remembered even in case of power failure.
To return to “Factory Set Point”, press the calibration button for 20 seconds. Indication of this is shown by a short
flash of the green and red LED (one after the other).
The 4--20 mA signal from the transmitter is permanently available. However, during calibration the signal is based
on default calibration values, so it will not show 0% at minimum capacity, nor 100% at maximum capacity!
Note: It is possible to reset the transmitter to default calibration by keeping the button pressed for 20 seconds.
However, the transmitter is reset to the transmitter manufacturer’s default values, which may differ very much from
the correct values for the actual compressor. Reset is indicated by the red and green LED flashing briefly in turn a
couple of times.

Page 10 of 12
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

Appendix 1

350

60
64
63

62
61
206
202
208

201
207C

356
204

43
203

207A

210
207D
207E

200
312
311

416
191
385
372
387

209
30
190
25
192

24
381

382
410

412
411
380

Fig. 6

Page 11 of 12
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

Apendix 2

224

350

351
223

352
227
73
74
226

72
71
221
219

70
216
62
60
61

210

207C
206
217
218

202
203
208

207B
204

201
207D

43
207A
207E

312
144

200
311

191
390

386
372
387

385
371

384
30
209
393
190
25
24
192
382
401

395

410

407
402

396

411
380
381
406

412
403

400
413

405

416 1-- T03_10

Fig. 7

Bas Pijnenburg
Product Development
Direct no.: +45 87 36 77 90
Fax no.: +45 87 36 77 05
e-mail: Bas.Pijnenburg@jci.com

Page 12 of 12