Johnson Controls Frick SGC 1913 Manual
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Johnson Controls Frick SGC 1913 Manual

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SAB 193-233-283 S A-frame
(including ATEX)
Screw compressor units

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  • Page 1 Engineering manual SAB 193-233-283 S A-frame (including ATEX) Screw compressor units...
  • Page 3 Manual for SAB 193/233/283 A-frame screw compressors Unit no. Compressor Compressor type Oil separator type OHU 04123/2719 D1 OHU 04136/3231 D2 Refrigerant R717 HFC/HCFC Other: _________ Oil type Oil type: _________________ Evap. temp. _____ Cond. temp. _____ Control UniSAB III None Other Single...
  • Page 4 Vessel data Design pressure External surface Type [bar] Condenser Evaporator Liquid separator Oil separator Safety valve: Data for calculation of Oil cooler downstream line accord- ing to EN 13136 Economiser Other Pressure loss, if any, from safety valve to customer connection (based on design pressure) [bar] _____________ Safety valve type: Back-pressure dependent...

  • Page 5: Table Of Contents

    Safety precaution definitions used in this manual ....13 Requirements for competent persons ........13 Signs and warnings ............... 14 Main users ................14 Identification of Johnson Controls Denmark equipment ................14 Compressor name plate ............15 Compressor name plate - ATEX ..........16 Labelling of explosion-proof equipment .......
  • Page 6 Technical description ..............34 Description of the screw compressor ........34 Marine application ..............36 Description of main components and systems ..... 37 Control system ..............37 Compressor ................38 Variable speed drive (VSD) ........... 39 Compressor lubrication system ..........40 Oil injection valve ..............
  • Page 7 4.36 Instrumentation ..............73 Physical and connection data ............. 75 Physical data ................75 Allowable flange loads ............76 Mounting of suction isolation valve ........77 Connection data ..............78 5.4.1 Connections to compressor unit ........78 5.4.2 Electrical connections ............. 84 5.4.3 List of components ............
  • Page 8 Safety equipment ..............101 7.10 Local regulations ..............101 7.11 Preparing the mounting site ..........101 7.12 Space requirements ............102 7.13 Lifting and loading instructions ........... 102 7.14 Unpacking and inspection ........... 102 7.15 Disposal of non-reusable materials ........102 7.16 Moving the equipment to the mounting site .......
  • Page 9 11.5 Visual inspection ..............135 11.6 Measures to be taken ............135 11.7 General rules for use of lubricating oil in refrigeration compressors ................ 137 11.8 Assessing the oil ..............137 11.9 Visual assessment ............... 138 11.10 Analytical evaluation ............138 11.11 Analysing the oil ..............
  • Page 10 Spare parts list ................160 Spare parts drawings ..............161 Final disposal ................162 18.1 Safety precautions .............. 162 18.2 Waste disposal ..............162 Appendices ................... 163 Index ....................164 Engineering manual - SAB 193-233-283 S A-frame (including ATEX) 10/168 008831 en 2020.10...

  • Page 11: Introduction

    Introduction 1. Introduction The Sabroe screw compressor unit may be configured with various types of equipment depending on its function and requirements. Some of the equipment may be described in this manual even though it is not featured on your particular unit. Purpose This manual provides all the data usually needed in the sales and planning phases.

  • Page 12: Amendments To The Manual

    Copyright © Johnson Controls Denmark This manual must not be copied without the written permission of Johnson Controls Denmark, and the contents must not be imparted to a third party nor be used for any unauthorised purpo- ses. Contravention will be prosecuted.

  • Page 13: Safety Precaution Definitions Used In This Manual

    Introduction Safety precaution definitions used in this manual Danger! Indicates an imminently hazardous situation which, if not avoided, will result in death or serious injury. Warning! Indicates a potentially hazardous situation or practice which, if not avoided, will result in death or serious injury.

  • Page 14: Signs And Warnings

    Identification of Johnson Controls Denmark equipment All Johnson Controls Denmark equipment can be identified by one or several name plates on the unit. The name plates are illustrated on the following pages.

  • Page 15: Compressor Name Plate

    Signs and warnings Compressor name plate Fig. 1: Compressor name plate Fig. 2: Refrigerant plates Note: The compressor is fitted with a name plate, Fig. 1, and one of the two refrigerant name plates shown in Fig. 2. The rotary screw compressor serial numbers contain the following information: Example: 10240A90000015Z.

  • Page 16: Compressor Name Plate - Atex

    Signs and warnings Compressor name plate - ATEX Fig. 3: Name plate for an ATEX compressor The ATEX compressor name plate contains this information: Manufacturer type designation. Model no. Manufacturer part number. Part no. Compressor manufacturing number. Serial no. Max. driver speed - rpm Maximum number of revolutions allowed.

  • Page 17: Labelling Of Explosion-Proof Equipment

    Signs and warnings Labelling of explosion-proof equipment ATEX: The compressor area of application is indicated next to the Ex-sign on the name plate. II 2 G T3/T4 Material group: II indicates that the equipment is suitable for use in industrial areas above ground. Material category: 2 indicates that the equipment is suitable for use in areas with possible occurrence of ex- plosive gasses.

  • Page 18: Vessel Name Plate

    Signs and warnings Vessel name plate Johnson Controls D e n m ar k ApS Johnson Controls Denmark ApS Christian X 's V e j 201 Christian X's Vej 201 2516-331 8 270 Højbj e rg, D e n m ark 8270 Højbjerg, Denmark...

  • Page 19: Unit/Pipe System Name Plate

    Signs and warnings Unit/pipe system name plate Johnson Controls Denmark ApS 2516-343 Johnson Controls Denmark ApS 2516-342 Christian X's Vej 201 Christian X's Vej 201 8270 Højbjerg, Denmark 8270 Højbjerg, Denmark www.sabroe.com www.sabroe.com Refrigeration unit Year Refrigeration unit Year Type...
  • Page 20 Signs and warnings The unit name plate is positioned on the frame and contains this information: Refrigeration unit No. Identification no. (serial no.) Year of manufacturing. Year Type Manufacturer's type designation. For EC PED/EAC approval: ‘Unit & Piping’ means that the CE/EAC mark applies to the complete unit including the piping system.

  • Page 21: Signs

    Signs and warnings Signs All signs which may be found on your equipment are shown below. The number of signs, however, may vary from one product to another. High surface High voltage/ The compressor may be temperature Risk of electric shock High pressure top-heavy (about 70°C)

  • Page 22: Safety Precautions

    • The compressor must only be used as a refrigeration compressor and within the operating limits specified in the manuals or in a written agreement with Johnson Controls Denmark. • The compressor must only be used with the refrigerant(s) and number of revolutions per minute, shown on the compressor name plate.

  • Page 23: Safety Precautions

    Safety precautions Warning! Johnson Controls Denmark is not liable for injuries to personnel or damage to equipment resulting from using the equipment for other purposes than the ones stated above. Safety precautions 3.2.1 General precautions These precautions should be used as a supplement to the safety precautions and warnings in- cluded in: •...

  • Page 24: Safety During Maintenance And Service

    Use the prescribed tools, and check that they are properly maintained and in good work- ing condition. In explosion-proof areas, use tools suited for this specific purpose. • Use only Johnson Controls Denmark original spare parts; other parts may impair the safety of the compressor/unit. •...

  • Page 25: Electrical Installations

    ATEX directive. If the installations are expanded or additional equipment is mounted, this must also be in conformity with the ATEX directive. For equipment not supplied by Johnson Controls Denmark, it is the contractor who is responsible for ensuring that the equipment is in conformity with the ATEX directive.

  • Page 26: Lubricating Oils

    Safety precautions 3.2.7 Lubricating oils Compressor oils include the following oil types: Code design Oil types Mineral oil, naphtenic base Synthetic oils based on alkylated aromatics (alkyl-benzene) Synthetic oils blended from alkyl-benzene and poly-alfa-olefin base stocks Semi synthetic oils (hydro-treated mineral oil on paraffinic base) Synthetic oils based on poly-alfa-olefin Synthetic oils based on polyol esters Synthetic oils based on polyalkylene glycols...

  • Page 27: F-Gas Regulation (Fluorinated Greenhouse Gases)

    Safety precautions 3.2.10 F-gas regulation (fluorinated greenhouse gases) In the European F-gas regulation, No 517/2014, about reduction of harmful gases in the atmos- phere, the European Parliament (EU) has established guidelines for the regulation of certain fluo- rinated greenhouse gases. The following is an extract from the guidelines and is relevant for end users and operators.
  • Page 28 Safety precautions Recovery of refrigerant Operators are responsible for putting in place arrangements for the proper recovery of fluorinated greenhouse gases by competent personnel to ensure recycling, reclamation or destruction. Certification of personnel According to directive 303/2008, it is mandatory for the member states to establish certification and training programs for personnel involved in leakage inspections and the recovery, recycling, reclamation and destruction of fluorinated gases.

  • Page 29: First Aid For Accidents With Ammonia

    Safety precautions 3.2.11 First aid for accidents with ammonia (Chemical formula: NH , refrigerant no.: R717) General Ammonia is not a cumulative poison. It has a distinctive, pungent odour that even at very low, harmless concentrations is detectable by most people. As ammonia is self-alarming, it serves as its own warning agent so that no person stays voluntar- ily in hazardous concentrations.

  • Page 30: First Aid For Accidents With Hfc/Hcfc

    Safety precautions 3.2.12 First aid for accidents with HFC/HCFC General HFC/HCFC form colourless and invisible gases, which are heavier than air and smell faintly of chloroform in high concentrations. Characteristics: • non-toxic • non-inflammable • non-explosive • non-corrosive When heated to above approx. 300° C, they break down into toxic acid gas components, which are strongly irritating and aggressive to nose, eyes and skin and are generally corrosive.

  • Page 31: Protecting The Operator As Well As The Environment

    Safety precautions 3.2.13 Protecting the operator as well as the environment Industrialisation affects our environment and it is therefore essential that we do what we can to minimise the harmful effect on nature. Many countries have passed legislation in an effort to reduce pollution and preserve the environ- ment.
  • Page 32 Safety precautions Furthermore, it can be said about refrigerants: HFC/HCFC If released into the atmosphere, halogenated refrigerants of the types CFC and HCFC (e.g. R22) will contribute to the depletion of the ozone layer in the stratosphere. The ozone layer protects the earth from the ultraviolet rays of the sun.
  • Page 33 Safety precautions In general, all brines must be considered harmful to nature and they must be used with caution. Be very careful when charging or purging a refrigeration plant. Never empty brines down a sewer or into the environment. The brine must be collected in suitable containers clearly marked with the contents and sent to an approved incineration plant.

  • Page 34: Technical Description

    Technical description 4. Technical description Description of the screw compressor The screw compressor unit is intended for high pressure operation and booster operation. Since it is designed and constructed as a ready-to-operate unit, all that is required is connection to the plant system.
  • Page 35 The serial number of each compressor is stamped into the compressor block. Fig. 13: Compressor name plate Always state the compressor serial number when contacting Johnson Controls Denmark. Engineering manual - SAB 193-233-283 S A-frame (including ATEX) 008831 en 2020.10...

  • Page 36: Marine Application

    Technical description Marine application When installing a unit on a ship, the behaviour of the ship at sea must be taken into consideration and thus the inclination of the unit. The compressor unit is designed to meet the most common requirements from the classification companies assuming the unit is installed with the motor/compressor shaft in the fore-and-aft di- rection of the ship, see Fig.

  • Page 37: Description Of Main Components And Systems

    Once compressor type, refrigerant and a few other functions have been se- lected, UniSAB III is ready for operation. UniSAB III is based on Johnson Controls Denmark's ex- tensive experience with design and operation of compressor control systems.

  • Page 38: Compressor

    Technical description Easy to operate UniSAB III has a systematic and easily accessible user interface which does not require any spe- cial knowledge or education. Operational data and status appear from the distinct display which features four lines with twenty characters each.

  • Page 39: Variable Speed Drive (Vsd)

    It should be noted that compressors running variable speed (VSD) are at higher risk of facing vi- brational problems than similar fixed-speed applications. Johnson Controls Denmark and the Engineering manual - SAB 193-233-283 S A-frame (including ATEX) 008831 en 2020.10...

  • Page 40: Compressor Lubrication System

    Technical description Sabroe Factory have gained comprehensive experience in VSD, and we are integrating this knowledge into both the mechanical design and the control systems of our products. For this rea- son, we cannot accept liability for any damage related to vibrations or variable speed drive on non-factory-built equipment.

  • Page 41: No Pump Oil System

    Technical description No pump oil system The screw compressor unit is designed to be self-lubricating. Oil supplied to the compressor from the oil separator is at system head pressure. In the compressor, oil from all lubricating points is returned to a point in the compressor body where the pressure is lower than the compressor dis- charge pressure.
  • Page 42 Technical description Fig. 19: Oil separator Design and operating mode As illustrated in Fig. 19 the oil separator system consists of two containers, an oil separator at the top and an oil reservoir at the bottom. In the oil separator the oil is separated from the discharge gas and taken to the oil reservoir.
  • Page 43 Technical description From the compressor Demister Oil return Oil return To oil vessel Fine oil separator element, pos. 55 Fig. 21: OHU 04136 However, the discharge gas still contains a certain amount of fine oil drops, which are separated as the discharge gas passes the fine oil separator elements (the fine filters). This oil is re- turned to the compressor in separate piping systems as described later in this section.

  • Page 44: Automatic Oil Return Valve

    Technical description 4.13 Automatic oil return valve 1: Inlet G1/4” 4: Stop valve, outlet side 2: Filter 5: Outlet G1/4” 3: Stop valve, inlet side 6: Sight glass Fig. 22 Note: Valve inlet and outlet are marked on the valve housing with "in" and “out”. Function The function of the automatic oil return valve, EVRB, is to return the separated oil in the fine sepa- rator to the compressor.

  • Page 45: External Oil Filter

    Technical description Fig. 23 Note: The sectional view shows the valve structure. Some of the internal oil channels are not visible. 4.14 External oil filter The compressor unit is equipped with an external oil filter, pos. 195/196, which is mounted in the oil pipe between the oil separator or oil cooler (if present) and the compressor.

  • Page 46: Unit With Double Oil Filter

    Technical description 4.15 Unit with double oil filter If the unit is equipped with two parallel oil filters, only one filter at a time must be in operation. The filter not in use can be cleaned when the compressor is in operation. When cleaning the oil filter during operation, please note that the pressure is higher when the vent valve/plug is opened.
  • Page 47 Technical description unload side of the cylinder. Simultaneously, oil contained in the load side of the cylinder flows out of compressor port SC2 through valve ports B and T to compressor suction side. Note: To control the rate of loading and unloading, change cycle time, proportional band and dead band set points with the control system.

  • Page 48: Compressor Oil Cooling Systems

    Technical description 4.17 Compressor oil cooling systems The unit can be equipped with one of several systems for controlling the compressor oil tempera- ture. They are single or dual-port liquid injection and refrigerant-cooled (thermosyphon) or water-cooled oil coolers. Each system is automatically controlled, independent of compressor loading or unloading.

  • Page 49: Suction Check Valve By-Pass

    Technical description Compressor Low Vi Tubing line Solenoid valve Motorised Strainer expansion Liquid refrigerant valve from receiver Liquid line Sight glass Fig. 27: P&I diagram, liquid injection with single port Compressor suction pressure Compressor Low Vi Compressor Tubing line High Vi To separator Solenoid valve...
  • Page 50 Technical description From separator cold-start valve Compressor end view For 8” and larger suction valve customer supplied line Fig. 29: Suction check valve by-pass Check valve CV-4 is installed on all units with suction pressure below atmospheric or installed with economiser option utilised on multiple compressor plants.

  • Page 51: Requirements For Ambient Temperatures And Humidity

    Technical description 4.19 Requirements for ambient temperatures and humidity Sabroe compressor units are generally designed for indoor installation within these limits: Humidity: • 10-90% relative humidity (not condensing). Temperature: Minimum 0°C (+32F). Limiting factors: • Avoid freezing of water charge systems during standstill •...

  • Page 52: Oil Carry-Over To Plant

    Technical description 4.20 Oil carry-over to plant Total oil carry-over estimate Formula: 0.36 x total ppm value x total mass flow (kg/s) (COMP1) = > (kg/100 h) The COMP1 calculation program provides the discharge temperature and the circulated mass flow of refrigerant through evaporator, economiser and side load. In the formula, the total mass flow (all single flow of refrigerant to be added provides condenser mass flow or total mass flow) must be used.

  • Page 53: Selecting Lubricating Oil For Sabroe Screw Compressors

    To ensure the compressor unit a long service life with safe and reliable operation, it is important to use an oil type recommended by Johnson Controls Denmark. Please refer to Sabroe oil recom- mendation where various oil types are listed in a table including oil brand, oil code and part numbers.

  • Page 54: Oil Level Switch

    Technical description ATEX: On ATEX-executions, the heating element(s) are ATEX-approved. Heating elements from Johnson Controls Denmark have a thermostat with manual reset. If the thermostat drops out, only compe- tent personnel should reactivate it. 4.24 Oil level switch Four red LEDs Plast housing PROCAP -LS20 M4 fixing screw...
  • Page 55 Technical description Once the compressor is running it will begin to force gas to the condenser at connection P2. As the condenser heats up, the pressure will begin to rise as the compressor suction pulls down in pressure. As soon as a differential pressure has developed between the condenser and suction side, these pressures will act across a piston inside the cold-start valve to partially overcome the spring force.

  • Page 56: Compressor Protecting System, Pos. 220 And 221

    Technical description 4.26 Compressor protecting system, pos. 220 and 221 Pilot valve BSV8 (Pos. 221) Main valve POV (Pos. 220) To oil separator Condensing Evaporating From evaporator condenser pressure pressure Fig. 33: System with closed valve In order to protect the compressor against an inadmissible high pressure (if the electric system has not already stopped the compressor), the compressor is fitted with a protecting system with one or two main valves, pos.

  • Page 57: Oil Cooling System And General Piping Layout

    Technical description ” Evaporating Oil separator, condenser Condensing pressure pressure Compressor Fig. 34: System with open valve 4.27 Oil cooling system and general piping layout General: Min. oil temperature before start-up: 4°C (+40°F) Min. oil temperature in running condition: 20°C (+68°F) Liquid injection oil cooling: The compressor oil is cooled by direct contact with the refrigerant injected through an optimised port location prior to the compressor discharge.
  • Page 58 Technical description It is imperative that an uninterrupted supply of high-pressure liquid refrigerant is provided to the injection system at all times. Two items are of extreme importance, the design of the re- ceiver/liquid injection supply and the size of the liquid line. It is recommended that the receiver is oversized sufficiently to retain a five minute supply of re- frigerant for oil cooling.

  • Page 59: Thermosyphon Oil Cooling

    Technical description Pound Liquid Liquid Kg per min. Unit Piping per min. volume volume per 5 min. Model line size per 5 min. cu ft liter R717 HS* SAB 193 S and L 75.5 34.2 59.4 SAB 233 S, 151.0 68.5 116.0 L and E...
  • Page 60 Technical description liquid/vapour mixture, which rises to the receiver, dropping out the remaining liquid before allow- ing the vapour to return to the condenser, completing the cycle. Piping arrangement for thermosyphon oil cooling systems The components and piping of a thermosyphon oil cooling system include a liquid source at con- densing pressure, adequate static heads to provide fluid flow, appropriate control valves, safety relief valves, service valves and pump-out connections.

  • Page 61: Water-Cooled Oil Cooling

    COMP1. The water supply must be sufficient to meet the required flow. Johnson Controls Denmark recommends a closed-loop system for the waterside of the oil cooler. Careful attention to water treatment is essential to ensure adequate life of the cooler if cooling tower water is used.

  • Page 62: Connection To Alfanova Oil Cooler

    Technical description 4.31 Connection to AlfaNova oil cooler The maximum permitted connection forces and moments during mounting and operation for Alfa- Nova heat exchangers are listed in the following tables. Keep these values in mind when design- ing your system. It is also recommended to minimise connection loads when designing piping systems.

  • Page 63: Kracht Oil Pump

    Technical description 4.32 KRACHT oil pump Drive shaft end Shaft seal Gear unit Housing Plain bearing bushes External gear pump End cover Fig. 39 The oil pump is an external toothed gear pump, which works according to the positive displace- ment principle.

  • Page 64: Economiser, High-Stage (Optional)

    Technical description Pump direction All our KRACHT pumps run clockwise (seen on shaft end). Rotating counterclockwise will damage the shaft seal. Before the initial start-up of the oil pump, remember to check that it has the correct rotation di- rection. Do this by looking through the fan shield mounted at the end of the motor, away from the oil pump.
  • Page 65 Technical description subcooling is provided by flashing liquid in the economiser cooler to an intermediate pressure level. The intermediate pressure is provided by a port located part way down the compression process on the screw compressor. As the screw compressor unloads, the economiser port will drop in pressure level, eventually being fully open to suction.
  • Page 66 Technical description Economiser kit optional Strainer Shipped loose Eco. line Damper with strainer Fig. 45: Anti-vibration economiser kit Fig. 46: Anti-vibration Economiser kit For refrigeration plants employing multiple compressors on a common economising vessel, re- gardless of economiser type, each compressor must have a back-pressure regulating valve in or- der to balance the economiser load, or gas flow, between compressors.
  • Page 67 Technical description Fig. 48: Direct expansion economiser system Fig. 47: Shell and coil economiser system Fig. 50: Multiple compressor economiser system Fig. 49: Flash economiser system Engineering manual - SAB 193-233-283 S A-frame (including ATEX) 008831 en 2020.10 67/168...

  • Page 68: General Piping Diagram

    Technical description 4.34 General piping diagram Fig. 51: General piping diagram - SAB 193 with OHU 04123 oil separator is shown here. Engineering manual - SAB 193-233-283 S A-frame (including ATEX) 68/168 008831 en 2020.10...
  • Page 69 Technical description Fig. 52: General piping diagram - SAB 233 with OHU 04136 oil separator is shown here. Engineering manual - SAB 193-233-283 S A-frame (including ATEX) 008831 en 2020.10 69/168...
  • Page 70 Technical description Legend (Covers all P&I diagrams in this manual) Compressor Temperature switch high alarm Check valve Thermowell Discharge pressure Vi control Flow glass SB-2 Inlet bearing and balance piston Hand valve SB-3 Discharge bearings and seal Heater SC-1 Slide valve - unload Level glass SC-2 Slide valve - load...

  • Page 71: Key To Piping Diagram

    Technical description 4.35 Key to piping diagram Valve positions during operation Designation In-operation position Pos. no. Suction stop valve Open Stop valve after oil separator Open Open to safety valve, Change over valve no. 1 or no. 2 104/PSV1 Safety relief valve (Closed) Fixed set point 105/PSV1 Safety relief valve...
  • Page 72 Technical description Designation In-operation position Pos. no. Heater High level indicator Liquid stop valve Open Stop valve Open Stop valve Open Stop valve Open Stop valve Closed Slide valve - unload Slide valve - load Moveable slide stop Moveable slide stop Compressor Electric motor Oil separator...

  • Page 73: Instrumentation

    Technical description 4.36 Instrumentation The screw compressor unit can be controlled by the UniSAB III control system, which is mounted on the unit and connected to a number of temperature and pressure sensors on the unit. The UniSAB III control system is described in a separate manual. Fig.
  • Page 74 Technical description YY3/-4 YY1/-2 ZI 2 ZI 3 PM-1 Fig. 54: Positions of valves and components SAB 193 with OHU 04123 Engineering manual - SAB 193-233-283 S A-frame (including ATEX) 74/168 008831 en 2020.10...

  • Page 75: Physical And Connection Data

    Physical and connection data 5. Physical and connection data This chapter includes: • a description of the physical data of the equipment. • complete information about the requirements of the surrounding system. The safety precautions are intended for all users. Safety precautions In addition to the safety precautions mentioned in chapter 3.

  • Page 76: Allowable Flange Loads

    Physical and connection data Allowable flange loads In any screw compressor installation, suction and discharge lines should be supported in pipe hangers (preferably within 2 ft of vertical pipe run) so that the lines will not move if disconnected from the compressor, see Table 12 and Table 13. Torque (ft-lbf) Torque {Nm] Noz.

  • Page 77: Mounting Of Suction Isolation Valve

    Physical and connection data Mounting of suction isolation valve The suction isolation valve is shipped separately from the factory, so it can be installed at various positions in the suction line piping to the compressor. Note: Do not install the valve at the compressor suction side with flow against the cone. If the isolation valve is installed in this position, uneven flow is generated across the suction check valve, which is mounted at the inlet to the compressor.

  • Page 78: Connection Data

    Physical and connection data Connection data 5.4.1 Connections to compressor unit See unit dimension sketches. Screw compressor dimension I (SUCT.) J (DISCH.) TOP VIEW SIDE VIEW Fig. 57 Approx. dimensions 1913 1918 2313 2317 2321 2813 2817 2821 2824 193 S 193 L 233 S 233 L...
  • Page 79 Physical and connection data Approx. dimensions 1913 1918 2313 2317 2321 2813 2817 2821 2824 193 S 193 L 233 S 233 L 233 E 283 S 283 L 283 E 283 X 101.6 152.4 203.2 (In.) (4.00) (6.00) (8.00) 75.7 91.4 111.0...
  • Page 80 Physical and connection data Compressor port locations COMPRESSOR PORT LOCATIONS - SAB 193 S, L (SGC 1913 AND 1918) SD-1: COALESCER BLEED SC-5: INLET PORT THREAD SIZE O-RING PRESSURE SB-3 1¹⁄₁₆-12 UN-2B 980A0012K66 SC-5 9/16-18 UNF-2B 980A0012K60 SC-6 9/16-18 UNF-2B 980A0012K60 SC-8 1¹⁄₁₆-12 UN-2B...
  • Page 81 Physical and connection data COMPRESSOR PORT LOCATIONS - SAB 233 S, L, E (SGC 2113, 2317 AND 2321) PORT THREAD SIZE O-RING SB-3 1¹⁄₁₆-12 UN-2B 980A0012K66 SD-1: COALESCER BLEED SC-5 9/16-18 UNF-2B 980A0012K60 SC-6 9/16-18 UNF-2B 980A0012K60 SC-8 1¹⁄₁₆-12 UN-2B 980A0012K66 SC-9 9/16-18 UNF-2B...
  • Page 82 Physical and connection data COMPRESSOR PORT LOCATIONS - SAB 283 S, L (SGC 2813 AND 2817) PORT THREAD SIZE O-RING SD-1: COALESCER BLEED SC-5 3/4-16 UNF-2B 980A0012K62 SC-14: LIQUID INJECTION BLEED SC-6 9/16-18 UNF-2B 980A0012K60 SC-8 1⁵⁄₁₆-12 UN-2B 980A0012K69 SC-9 9/16-18 UNF-2B 980A0012K60 SC-13 9/16-18 UNF-2B 980A0012K60 SC-14 9/16-18 UNF-2B 980A0012K60...
  • Page 83 Physical and connection data COMPRESSOR PORT LOCATIONS - SAB 283 E, X (SGC 2821 AND 2824) SD-1: COALESCER BLEED PORT THREAD SIZE O-RING SC-14: LIQUID INJECTION BLEED SC-5 3/4-16 UNF-2B 980A0012K62 SC-6 9/16-18 UNF-2B 980A0012K60 SC-8 1⁵⁄₁₆-12 UN-2B 980A0012K69 SC-9 9/16-18 UNF-2B 980A0012K60 SC-13 9/16-18 UNF-2B 980A0012K60 SC-14 9/16-18 UNF-2B 980A0012K60 SD-1...

  • Page 84: Electrical Connections

    Physical and connection data 5.4.2 Electrical connections The screw compressor unit can be controlled by a UniSAB III regulation and control system, which is mounted on the unit and connected to a number of temperature and pressure sensors on the unit.

  • Page 85: List Of Components

    Physical and connection data 5.4.3 List of components Suction gas temperature Discharge gas temperature Oil temperature Separator oil temperature Oil pressure Oil pressure filter before compressor Discharge gas pressure Suction pressure Pressure switch control LSLL Low level shutdown HTR 1 Heater High level transmitter Capacity linear transmitter, slide valve...
  • Page 86 230 VAC, see the Engineering Manual for UniSAB III. With UniSAB III As standard, units are supplied with the Johnson Controls Denmark control system, UniSAB III. UniSAB III is described in a separate manual, which also includes a description of its general con- trols and how these are connected to UniSAB III.

  • Page 87: Technical Data

    Technical data 6. Technical data This chapter provides the technical data of the equipment. In this chapter technical data is de- fined as: • Data for unit • Data for compressor • Working range • Handling the compressor • Noise level data •...

  • Page 88: Other Data

    Technical data Oil separator OHU 04136 Max. net. Width Length Height Compressor type 4 HH weight mm * kg.* SAB 233 OHU 04136 1800 3660 2200 4800 SAB 283 S OHU 04136 1800 3660 2300 5500 Table 17: Unit dimension data * Suction stop valve not included External heat surface (m 5.4 m...

  • Page 89: Planning The Machine Room

    Technical data Geometrical swept volume Min. Max. drive shaft Rotor Speed Speed 2950 Rotor Compr. dia. /Rev. /Rev. model SGC 1913 1.35 1,000 3,600 0.16653 0.004713 SGC 1918 1,000 3,600 0.22204 0.006284 1,112 SGC 2313 1.35 1,000 3,600 0.29301 0.008292 1,468 SGC 2317 1,000...

  • Page 90: Minimum Compressor Flow At 3550 Rpm

    Technical data Minimum compressor flow at 3550 rpm The minimum flow capacity for each compressor varies depending on its geometry and its operat- ing conditions. Typical minimum flow for each of our compressor models is listed below. Table 22 represents minimum suction flow with the slide valve fully unloaded. Minimum flow* Unit SAB 193 S...

  • Page 91: Operating Limits

    Technical data Operating limits Fig. 66 shows an example of a permissible working range for a compressor. The operating limits depend on various factors such as the specific compressor, the compressor cooling method, whether there is an economiser and which refrigerant is used. The relevant diagram can be ob- tained from the COMP1 calculation program.

  • Page 92: Selecting Electric Motor

    Technical data Selecting electric motor The IEC electric motor types IP23 or IP54 (55) are the motors normally used to drive the compressors. Fig. 67: IP23 Drip-proof motor When selecting an electric motor, the aspects discussed below should be taken into consideration. Motor dimension The motor size is determined on the basis of power demands of the compressor during the current operating conditions calculated by the Sabroe COMP1 program.

  • Page 93: Motor Selection And Starting Torque

    Technical data Motor selection and starting torque Motors must be sized adequately for all expected operating conditions as start-up, pull down and load variations quite often require significantly more horsepower than nominal design. Motor starting torque capacity must also be considered, especially when across-the-line start is not used.

  • Page 94: Motor/Compressor Torque

    Technical data Nm [Ft-lb] [Psig] Bar Percentage of normal run speed Speed vs starting torque curve fully unloaded Fig. 69: Starting torque curves, booster Starting torque for specific compressor Multiply the starting torque value from high-stage or booster curves at 100% of normal run speed by starting torque multiplier for appropriate compressor size.

  • Page 95: Direction Of Rotation

    Technical data 6.10 Direction of rotation The direction of rotation of the compressor is clockwise when looking at the coupling flange and the compressor as illustrated in Fig. 71. Fig. 71: Direction of rotation 6.11 Emergency stop The compressor control system must be equipped with an emergency stop. If the compressor is supplied with a UniSAB III control system, this emergency stop will be an in- tegrated part of the system as shown in Fig.

  • Page 96: Noise Data

    SAB 283 L SAB 283 E SAB 283 X Table 24: Noise data Noise data for other operating conditions can be provided by Johnson Controls Denmark on request. Note: • The actual SPL value on site will be between the stated SPL and SWL depending on the acoustic environment in the machine room.

  • Page 97: Vibrations And Test Pressure Levels

    – and/or 95+% pure axial direction levels ISO 10816-3 is used. • When placing the unit on the vibration dampers supplied by Johnson Controls Denmark (additional), vibrations against the foundation are reduced by: – 85-95% for screw compressor units –...
  • Page 98 Technical data • Higher vibration levels may occur if: – the motor and compressor have not been aligned in accordance with requirements. – the compressor runs at an incorrect Vi ratio (screw compressors only). – the piping connections have been executed in a way that makes them force pull or push powers on the compressor unit, or transfer vibrations to the unit caused by natural vibrations or connected machinery.

  • Page 99: Test Pressure Levels For Standard Compressors And Components

    Table 25 shows the standard pressure levels used by Johnson Controls Denmark. For specific ap- plications the authorities may, however, demand a higher test pressure level. Such requirements can be met, within certain limits, for Sabroe compressors at an additional price.

  • Page 100: Installation Instructions

    Installation instructions 7. Installation instructions Installation This chapter describes: • The dangers that may occur from failure to follow instructions and safety precautions per- taining to the installation phase. • How to install the equipment safely and effectively. This chapter is primarily intended for installation supervisors, installation technicians and electri- cians.

  • Page 101: Personnel Requirements

    Installation instructions Personnel requirements The personnel carrying out the installation must be competent and well-trained within the area of refrigeration technique, possess knowledge of refrigeration systems and have experience with piping as well as wiring installations. Where authorisation is required, the electrician must pos- sess an approved authorisation.

  • Page 102: Space Requirements

    Installation instructions Check that all access roads are wide enough for the unit to pass, see the dimension sketches. Block the mounting site. The site must be blocked to prevent unauthorised personnel from being injured or causing damage. Clear the mounting site. 7.12 Space requirements When installing the unit, make sure that the plant can be serviced without problems, i.e.

  • Page 103: Alignment Of Compressor And Unit

    Installation instructions 7.17 Alignment of compressor and unit To ensure that the compressor and motor have long service lives and vibrationless operation, the compressor/motor and unit must be aligned with care. Misalignment of the compressor unit may produce stress and vibrations which can be transmitted to the compressor or motor and cause a breakdown.
  • Page 104 Installation instructions Achieving parallel shafts in horizontal plane • Turn the coupling so that the alignment gauge is in upper position. • Guide the measuring pin (pos. 2) towards the coupling flange, using a 1.0 mm feeler gauge, and fix the pin. Remove the feeler gauge •...
  • Page 105 Installation instructions Max. variation at 180°C rotation Pos. 1 0–0.10 horizontal Roller + slide bearings 0.05–0.15 above shaft with slide bearings Pos. 1 Roller + roller or vertical 0–0.10 slide + slide bearings Pos. 2 0–0.10 Table 26 Achieving correct centre height •...

  • Page 106: Laying The Unit Foundation

    Installation instructions 7.20 Laying the unit foundation When mounting a standard unit for stationary purposes, there are three options as described in the following: Mounting directly on the foundation Mass damping between unit and building Damping using vibration dampers 7.21 Mounting directly on the foundation When installing a unit directly on a concrete foundation, the foundation should be cast in accord- ance with the foundation drawings.

  • Page 107: Mass Damping Between Unit And Building

    If you have any questions, please contact your local Johnson Controls representative. 7.23 Damping using vibration dampers...
  • Page 108 Mounting instruction supplied by Johnson Con- trols Denmark for each particular unit. On delivery of a unit from Johnson Controls Denmark, the vibration dampers have not been mounted. They are included in the delivery and marked with a code.
  • Page 109 Installation instructions dampers, H’ or h’ should be reduced by typically 1 to 2 mm. When the adjustment is correct, tight- en the lock nut. The alignment of the unit against the foundation is now completed. See also sub- section 7.18 Alignment of unit against foundation. At standstill, the motor and compressor vibration levels caused by external forces must not exceed 1 [mm/s] RMS.

  • Page 110: Vsd Equipment

    Send the information table, including appendices, to your local Johnson Controls representative, who will then select the appropriate dampers. 7.24...
  • Page 111 Installation instructions Group I Warning in COMP1 – Refrigerants in this group have the highest risk of requiring many and signifi- cant design changes to avoid vibration damage of the unit. They are therefore NOT recommended for VSD operating units, and it must be avoided to sell VSD units with refrigerants in this group. Group II Refrigerants in this group have some risk of requiring some design changes or preventive sup- ports - this means that extra lead time and/or additional engineering hours (cost) should be ex-...

  • Page 112: Calculation Of Centre Of Gravity, Support Reactions And Tipping Angle

    Installation instructions 7.25 Calculation of centre of gravity, support reactions and tipping angle Calculation example: SAB 193 L, IEC 280, single oil filter, oil cooler type AlfaNova, no oil pump 1. Calculate compressor centre of gravity (only necessary when calculation of tipping angle is desired) Calculate: z (Table 29 Column 9) = h + zi + J.

  • Page 113: Sab 193 S

    Installation instructions Motor displacement Compressor Centre of gravity on unit Column Column Column Column Column Column Column Column Column Shaft ∑M height flange comp motor motor ∆z 1288 SAB 120 1031 1222 1562 (IEC250) 1305 SAB 151 1242 1522 (IEC250) SAB 193 S 1217 1323...
  • Page 114 Installation instructions Electric motor Motor Column 10 Column 11 Motor weight from motor data sheet + 40 kg for ∆x motor motor support See column 1 in Table 29 241.5 and column 10 in Table 31 =x flange - ∆x motor 266.5 304.5 See column 2 in Table 29...
  • Page 115 Installation instructions Calculated centre of gravity 3604 1298 1041 XG=M*X/∑M Table 34 Calculated support reactions F1=Mt*YG/b*(l-XG)/l F2=Mt*(b-YG)/b*(l-XG)/l F3=Mt*YG/b*XG/l F4=Mt*(b-YG)/b*XG/l 1112 3604 Table 35 Reactions: Unit to be seen from top x = 2268 = L, x = 0, y = 906 Y = 906 = b Compressor Motor...

  • Page 116: Sab 233 S

    Installation instructions Compressor units with oil separator OHU 04136 Note: Only calculations with separator OHU 04136 can be made using the data below. Dimensions of oil separator OHU 04136 (l, b measured between "feet", h to the upper side of the horizontal profiles). Length x Width y Height z...

  • Page 117: Sab 283 L

    Installation instructions Oil filter, Oil cooler, Oil pump Type 3HH 34 134.4 1350 -180 3HH 66 159.6 1300 -180 Oil cooler Wahterus 3 HH 116 207.6 1270 -180 3 HH 146 255.6 1240 -180 4 HH 222 -180 SAB 193 960A0082 2440 Oil pump...
  • Page 118 Installation instructions kg*mm kg*mm kg*mm Separator 3,139,000 1,049,200 1,100,800 1375 1825 360,000 200,000 180,000 Various 1800 1000 Disc valve 148,000 92,000 76,000 1850 1150 KDC DN 125 307,800 154,800 57,600 1710 Compressor 3,208,054 895,424 2,549,654 1646 1949 1549 Table 38 Suction stop 189,000 108,000...
  • Page 119 Installation instructions Reactions: Unit to be seen from top 1376 1302 x = 3419 = L, x = 0, y = 1070 Y = 1070 = b Compressor Motor 1461 1383 x = 0, x = 3419 =l, y = 0 y = 0 Filter Oil cooler...

  • Page 120: Instruction For Mounting Of Coupling

    The toolset (part no. 3083-398) is shown in Fig. 82 and is available from the Johnson Controls Industrial Re- frigeration Parts Centre in Denmark, if required. The use of the toolset is described in the “Com- missioning guide, mechanical”.

  • Page 121: Bpu Coupling Installation Procedure

    Installation instructions 7.27 BPU coupling installation procedure Disc pack lock nuts Hub clamping bolts screw Keyways located Set screw 180° opposite Fig. 83 Inspect shafts and hubs to make sure they are free from burrs. Fit the key to the shaft. Note: Never tighten the clamp bolts without the hub mounted onto the appropriately sized shaft.
  • Page 122 Installation instructions 13. Install the unitised flex disc in the other end of the coupling. The unitised flex disc, as in- stalled, should look flat and parallel with the mating hub and spacer flanges. 14. Torque the disc pack lock nuts as recommended in Table 47. Hold the bolts in place while the lock nuts are torqued.

  • Page 123: Piping Connections

    Steel pipes expand approx. 1 mm per metre per 100°C. Johnson Controls Denmark recommends the pipe layout shown in example 2 of the sketch, Fig. 85. Example 1 illustrates a pipe layout which is too rigid.

  • Page 124: Connecting Electricity Supply

    Follow the instructions in the UniSAB III manual. Control without UniSAB III. If the unit is going to be controlled by a system not delivered by Johnson Controls Denmark, the connection must be made as described in the schematic control diagrams of the actual control system.

  • Page 125: Pressure Testing

    Installation instructions 7.30 Pressure testing After installation, the unit must be pressure tested and pumped down. Pressure testing of refrigeration plant Before charging refrigerant to the plant, it must be pressure tested and pumped down. Pressure test the plant with one of the following: •...

  • Page 126: Evacuation Of The Refrigeration Plant

    Installation instructions • test pressure • comments 7.31 Evacuation of the refrigeration plant After pressure testing, the refrigeration plant must be evacuated to remove atmospheric air and moisture. Evacuation must be carried out on all types of plants, regardless of the refrigerant type to be charged to the plant.

  • Page 127: Final Installation Check

    Installation instructions describes the oil charging procedure and subsection 11.13 Oil charge explains the amount of oil to be charged. 7.33 Final installation check After completing installation, go through the following checklist. Danger! It is of vital importance that all security systems and their functions are checked before start-up. Failure to comply with safety precautions may cause death, personal injury or damage to the equipment.

  • Page 128: Components

    Components 8. Components This chapter describes the product components and the different accessories that can be mounted. This chapter is primarily intended for constructing engineers, service technicians, future custom- ers, sales personnel and personnel in the process of training. General The screw compressor unit is supplied as a complete plant mounted on a base frame.

  • Page 129: Unisab Iii

    Components UniSAB III The UniSAB III control receives its impulses from pressure transducers and temperature sensors. Pressure transducers, marked PE1 , PE2 , PE3 and PE4 See chapter 5. Physical and connection data. Temperature sensors, marked TE5 , TE6 and TE7 See chapter 5.

  • Page 130: Settings

    Settings 9. Settings Control system Compressors are delivered with the UniSAB III reading, safety and capacity regulating system only. Note: Changes in factory settings must only be carried out by an authorised refrigeration company. The control system is described in the UniSAB III Operating manual. A UniSAB III Engineering manual is also available.

  • Page 131: Operating Instructions

    Operating instructions 10. Operating instructions This chapter is included in the separate Operating manual. Please consult this manual if you need information on how to operate the compressor. Engineering manual - SAB 193-233-283 S A-frame (including ATEX) 008831 en 2020.10 131/168...

  • Page 132: Maintenance Instructions

    Maintenance instructions 11. Maintenance instructions This chapter describes: • Dangers resulting from failure to comply with safety precautions when performing main- tenance tasks. • Scheduled maintenance tasks for this equipment, and how to carry them out safely. • When these scheduled maintenance tasks should be performed. This chapter is primarily intended for operators and service engineers.

  • Page 133: Stopping Routine

    Maintenance instructions 11.3 Stopping routine Comprehensive maintenance often requires the compressor to be stopped for a certain period of time. Stopping and starting up compressor during a short period of standstill Before stopping the compressor, capacity must be reduced to the lowest capacity stage for a few minutes.
  • Page 134 Maintenance instructions Table 49: Maintenance intervals Engineering manual - SAB 193-233-283 S A-frame (including ATEX) 134/168 008831 en 2020.10...

  • Page 135: Visual Inspection

    Maintenance instructions 11.5 Visual inspection Oil pressure Check that the oil pressure complies with the recommended cut-out pressure. Oil level Check the oil level in the compressor. It is of vital importance for the service life of the compressor that an optimal lubrication is maintained. The oil must always, as a minimum, be visible in the oil level glass.
  • Page 136 Maintenance instructions Condensing pressure The terms “condensing pressure” or "high pressure", as used here, refer to the pressure at the compressor outlet side. Usually the pressure is the same at the condenser inlet as at the compres- sor outlet. The only difference is the pressure drop in the line. Because of this pressure drop in the line, the pressure is a little higher at the compressor than at the inlet to the condenser.

  • Page 137: General Rules For Use Of Lubricating Oil In Refrigeration Compressors

    An oil analysis provides important information on how the compressor runs. Johnson Controls Denmark therefore recommends that the oil analyses are carried out at regular intervals as described.

  • Page 138: Visual Assessment

    Naturally, the oil sample can be analysed by the oil supplying company. As a special offer to our customers, Johnson Controls Denmark has developed an analytical concept, so that we are able to analyse all oil makes. This will mean a uniform reporting of the results.

  • Page 139: Charging Compressor With Lubricating Oil

    The report will always be sent to the address stated on the sample label included in the form set. A copy will be sent to Johnson Controls Denmark so that we are in a position to advise you, if required.
  • Page 140 Maintenance instructions Open the ball valve, pos. 9, and service valve, pos. 106, and start the pump, pos. 5. Circulate the oil until the system is free from air bubbles. Close the ball valve, pos. 9. The oil will now be charged to the unit. When the desired amount of oil has been charged to the unit, stop the pump and close the service valve, pos.
  • Page 141 Maintenance instructions Fig. 87: Piping diagram for oil charging Engineering manual - SAB 193-233-283 S A-frame (including ATEX) 008831 en 2020.10 141/168...

  • Page 142: Oil Charge

    We advise you to contact your local Johnson Controls representative about oil change as it is rec- ommended to replace all filters in the unit at the same time. Local contact details are available on www.sabroe.com.

  • Page 143: Motor

    Please refer to the motor manual and/or the motor name plate. Replacing motor bearings Please contact your local Johnson Controls service organisation. Engineering manual - SAB 193-233-283 S A-frame (including ATEX) 008831 en 2020.10...

  • Page 144: Faultfinding Instructions

    Faultfinding instructions 12. Faultfinding instructions In this chapter you will find: • A list of common problems • Suggested causes and recommended actions to solve the problem. This chapter is primarily intended for service engineers. Qualification requirements Faultfinding requires competent and highly skilled personnel with extensive knowledge of the sys- tem.

  • Page 145: Troubleshooting

    Faultfinding instructions 12.2 Troubleshooting The tables below cover the most common problems. For detailed troubleshooting of the refrigera- tion plant, please refer to the manual of the plant or common refrigeration literature. Refrigeration plant, general issues Symptom Probable cause Solution Refrigeration load lower than com- Reduce compressor capacity.
  • Page 146 Faultfinding instructions Compressor unit, general issues Symptom Probable cause Solution Check main switch and fuses. Reset Electrical supply. emergency stop switch, etc. Register the alarm, correct if neces- Compressor cannot Alarm in control system. sary and reset (refer to the Control start manual).
  • Page 147 Faultfinding instructions Compressor unit - oil separation Symptom Probable cause Solution Lower level by opening/adjusting Maintaining too high oil level. the oil return valve. Refrigerant carry-over or liquid in- Correct operation. Gradual oil loss with jection overfeeding. an oil level in the co- Loss of suction superheat.
  • Page 148 Faultfinding instructions Compressor block Symptom Probable cause Solution Main oil injection valve may be Open valve. closed. Main oil injection valve may be open Adjust. too far. Bearing damage or excessive wear. Replace bearings. Excessive noise and Slide valve/slide stop out of calibra- Calibrate.
  • Page 149 Faultfinding instructions Demand oil pump system (optional) Symptom Probable cause Solution Pump rotation. Check. Open valve. Service valves closed. Check pressure difference across Filter cartridges may be blocked. Pump will not pro- filters. Strainer may be blocked. duce enough oil Clean strainer.

  • Page 150: Service Instructions

    Service instructions 13. Service instructions Please contact your local Johnson Controls representative about service-related issues. Engineering manual - SAB 193-233-283 S A-frame (including ATEX) 150/168 008831 en 2020.10...

  • Page 151: Transport Instructions

    Transport instructions 14. Transport instructions This chapter describes: • Dangers that may occur if the transport instructions and safety precautions are not observed. • How to assemble and transport this equipment in a safe way. This chapter is primarily intended for transport supervisors, authorities and personnel involved in loading, unloading and transporting the equipment.

  • Page 152: Transport Data

    Transport instructions 14.2 Transport data Weight and dimensions When dispatched, the unit is placed on a wooden frame and covered by plastic film. The wooden frame is adjusted to the size of the unit. Lenght Width For dimensions, see Table 15 in subsection 6.1 Data for compressor units. For compressor weight, see Table 21 in subsection 6.2 Other data.

  • Page 153: Loading Instructions

    Transport instructions 14.5 Loading instructions Warning! This screw compressor unit may be top-heavy. Use caution when rigging and handling to prevent the unit from tipping. When unpacked, the unit can be lifted with a crane. The unit must be lifted in the lifting eyes on the unit.

  • Page 154: Transport Instructions

    Transport instructions Danger! Risk of injury to personnel and damage to equipment! Johnson Controls Denmark is not liable for injury to personnel or damage to equipment caused by the use of transport methods which are not recommended in this document or stated in a separate agreement between a transport com- pany and Johnson Controls Denmark.
  • Page 155 Transport instructions manufacturers have lower limits for standstill vibrations. Cover the unit to protect it from dust and dirt. The unit must not be stored with other objects giving off acidic vapours or the like, as this can have a corrosive effect on the unit. It is moreover required that the store room is dry (non- condensing) and frost-free.

  • Page 156: Commissioning Instructions

    The instructions in this manual must be read before start-up. Johnson Controls Denmark offers courses which deal with operation of and service on the unit in question. It is recommended that both the supervisor and the operator take these courses.

  • Page 157: Preparations On The Mounting Site

    Commissioning instructions Please see the “Commissioning guide, controls” (005202), which is available from the login area on www.sabroe.com, for preparations before first start-up, or contact your local Johnson Controls representative. Danger! Inadequate or incorrect setting of pressure transducers may result in compressor breakdown or personal injury.

  • Page 158: Start-Up

    Commissioning instructions 15.5 Start-up The plant can now be put into operation, See Operating manual. After five hours of operation, the alignment between motor and compressor must be checked again while the compressor is still warm. Before letting the plant start to work, activate the emer- gency stop and dismount the main fuses to ensure that the motor does not start unintentionally.

  • Page 159: Commissioning Checklist

    Commissioning instructions 15.7 Commissioning checklist Date: Name: Compressor serial no.: Check before start-up Read and understand all Sabroe manuals (compressor, UniSAB , chiller, etc.) Read and understand manuals for third party components (electric motors, valves, etc.) Check unit installation and vibration damper adjustment Carry out functional testing of safety equipment Read the opening pressures on all safety valves, and check that they are correct Carry out vacuum test...

  • Page 160: Spare Parts List

    Spare parts list 16. Spare parts list 16.1 Please see separate spare parts manual Engineering manual - SAB 193-233-283 S A-frame (including ATEX) 160/168 008831 en 2020.10...

  • Page 161: Spare Parts Drawings

    Spare parts drawings 17. Spare parts drawings 17.1 Please see separate spare parts manual Engineering manual - SAB 193-233-283 S A-frame (including ATEX) 008831 en 2020.10 161/168...

  • Page 162: Final Disposal

    Final disposal 18. Final disposal 18.1 Safety precautions Danger! Before dismantling the plant, read the safety precautions carefully. Dismantling a refrigeration unit to be scrapped must be carried out safely. Only competent refrigeration personnel must perform the dismantling as fundamental knowledge of refrigeration systems and the risks involved are required.

  • Page 163: Appendices

    Appendices 19. Appendices This section includes data sheets and instructions concerning the components and torque tables. List of torque Valves Valves, type SCV 40-200 Diagrams and sketches Piping diagram..............order specific Wiring diagram..............order specific Dimension sketch..............order specific Placing of vibration dampers..........order specific Electric motor Instruction for motor............

  • Page 164: Index

    Index Accessories ..........................101 Accidents with HFC/HCFC......................30 Alignment ..........................103 Amendments to the manual ....................... 12 Ammonia............................ 32 Ammonia accidents - first aid ..................... 29 Appendix ..........................163 Application of the compressor ....................22 ATEX .........................17, 22, 25, 54 Batteries ..........................
  • Page 165 Dimensional outline of compressors................... 78 Dimensions ..........................152 Direction of rotation ........................95 Documentation ........................157 Double oil filter ........................... 46 Dual dip tube method ......................... 58 Dual-port liquid injection......................48 Economiser ..........................64 Electric motor......................88, 92, 114, 117 Electrical connections......................... 84 Electricity supply ........................
  • Page 166 Key to piping diagram ........................ 71 Kracht oil pump .......................... 63 Legend ............................70 Lifting the unit .......................... 153 Liquid injection........................... 48 Liquid injection adjustment ......................48 Liquid injection oil cooling ......................57 List of components ........................85 Loading ............................ 153 Loading range ..........................
  • Page 167 Periodic maintenance ....................... 132 Personnel requirements ......................156 Piping connections ........................123 Piping diagram ........................... 68 Piping layout ..........................57 Piping system........................... 142 Port locations of compressor ...................... 78 Positions of valves and components ................... 73 Power supply ..........................25 Pressure testing ........................
  • Page 168 UniSAB III ..........................37, 86 Unit connections......................... 78 Unit/pipe system name plate ..................... 19 Variable speed drive ........................39 Vessel name plate ........................18 ..............................47 Vibration dampers....................107, 112, 119 Vibration data ..........................97 Visual inspection ........................135 Water-cooled oil cooling ......................57, 61 Weight............................
  • Page 170 Johnson Controls Denmark ApS SABROE Factory Christian X's Vej 201 ∙ 8270 Højbjerg Denmark Phone +45 87 36 70 00 Version 6 www.sabroe.com...
  • Page 171 Danfoss POV Suction flange Compressor model Bolt Torque Torque size [Nm] Note! SAB 120 S-E Size [Nm] Mark all bolts with a yellow marker SAB 151 S-E when they are torqued. POV 600 / DN 40 SAB 193 S SAB 193 L POV 1050 / DN 65 SAB 233 S Mount the cutting ring and union...

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