Table of Contents
Advertisement
Quick Links
Advertisement
Table of Contents
Related Manuals for Johnson Controls SABROE SAB 120 S
Summary of Contents for Johnson Controls SABROE SAB 120 S
- Page 1 Operating manual SAB 120-151 A-frame (including ATEX) Screw compressor units...
- Page 3 Manual for SAB 120-151 A-frame screw compressors Unit no. Compressor Compressor type Refrigerant HFC/HCFC ____ Other: _________ R717 Oil type Oil type: ____________________ Evap. temp. ______ Cond. temp. ______ Control Unisab III None Other Single Dual Oil filter Refrigerant-cooled oil cooler Water-cooled oil cooler Oil cooling Liquid injection in compressor...
- 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
Areas of application ..............11 Application of the screw compressor ........11 Application of combustion engines ........11 Compressor unit identification ........... 12 Identification of Johnson Controls Denmark equipment ................12 Unit/pipe system name plate ..........13 Compressor name plate ............15 Compressor name plate - ATEX .......... - Page 6 Compressor ................34 Compressor lubrication system ..........35 No pump oil system ............... 35 Demand pump oil system ............35 6.10 Cold-start system ..............36 6.11 Compressor oil separation system ........36 6.12 Automatic oil return valve ............. 38 6.13 Compressor hydraulic system ..........
-
Page 7: Introduction To Operating Manual
It is important that the operating personnel familiarise themselves with the contents of this man- ual in order to ensure proper and efficient operation. Johnson Controls Denmark is not liable for damage occurring during the warranty period where this is attributable to incorrect operation. -
Page 8: Compressor Name, Sabroe/Frick
Introduction to operating manual Compressor name, SABROE/Frick The compressor in a SABROE SAB 120 and 151 screw compressor unit is manufactured by Frick. Below is indicated which Frick compressor is part of the different SABROE units. SABROE name Frick name (compressor/unit) (compressor) SAB 120 S... - Page 9 Copyright © Johnson Controls Denmark ApS 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 10: Safety Precaution Definitions Used In This Manual
Introduction to operating manual 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 11: Areas Of Application
However, check with the local authorities as exemptions to this rule may be granted. 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. Operating manual - SAB 120-151 A-frame (including ATEX) 008668 en 2019.08... -
Page 12: Compressor Unit Identification
3. Compressor unit identification 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. Operating manual - SAB 120-151 A-frame (including ATEX) 12/61 008668 en 2019.08... -
Page 13: Unit/Pipe System Name Plate
Compressor unit identification 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 14 Compressor unit identification 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 15: Compressor Name Plate
Compressor unit identification Compressor name plate Fig. 4: Compressor name plate Fig. 5: Refrigerant plates Note: The compressor is fitted with a name plate, Fig. 4, and one of the two refrigerant name plates shown in Fig. 5. The rotary screw compressor serial numbers contain the following information: Example: 10240A90000015Z. -
Page 16: Compressor Name Plate - Atex
Compressor unit identification Compressor name plate - ATEX Fig. 6: 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
Compressor unit identification 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
Compressor unit identification 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: Safety Precautions
Safety precautions 4. Safety precautions 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 20: During Operation
Safety precautions General Use these precautions as a supplement to the safety precautions and warnings included in: • All other manuals pertaining to the compressor/unit. • Local, plant and shop safety rules and codes. • National safety rules and regulations. Read and understand all safety instructions before setting up, operating or servicing/performing maintenance on the compressor. -
Page 21: 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 22: 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 23: Purging A Refrigeration Plant
Safety precautions Purging a refrigeration plant Purging of air or other non-condensable gases is required in order to keep high system perform- ance and avoid corrosion of the equipment, which could endanger the safety of persons and equipment. When purging a refrigeration system, make sure to observe the following: •... - Page 24 Safety precautions Bans on GWP R404A/R507A and other refrigerants with a GWP over 2500 are banned from new stationary sys- tems after 2020. Existing systems can be serviced with reclaimed refrigerant until 2030, provided that proper-quality refrigerant is available. Read the local regulations. Labelling The unit must be fitted with a label (name plate).
-
Page 25: Sound Measurement And Noise Data
SAB 151 M SAB 151 L SAB 151 E Table 5 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 26: Installation
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. Specifically, the contractor is responsible for equalising potential differences on the compressor. -
Page 27: Operating Instructions
Operating instructions 6. Operating instructions Read chapter 4. Safety precautions carefully before operating the unit. Description of unit Control system The compressor unit is controlled by an electronic control system (EC) see Fig. 9. The control sys- tem is described in a separate manual, delivered with the unit. Principle drawing Behind 126 Not shown... - Page 28 Operating instructions PM-1 Fig. 10: Positions of valves and components shown on a SAB 151 unit. Operating manual - SAB 120-151 A-frame (including ATEX) 28/61 008668 en 2019.08...
-
Page 29: Principle P&I Diagram
Operating instructions Principle P&I diagram Fig. 11: Principle P&I diagram, SAB 120/151. SAB 151 with OHU 04123 oil separator is shown here. Operating manual - SAB 120-151 A-frame (including ATEX) 008668 en 2019.08 29/61... - Page 30 Operating instructions 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 31: P&I Diagrams - Liquid Injection, Single And Dual Port
Operating instructions P&I diagrams - liquid injection, single and dual port Compressor Low Vi Tubing line Solenoid valve Motorised Strainer expansion Liquid refrigerant valve from receiver Liquid line Sight glass Fig. 12: P&I diagram - liquid injection, single port Compressor suction pressure Compressor Low Vi... -
Page 32: Valve Positions During Operation
Operating instructions 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 (Closed) Fixed set point... - Page 33 Operating instructions Designation In-operation position Pos. no. Oil pressure before filter Discharge pressure Suction pressure Pressure switch control Low level shutdown Heater High level indicator Liquid injection - optional Liquid stop valve Open Stop valve Open Stop valve Open Stop valve Open Stop valve Closed...
-
Page 34: Description Of Main Components And Systems
Operating instructions Description of main components and systems The screw compressor unit is an integrated system consisting of the following major subsystems: • Control system • Compressor • Compressor lubrication system • Compressor oil separation system • Compressor hydraulic system •... -
Page 35: Compressor Lubrication System
Operating instructions COMPRESSOR Fig. 14: Shaft rotation Compressor rotation is clockwise when facing the end of the compressor drive shaft. The compressor should never be operated in reverse rotation as bearing damage will result. Compressor lubrication system The compressor is designed specifically for operation without oil pump for high-stage service. Boosters and some low-differential pressure applications require the demand pump option. -
Page 36: Cold-Start System
Operating instructions 6.10 Cold-start system The unit is equipped with a special "cold-start" discharge valve. This valve ensures a rapid devel- opment of oil pressure at initial start-up in order to lubricate the compressor without requiring an oil pump, even in cold ambient temperatures with all pressures equalised. Warning! Be extremely careful when dismantling the cold-start valve on the discharge side of the unit, as condensed refrigerant often is trapped between the cold-start valve and the stop valve. - Page 37 Operating instructions From the compressor Demister Oil return Oil return To oil vessel Fine oil separator element, pos. 55 Fig. 16: Principle for 0HU 04136 Note: Automatic oil return: Open the service valves completely to keep the coalescer end of the separator free of oil.
-
Page 38: Automatic Oil Return Valve
Operating instructions 6.12 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. 17 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 39: Compressor Hydraulic System
Operating instructions Fig. 18 Note: The sectional view shows the valve structure. Some of the internal oil channels are not visible. 6.13 Compressor hydraulic system The hydraulic system of the compressor utilises oil pressure from internally drilled passages in the compressor casing to selectively load and unload the compressor by applying this pressure to the actuating hydraulic piston of the movable slide valve (MSV). -
Page 40: Volumizer Ii Vi Control
Operating instructions Control valve port labels Energise “b” coil (YY2) to load Energise “a” coil (YY1) to unload Fig. 19: Control valve Adjustment (capacity control) Capacity slide valve movement for SAB 120 and 151 without adjustment, driven by the pressure difference between suction and discharge sides of the compressor, will cause the capacity slide to move fast towards higher capacity (up) and slow towards lower capacity (down). -
Page 41: Compressor Oil Cooling System
Operating instructions 6.16 Compressor oil cooling system 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, thermosyphon, or water-cooled oil coolers. Each system is automatically controlled, independent of compressor loading or unloading. Oil cooling systems maintain oil temperature within the following ranges for R717 and R22: Liquid injection oil cooling: 55-65°C... -
Page 42: Heating Element
Operating instructions 6.20 Heating element To keep the compressor lubricating oil warm during a period of standstill, a heating element is built into the oil reservoir. Before start-up, the heating element must be switched on for 6-8 hours to ensure that only a minimum of refrigerant remains in the oil. If there is too much refrigerant in the oil, the oil loses its lubricating properties. - Page 43 Operating instructions On start-up the unit should be operated at the highest load possible for 3 hours. During that period, adjust liquid injection oil cooling, if applicable. If unit has water-cooled oil cooling, adjust water control valve to cooler (if applicable). The compressor slide valve should be calibrated.
-
Page 44: Normal Start-Up Procedure
Operating instructions Failure to properly adjust this valve can lead to excessive noise and vibration of the compressor and unit, premature failure of the bearings, liquid loading of the rotors, liquid starvation of the rotors and catastrophic failure of the compressor. 6.23 Normal start-up procedure Normal start-up procedure... - Page 45 Synthetic components in the compressor may deteriorate over time even if they are kept flooded with oil. A warm and dry environment is essential to minimise environmental and corro- sive damage. For further information, contact Johnson Controls Denmark. Operating manual - SAB 120-151 A-frame (including ATEX) 008668 en 2019.08...
-
Page 46: Troubleshooting
Troubleshooting 7. 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 47 Troubleshooting 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 48 Troubleshooting 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 49 Troubleshooting 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 50 Troubleshooting 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. Oil pressure regulator set too low or pressure to start Readjust or repair.
-
Page 51: Maintenance Instructions
Motor lubrication and other routine maintenance tasks are usually based on running time. Please refer to Table 13: Maintenance intervals . Major overhaul For major maintenance tasks such as compressor overhauls, contact Johnson Controls Denmark. Operating manual - SAB 120-151 A-frame (including ATEX) 008668 en 2019.08... -
Page 52: Maintenance Intervals
Maintenance instructions Maintenance intervals Table 13: Maintenance intervals Operating manual - SAB 120-151 A-frame (including ATEX) 52/61 008668 en 2019.08... -
Page 53: Monitoring Of Operation
Maintenance instructions Discharge flange to Suction flange SABROE separator flange Compressor designation Torque Torque model Bolt size Bolt size (Nm) (Nm) SAB 120 XJF 120 SAB 151 XJF 151 Table 14: Torque requirements Note: Based on: Gaskets-Garlock® Blue-Gard® 3300 or Klingersil C-4430 Bolts-class 8.8 or stronger hex head bolts, lightly oiled and clean. - Page 54 Maintenance instructions Checklist Checklist Checklist for commissioning of compressor, chiller and heat pump units Start-up log: Monitoring of operation at start-up Compressor serial no.: Date: Name: Compressor serial no.: Date: Name: Check before start-up Observation Value Read and understand all Sabroe manuals (compressor, Unisab, chiller, etc.) Operation time [hours ] Read and understand manuals for third party components (electric motors, valves,...
-
Page 55: Oil
The oil in the unit must be changed after a specific number of operating hours or when an oil anal- ysis shows that it needs to be changed. We advise you to let Johnson Controls Denmark’s service organisation change the oil as it is rec- ommended to replace all filters in the unit at the same time. -
Page 56: Charging Compressor With Lubricating Oil
Maintenance instructions Optional Note: Always keep approximately 25% extra oil available to refill at first start-up. Charging compressor with lubricating oil Caution! Only charge oil when the unit pressure is below 6 bar! Oil charging is carried out by means of a portable oil charging pump, see Fig. 21. Proceed as follows: Connect the high-pressure hose, pos. -
Page 57: Motor
In connection with electric motors, it is absolutely essential to lubricate the bearings correctly and use the appropriate type of grease. Please refer to the motor manual and/or the motor name plate. Replacing motor bearings Please contact Johnson Controls Denmark’s service organisation. Operating manual - SAB 120-151 A-frame (including ATEX) 008668 en 2019.08 57/61... -
Page 58: Final Disposal
Final disposal 9. Final disposal 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 59: Compliance
10.1 Declaration of conformity Johnson Controls Denmark declares on the signed declaration of conformity that the unit is manu- factured and CE-marked in conformity with relevant directives and standards. The printed version of this operating manual, which is delivered with the unit, contains a trans- lated version of the declaration, however not filled in with the specific data for your unit. -
Page 60: Index
Index Amendments to the manual ......................8 ATEX ........................11, 17, 21, 42 Batteries ............................ 58 Capacity control ......................... 39 Charging compressor ......................... 56 Cold-start system........................36 Combustion engines - application ....................11 Competent persons - requirements.................... 10 Compressor name ........................8 Compressor name plate ...................... - Page 61 Monitoring of operation ......................53 Motor lubrication ........................57 Noise data ..........................25 Normal start-up procedure......................44 Oil .............................. 55 Oil cooler ............................ 55 Oil filter ............................55 Oil return valve........................... 38 Oil separator ..........................55 Oil types ............................. 22 Piping system..........................
- Page 62 Johnson Controls Denmark ApS SABROE Factory Christian X's Vej 201 ∙ 8270 Højbjerg Denmark Phone +45 87 36 70 00 Version 5 www.sabroe.com...
Need help?
Do you have a question about the SABROE SAB 120 S and is the answer not in the manual?
Questions and answers