Johnson Controls SAB 355 Engineering Manual
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Johnson Controls SAB 355 Engineering Manual

Screw compressor unit
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Summary of Contents for Johnson Controls SAB 355

  • Page 1 Engineering manual SAB 355 (including ATEX) Screw compressor unit...
  • Page 3 Size IEC _________ Anti-condensation heater Drive type Fixed speed Variable speed (VSD) pcs. Coalescer filter UniSAB setting values Separator velocity ref. _____ Separator velocity ref. CR _____ Engineering manual - SAB 355 Screw compressor unit (including ATEX) 004100 en 2020.10 3/156...
  • Page 4 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 Back-pressure independent Engineering manual - SAB 355 Screw compressor unit (including ATEX) 4/156 004100 en 2020.10...

  • Page 5: Table Of Contents

    First aid for accidents with ammonia ......30 3.2.12 First aid for accidents with HFC/HCFC ......31 3.2.13 Protecting the operator as well as the environment ..............32 Engineering manual - SAB 355 Screw compressor unit (including ATEX) 004100 en 2020.10 5/156...
  • Page 6 General key to piping diagram ........69 4.1.34 General piping diagram ..........71 4.1.35 General key to piping diagram - continued ....72 4.1.36 Instrumentation ............. 73 Engineering manual - SAB 355 Screw compressor unit (including ATEX) 6/156 004100 en 2020.10...
  • Page 7 Tools and accessories ............95 Safety equipment ..............95 7.10 Local regulations ..............95 7.11 Preparing the mounting site ..........96 7.12 Space requirements .............. 96 Engineering manual - SAB 355 Screw compressor unit (including ATEX) 004100 en 2020.10 7/156...
  • Page 8 Maintenance of compressor unit ......... 122 11.3 Stopping routine ..............123 11.4 Long-term storage .............. 123 11.5 Maintenance intervals ............124 11.6 Visual inspection ..............125 Engineering manual - SAB 355 Screw compressor unit (including ATEX) 8/156 004100 en 2020.10...
  • Page 9 Preparations on the mounting site ........146 15.4 Evacuation and charging of refrigerant ......146 15.5 Start-up ................147 15.6 Commissioning set .............. 147 15.7 Commissioning checklist ............. 148 Engineering manual - SAB 355 Screw compressor unit (including ATEX) 004100 en 2020.10 9/156...
  • Page 10 ................149 Spare parts drawings ..............150 Final disposal ................151 18.1 Safety precautions .............. 151 18.2 Waste disposal ..............151 Torque .................... 152 Index ....................153 Engineering manual - SAB 355 Screw compressor unit (including ATEX) 10/156 004100 en 2020.10...

  • Page 11: Introduction

    If not, the warranty no longer applies. Compressor name, Sabroe/Frick The compressor in a Sabroe SAB 355 screw compressor unit is manufactured by Frick. Below is in- dicated how the Sabroe and Frick compressor names are made up and how they correspond to each other.

  • 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

    Assign only competent personnel instructed in safety and all machine functions to operate or service the compressor/unit according to EN 13313. • Operators and maintenance personnel must carefully read, understand and fully comply with all alarms and instructions. Engineering manual - SAB 355 Screw compressor unit (including ATEX) 004100 en 2020.10 13/156...

  • Page 14: Signs And Warnings

    Main users Information concerning Signs and warnings is intended for all users. The following describes the importance of the individual signs attached to the Johnson Controls Denmark products. Before a compressor/unit is put into operation, it must be fitted with the warning signs belonging to the type of compressor/unit in accordance with the rules and regulations in force.

  • Page 15: Identification Of Johnson Controls Denmark Equipment

    Signs and warnings Identification of Johnson Controls Denmark equipment All Johnson Controls Denmark equipment can be identified by one or several name plates placed as illustrated in the following drawing: Fig. 1 Compressor name plate Vessel name plate Unit pipe system name plate Components placed high above the ground, the POV relief valve system and the suction strainer with stop valve are dismounted and blanked off for transportation purposes.

  • Page 16: Compressor Name Plate

    Serial no. Max. driver speed - rpm Maximum number of revolutions allowed. Max. allowable pressure - psig/ Maximum working pressure of compressor (psig/bar). Manufacturing country. Assembled in Engineering manual - SAB 355 Screw compressor unit (including ATEX) 16/156 004100 en 2020.10...

  • Page 17: Compressor Name Plate - Atex

    Serial no. Max. driver speed - rpm Maximum number of revolutions allowed. Max. allowable pressure - psig/ Maximum working pressure of compressor (psig/bar). Manufacturing country. Assembled in Engineering manual - SAB 355 Screw compressor unit (including ATEX) 004100 en 2020.10 17/156...

  • Page 18: Labelling Of Explosion-Proof Equipment

    450°C 380°C 500°C 300°C 230°C 350°C 200°C 130°C 250°C 135°C 65°C 185°C 100°C 30°C 150°C 85°C 15°C 135°C Table 2: Temperature classes - screw compressors Engineering manual - SAB 355 Screw compressor unit (including ATEX) 18/156 004100 en 2020.10...

  • Page 19: Vessel Name Plate

    Note: Depending on the supplier of the pressure vessel/heat exchanger, the layout and content of the vessel name plate may differ from the Sabroe name plate above. Engineering manual - SAB 355 Screw compressor unit (including ATEX) 004100 en 2020.10...

  • Page 20: Unit/Pipe System Name Plate

    Давление Сторона ВД Категория Допустимое давление макс бар Давление ислытания бар Допустимая темп мин/макс °С Fig. 9: Name plate for unit with EurAsian Conformity mark (EAC) Engineering manual - SAB 355 Screw compressor unit (including ATEX) 20/156 004100 en 2020.10...
  • Page 21 Eurasian Customs Union. Note: Main supply voltage can be found on the motor and/or electrical panel name plate. Engineering manual - SAB 355 Screw compressor unit (including ATEX) 004100 en 2020.10 21/156...

  • Page 22: Signs

    In such cases, a yellow sign is affixed pacemakers or any other implanted to a visible spot on the compressor. medical electronic device. Engineering manual - SAB 355 Screw compressor unit (including ATEX) 22/156 004100 en 2020.10...

  • Page 23: 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 24: 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 25: 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 26: 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 27: Lubricating Oils

    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 Engineering manual - SAB 355 Screw compressor unit (including ATEX) 004100 en 2020.10...
  • Page 28 The equipment must be checked for leakage within one month after a leak has been repaired to ensure that the repair has been effective. Engineering manual - SAB 355 Screw compressor unit (including ATEX) 28/156 004100 en 2020.10...
  • Page 29 For further information, please see the F-gas regulation in full. Engineering manual - SAB 355 Screw compressor unit (including ATEX) 004100 en 2020.10 29/156...

  • Page 30: First Aid For Accidents With Ammonia

    Consult a doctor about actual frostbite. After washing, apply wet compresses, wetted with a sterile isotonic (0.9%) NaCl-solution (salt water), to affected areas until medical advice is available. Engineering manual - SAB 355 Screw compressor unit (including ATEX) 30/156 004100 en 2020.10...

  • Page 31: First Aid For Accidents With Hfc/Hcfc

    Skin: In case of frost-bite, immediately rinse with luke-warm water (max. 37°C) and remove all clothes impeding blood circulation. Consult a doctor. Avoid direct contact with contaminated oil/refrigerant mixtures from electrically burnt-out her- metic compressors. Engineering manual - SAB 355 Screw compressor unit (including ATEX) 004100 en 2020.10 31/156...

  • Page 32: Protecting The Operator As Well As The Environment

    %. Certain countries may, however, have official limits different from the ones stated. Halogenated refrigerants HCFC Ammonia R134a R404A R407C R507 R717 R744 Unit Time weighted 0.005 vol. % average during a week Warning smell vol. % 0.002 Engineering manual - SAB 355 Screw compressor unit (including ATEX) 32/156 004100 en 2020.10...
  • Page 33 Salt solutions (brines) of calcium chloride (CaCl ) or sodium chloride (NaCl) are often used. In recent years alcohol, glycol and halogenated compounds have been used in the production of brine. Engineering manual - SAB 355 Screw compressor unit (including ATEX) 004100 en 2020.10 33/156...
  • Page 34 Note: These instructions only provide general information. The owner of the refrigeration plant is responsible for ensuring that all codes, regulations and industry standards are complied with. Engineering manual - SAB 355 Screw compressor unit (including ATEX) 34/156 004100 en 2020.10...

  • Page 35: Technical Description

    Compressor description Fig. 12: Screw compressor Engineering manual - SAB 355 Screw compressor unit (including ATEX) 004100 en 2020.10 35/156...
  • Page 36 Serial number Fig. 13: Model and serial number explanation The SAB 355 S, L, E and X screw compressor units are equipped with SGC compressors, types SGCB 355 and SGCH 355. Chapter 6. Technical data includes a list of tables of the screw compressors indicating weight, di- mensions, etc.

  • Page 37: Marine Application

    We strongly recommend checking the centre of gravity and the tipping angle of the ac- tual unit. If the tipping angle is too small, precautions must be taken to ensure the unit is safe. Engineering manual - SAB 355 Screw compressor unit (including ATEX) 004100 en 2020.10 37/156...

  • Page 38: 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 39: Compressor

    The rotary screw compressor uses mating asymmetrical profile helical rotors to provide a continu- ous flow of refrigerant vapour. Rotor lobe combination 4+6 male rotor drive is designed for both Engineering manual - SAB 355 Screw compressor unit (including ATEX) 004100 en 2020.10...
  • Page 40 Compressor rotation is clockwise when facing the compressor drive shaft. See Fig. 17. Never op- erate the compressor in reverse rotation as this will damage the bearings. Engineering manual - SAB 355 Screw compressor unit (including ATEX) 40/156 004100 en 2020.10...

  • Page 41: 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 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.

  • Page 42: Suction Filter With Built-In Non-Return Valve

    A shaft seal is mounted at the shaft end (driving shaft) of the male rotor. The shaft seal ensures complete tightness between the compressor housing and the compressor shaft, thus preventing atmospheric air from entering the compressor. Engineering manual - SAB 355 Screw compressor unit (including ATEX) 42/156 004100 en 2020.10...

  • Page 43: No Pump Oil System

    The sight glass in the valve indicates flow variations. Note: The normal operating oil level is halfway in the top sight glass which is located midway along the oil separator shell. Engineering manual - SAB 355 Screw compressor unit (including ATEX) 004100 en 2020.10 43/156...
  • Page 44 From the compressor Demister Oil return Oil return To oil vessel Fine oil separator element, pos. 55 Fig. 21 Engineering manual - SAB 355 Screw compressor unit (including ATEX) 44/156 004100 en 2020.10...
  • Page 45 31. The correct amount of oil in the unit is stated in Table 34: Oil charge in section 11.15 Oil charge. Engineering manual - SAB 355 Screw compressor unit (including ATEX) 004100 en 2020.10...
  • Page 46 After a long period of standstill where the heating elements have been switched off they must be connected for at least 8 hours before the unit is put into operation. Engineering manual - SAB 355 Screw compressor unit (including ATEX) 46/156...

  • Page 47: Automatic Oil Return Valve

    7, gas bubbles will be visible. The valve can be serviced by closing the stop valves, pos. 3 and 4. Engineering manual - SAB 355 Screw compressor unit (including ATEX) 004100 en 2020.10 47/156...

  • Page 48: External 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. Engineering manual - SAB 355 Screw compressor unit (including ATEX) 48/156...

  • Page 49: Compressor Hydraulic System

    Note: To control the rate of loading and unloading, change cycle time, proportional band and dead band set points with the control system. If additional control is needed, throttle SC2 or BP. Engineering manual - SAB 355 Screw compressor unit (including ATEX) 004100 en 2020.10...

  • Page 50: Compressor Oil Cooling Systems

    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. Engineering manual - SAB 355 Screw compressor unit (including ATEX) 50/156 004100 en 2020.10...
  • Page 51 Compressor Low Vi Tubing line Solenoid valve Motorised Strainer expansion Liquid refrigerant valve from receiver Liquid line Sight glass Fig. 28: P&I diagram, liquid injection with single port Engineering manual - SAB 355 Screw compressor unit (including ATEX) 004100 en 2020.10 51/156...

  • Page 52: Suction Check Valve By-Pass

    Fig. 30: 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. Engineering manual - SAB 355 Screw compressor unit (including ATEX) 52/156 004100 en 2020.10...
  • Page 53 NV-2 must be closed if the oil pump should run for long periods of time when the compressor is stopped. This is important in order to avoid oil being pumped up the suction line. Engineering manual - SAB 355 Screw compressor unit (including ATEX) 004100 en 2020.10...

  • Page 54: Requirements For Ambient Temperatures And Humidity

    TI 2016-05). For site-built systems, it is the obligation of the contractor to install similar and ad- equate means to avoid undesired condensing. Suction check valve power assistance is not necessary on check valves with linear ball bearings. Engineering manual - SAB 355 Screw compressor unit (including ATEX) 54/156 004100 en 2020.10...

  • Page 55: Balance Piston Pressure Regulator

    From oil manifold To SB-2 compressor port Solenoid valve Restriction orifice (pipe) Fig. 31: High-stage SB-2 oil supply line diagram (only for SGCH 355) H = High pressure Engineering manual - SAB 355 Screw compressor unit (including ATEX) 004100 en 2020.10 55/156...

  • Page 56: Oil Carry-Over To Plant

    Oil separator load (%) * 14 R717: Oil separator load (%) * 25 HC/HCFC/HFC: Total oil carry-over (ppm) = Vapour (ppm) + liquid (ppm) (Practical) Engineering manual - SAB 355 Screw compressor unit (including ATEX) 56/156 004100 en 2020.10...

  • Page 57: 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 58: Oil Level Switch

    When the differential pressure reaches and exceeds 2.0 bar [30 psi], the piston fully overcomes the spring force and powers the valve fully open for a very low operating pressure drop. Engineering manual - SAB 355 Screw compressor unit (including ATEX) 58/156 004100 en 2020.10...

  • Page 59: Compressor Protecting System, Pos. 220 And 221

    220 and corresponding pilot valve(s), pos. 221, see Fig. 35. Engineering manual - SAB 355 Screw compressor unit (including ATEX) 004100 en 2020.10...

  • Page 60: Oil Cooling System And General Piping Layout

    28 bar on both sides. The oil temperature is maintained between 50°C [120° F] and 60° C [140° F] for ammonia and halocarbons with a thermally controlled valve. The oil Engineering manual - SAB 355 Screw compressor unit (including ATEX) 60/156...

  • Page 61: Liquid Injection Oil Cooling

    The level control method, Fig. 38, utilises a float level control on the receiver to close a solenoid valve feeding the evaporator when the liquid falls below the amount necessary for five minutes of liquid injection oil cooling. Engineering manual - SAB 355 Screw compressor unit (including ATEX) 004100 en 2020.10 61/156...

  • Page 62: Thermosyphon Oil Cooling

    Thermosyphon oil coolers have the further advantages of eliminating water (or glycol) pump power consumption and maintenance, fouling and potential system contamination. Engineering manual - SAB 355 Screw compressor unit (including ATEX) 62/156 004100 en 2020.10...
  • Page 63 Fig. 39 1. The thermosyphon oil cooler is supplied with the oil side piped to the compressor unit and stub ends supplied on the refrigerant side. Engineering manual - SAB 355 Screw compressor unit (including ATEX) 004100 en 2020.10 63/156...

  • Page 64: 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 65 Do this by looking through the fan shield mounted at the end of the motor, away from the oil pump. Suction side Pressure side Pump running clockwise Fig. 43 Engineering manual - SAB 355 Screw compressor unit (including ATEX) 004100 en 2020.10 65/156...

  • Page 66: Economiser, High-Stage (Optional)

    In cases where wide swings in pressure are anticipated in the flash economiser vessel, it may be necessary to add an outlet pressure regulator to the flash vessel outlet to avoid overpressure of Engineering manual - SAB 355 Screw compressor unit (including ATEX) 66/156...
  • Page 67 Fig. 50. It is also recommended that the back-pressure regulating valves, used on economiser lines, should be specified with electric shutoff option. The electric shutoff feature is necessary to Engineering manual - SAB 355 Screw compressor unit (including ATEX) 004100 en 2020.10...
  • Page 68 Fig. 49: Direct expansion economiser system Fig. 48: Shell and coil economiser system Fig. 51: Multiple compressor economiser system Fig. 50: Flash economiser system Engineering manual - SAB 355 Screw compressor unit (including ATEX) 68/156 004100 en 2020.10...

  • Page 69: General Key To Piping Diagram

    Non-return valve (check valve) Check valve Strainer before oil pump Oil pump Open Stop valve before oil pump Suction gas temperature Discharge gas temperature Lubricating oil temperature Engineering manual - SAB 355 Screw compressor unit (including ATEX) 004100 en 2020.10 69/156...
  • Page 70 Note: On units delivered without valves, the bracketed figures near the branches refer to the component numbers in this list. These components must be fitted by the customer. Engineering manual - SAB 355 Screw compressor unit (including ATEX) 70/156 004100 en 2020.10...

  • Page 71: General Piping Diagram

    Technical description 4.1.34 General piping diagram Fig. 52 Engineering manual - SAB 355 Screw compressor unit (including ATEX) 004100 en 2020.10 71/156...

  • Page 72: General Key To Piping Diagram - Continued

    YY-4 Energise decrease volume ratio YY-5 Solenoid valve Temperature indicator Temperature switch YY-9 Dual-port liquid injection solenoid Capacity linear transmitter, slide valve Volumizer transmitter - slide stop Engineering manual - SAB 355 Screw compressor unit (including ATEX) 72/156 004100 en 2020.10...

  • Page 73: Instrumentation

    Fig. 53 and Fig. 54 show the positions of sensors, valves, etc. See also the general piping diagram in this section, Fig. 52. The numbers refer to 4.1.33 General key to piping diagram. Fig. 53 Engineering manual - SAB 355 Screw compressor unit (including ATEX) 004100 en 2020.10 73/156...
  • Page 74 Technical description Fig. 54 Engineering manual - SAB 355 Screw compressor unit (including ATEX) 74/156 004100 en 2020.10...

  • Page 75: Physical And Connection Data

    If in doubt, contact the local authorities. Physical data Dimension sketches Dimension sketches and tables, see chapter 6. Technical data. • Data for SAB 355 S, L, E and X compressor and unit • Data for compressor • Block weight and centre height •...

  • Page 76: Connection Data

    The pipe connection is welded on the connecting branch of the valve. Note: Be careful not to damage the valve and other parts of the unit when welding. See chapter 7. Installation instructions. Engineering manual - SAB 355 Screw compressor unit (including ATEX) 76/156 004100 en 2020.10...
  • Page 77 The drive end mounting holes in the compressors are located inboard of the discharge flange with respect to the drive shaft. • Suction strainer and housing are not integrated. Engineering manual - SAB 355 Screw compressor unit (including ATEX) 004100 en 2020.10 77/156...
  • Page 78 TW-1 3/4-14 X - Must connect to O - Optional connect to S - Service connection Fig. 56: Compressor port locations - SGC 3511 and 3515. Engineering manual - SAB 355 Screw compressor unit (including ATEX) 78/156 004100 en 2020.10...
  • Page 79 TW-1 3/4-14 X - Must connect to O - Optional connect to S - Service connection Fig. 57: Compressor port locations - SGC 3519 and 3524. Engineering manual - SAB 355 Screw compressor unit (including ATEX) 004100 en 2020.10 79/156...

  • Page 80: 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. Fig. 58: Positions of valves and components Engineering manual - SAB 355 Screw compressor unit (including ATEX) 80/156 004100 en 2020.10...

  • Page 81: List Of Components

    UniSAB III electronic control system Motor, pos. M Connection data for supply voltage: Permissible variation: +10%/-15% Frequency: 45-65 Hz Power: Supply voltage and motor power appear from the order sheet. Engineering manual - SAB 355 Screw compressor unit (including ATEX) 004100 en 2020.10 81/156...
  • Page 82 230 VAC, see Engineering Manual for UniSAB III. With UniSAB III As standard, units are delivered with Johnson Controls Denmark control system UniSAB III. The control system is described in a separate manual, which also includes a description of the general controls of UniSAB III and how these are connected to the system.

  • Page 83: Technical Data

    SAB 355 2370 5584 3700 13000 OHU 7650/6050 SAB 355 2415 4985 3491 10400 OHU 6042/5030 Table 11: Unit dimension data * Excluding motor oil and water Engineering manual - SAB 355 Screw compressor unit (including ATEX) 004100 en 2020.10 83/156...

  • Page 84: Other Data

    4,407 SAB 355 X 10,155 4,606 Table 14: Compressor weight (without coupling) Selection of vibration dampers See section 7. Installation instructions for selection of vibration dampers. Engineering manual - SAB 355 Screw compressor unit (including ATEX) 84/156 004100 en 2020.10...

  • Page 85: Planning The Machine Room

    Operating limits The diagram below, Fig. 62, shows the permissible working range for the compressor. Always con- tact your local Johnson Controls representative before letting the compressor operate under op- erating conditions outside the specified working range. Engineering manual - SAB 355 Screw compressor unit (including ATEX) 004100 en 2020.10...

  • Page 86: Motor Selection And Starting Torque

    6.45 135.1 5.69 SAB 355 X 8.99 145.0 6.11 1. High-stage or booster application. 2. Including standard compressor coupling half. 3. Inertia resolved to drive shaft. Engineering manual - SAB 355 Screw compressor unit (including ATEX) 86/156 004100 en 2020.10...
  • Page 87 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. Engineering manual - SAB 355 Screw compressor unit (including ATEX) 004100 en 2020.10 87/156...

  • Page 88: Motor/Compressor Torque

    Star-delta Motor A Motor B Motor A: Adequate to start the compressor Motor B: Will not start the compressor Compressor Speed 100% Fig. 65: Motor/compressor torque Engineering manual - SAB 355 Screw compressor unit (including ATEX) 88/156 004100 en 2020.10...

  • Page 89: Direction Of Rotation

    • The emergency stop must be able to stop any dangerous situation, as quickly as possible, without this leading to any further danger. Engineering manual - SAB 355 Screw compressor unit (including ATEX) 004100 en 2020.10 89/156...

  • Page 90: Series 52 Coupling

    SAB 355 L SAB 355 E SAB 355 X Table 16: Noise data Noise data for other operating conditions can be provided by Johnson Controls Denmark on request. Engineering manual - SAB 355 Screw compressor unit (including ATEX) 90/156 004100 en 2020.10...

  • Page 91: Vibrations And Test Pressure Levels

    The measurements are made as illustrated in the figure below (points A-D). Fig. 68: Vibration data Pay attention to the following, however: • Motors comply with EN 60034-14 (CEI/IEC 34-14) Class N. Engineering manual - SAB 355 Screw compressor unit (including ATEX) 004100 en 2020.10 91/156...
  • Page 92 – 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 93: Test Pressure Levels For Standard Compressors And Components

    Table 17 shows the standard pressure levels used by Johnson Controls Denmark. In case of spe- cific applications, the authorities may, however, demand a higher test pressure level. Within cer- tain limits, such requirements can be met for Sabroe compressors - at an additional price.

  • Page 94: Installation Instructions

    EN 378. Installation drawings Before commencing the installation, make sure to have drawings showing how to connect the unit available. Engineering manual - SAB 355 Screw compressor unit (including ATEX) 94/156 004100 en 2020.10...

  • Page 95: Personnel Requirements

    The installation must be carried out in accordance with the prevailing rules of the installation site and the regulations of the particular area. If in doubt, contact the local authorities. Engineering manual - SAB 355 Screw compressor unit (including ATEX) 004100 en 2020.10...

  • Page 96: Preparing The Mounting Site

    Materials from the unit packing which cannot be reused must be disposed of according to local regulations. 7.18 Moving the equipment to the mounting site After unloading and unpacking See chapter 14. Transport instructions. Engineering manual - SAB 355 Screw compressor unit (including ATEX) 96/156 004100 en 2020.10...

  • Page 97: Alignment Of Compressor And Unit

    7.24 Damping using vibration dampers. In both cases, the unit must be aligned before fitting the connecting pipes to the installation. Engineering manual - SAB 355 Screw compressor unit (including ATEX) 004100 en 2020.10 97/156...

  • Page 98: Laying The Unit Foundation

    See subsection 7.23 be- low for details on the elevated concrete slab. Engineering manual - SAB 355 Screw compressor unit (including ATEX) 98/156 004100 en 2020.10...

  • Page 99: Mass Damping Between Unit And Building

    If you have any questions, please contact your local Johnson Controls representative. 7.24 Damping using vibration dampers...
  • Page 100 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 101 As the loads on the supporting surfaces of the unit vary, different vibration dampers may be used on the same unit. Consequently, it is important to position them in the right places complying with the order specific drawing supplied with the unit. Engineering manual - SAB 355 Screw compressor unit (including ATEX) 004100 en 2020.10 101/156...

  • Page 102: Vsd Equipment

    Send the information table, including appendices, to your local Johnson Controls representative, who will then select the appropriate dampers. 7.25...
  • Page 103 Engineering manual - SAB 355 Screw compressor unit (including ATEX) 004100 en 2020.10...

  • Page 104: Calculation Of Centre Of Gravity, Support Reactions And Tipping Angle

    17414 3904 1400 1976 Table 20: Dimensions 4814 4697 1976 1400 - 635 = 4814 = 17414 * 3904 * 1400 4000 3903 Table 21: Forces Engineering manual - SAB 355 Screw compressor unit (including ATEX) 104/156 004100 en 2020.10...
  • Page 105 Table 22: Component placement example 2118 1778 Table 23: Centre of gravity 20062 4585 1500 2467 Table 24: Dimensions 5896 5062 4899 4206 Table 25: Forces Engineering manual - SAB 355 Screw compressor unit (including ATEX) 004100 en 2020.10 105/156...
  • Page 106 Table 26: List of vibration dampers Compression Max. load Type [kg] TF3000-80 1450 2150 3000 TF4000-80 1530 2450 4700 4000 TF6000-80 1000 2000 3000 4000 6000 Table 27: Loading range Engineering manual - SAB 355 Screw compressor unit (including ATEX) 106/156 004100 en 2020.10...

  • Page 107: Auxiliary Tools For Coupling Alignment

    Fig. 76: Auxiliary tools for coupling alignment 2 Furthermore, an alignment tool and a feeler gauge are delivered for coupling alignment as shown in Fig. 78. Engineering manual - SAB 355 Screw compressor unit (including ATEX) 004100 en 2020.10 107/156...

  • Page 108: Mounting Of Series 52 Coupling

    Tie a string or a piece of thread through one of the bolt holes in the coupling discs in order to avoid that the plates are turned in relation to each other and to the flange. Engineering manual - SAB 355 Screw compressor unit (including ATEX) 108/156 004100 en 2020.10...
  • Page 109 Fig. 77. The torque is shown in the table below. • However, do not mount the bolts that secure the flexible discs to the motor flange until the alignment has been completed. Engineering manual - SAB 355 Screw compressor unit (including ATEX) 004100 en 2020.10 109/156...

  • Page 110: Alignment Procedure For Coupling

    Insert liners with thickness Y either under both front feet or both rear feet, tilting the mo- tor at the desired end. Use the following formula for calculation of the liner thickness: Engineering manual - SAB 355 Screw compressor unit (including ATEX) 110/156...
  • Page 111 Remember that the motor must be secured during each measuring. Final installation Tighten the fixing bolts on the motor. Dismantle the alignment tool. Engineering manual - SAB 355 Screw compressor unit (including ATEX) 004100 en 2020.10 111/156...

  • Page 112: 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. 82. Example 1 illustrates a pipe layout which is too rigid.
  • Page 113 Piping connections to external safety valves are made according to current legislation in the coun- try in question. Connection to economiser Piping connection to the economiser is made according to the piping diagram applying to the plant. Engineering manual - SAB 355 Screw compressor unit (including ATEX) 004100 en 2020.10 113/156...

  • Page 114: 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 115: Pressure Testing

    10 bar pressure. When pressure testing, make a pressure test report containing the following: • date of pressure testing • name of person performing the test Engineering manual - SAB 355 Screw compressor unit (including ATEX) 004100 en 2020.10 115/156...

  • Page 116: Evacuation Of The Refrigeration Plant

    The oil is chosen according to the Sabroe oil recommendation. Oil charging is carried out by means of a special oil pump. Subsection 11.14 Charging compressor with lubricating oil Engineering manual - SAB 355 Screw compressor unit (including ATEX) 116/156...

  • Page 117: Final Installation Check

    Check that all bolts are tightened to the indicated Torque torque. Electrical connection Check all electrical connections. Check that the oil level is at the middle of the sight Oil charging glass. Engineering manual - SAB 355 Screw compressor unit (including ATEX) 004100 en 2020.10 117/156...

  • Page 118: Components

    Sub-components Base frame Welded steel sections, treated and painted. Motor The standard SAB 355 units are available with motors in different sizes, with different enclosures, power and supply voltage. • Makes: Schorch and Leroy-Somer • Supply voltage: 3 x 400V 50 Hz or 3 x 440V 60 Hz •...

  • Page 119: Unisab Iii

    See description in subsection 4.1.10 Flow security and chapter 5. Physical and connection data. Accessories If the compressor is going to be installed in rooms where explosive gasses may occur, special ex- plosion-proof components can be supplied. Engineering manual - SAB 355 Screw compressor unit (including ATEX) 004100 en 2020.10 119/156...

  • Page 120: Settings

    A UniSAB III Engineering manual is also available. This manual describes the control system in more detail. Therefore, set point settings, for instance, are not described in this chapter. Engineering manual - SAB 355 Screw compressor unit (including ATEX) 120/156 004100 en 2020.10...

  • Page 121: 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 355 Screw compressor unit (including ATEX) 004100 en 2020.10 121/156...

  • Page 122: Maintenance Instructions

    Motor lubrication and other routine maintenance tasks are usually based on running time. Please refer to Table 33: Maintenance intervals. Major overhaul For major maintenance tasks such as compressor overhauls, contact your local service provider. Engineering manual - SAB 355 Screw compressor unit (including ATEX) 122/156 004100 en 2020.10...

  • Page 123: Stopping Routine

    A warm and dry environment is essential to minimise environmental and corro- sive damage. For further information, please contact your local sales representative. Engineering manual - SAB 355 Screw compressor unit (including ATEX) 004100 en 2020.10 123/156...

  • Page 124: Maintenance Intervals

    Maintenance instructions 11.5 Maintenance intervals Table 33: Maintenance intervals Engineering manual - SAB 355 Screw compressor unit (including ATEX) 124/156 004100 en 2020.10...

  • Page 125: Visual Inspection

    This rule sets a maximum value for the suction pressure. Engineering manual - SAB 355 Screw compressor unit (including ATEX) 004100 en 2020.10 125/156...
  • Page 126 If the condensing pressure level be- comes too low, it will result in operational failures. Engineering manual - SAB 355 Screw compressor unit (including ATEX) 126/156 004100 en 2020.10...

  • Page 127: 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 128: 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 129: Oil Change

    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 130: Charging Compressor With Lubricating Oil

    1/4”RG 3/8”RG 1/2”RG 7/8”RG RG= Pipethread Length: 460 mm Height: 350 mm Width: 340 mm Weight: 22 kg Part number: 4541.001 Fig. 83: Oil charging Engineering manual - SAB 355 Screw compressor unit (including ATEX) 130/156 004100 en 2020.10...
  • Page 131 Maintenance instructions Fig. 84: Piping diagram for oil charging Engineering manual - SAB 355 Screw compressor unit (including ATEX) 004100 en 2020.10 131/156...

  • Page 132: Oil Charge

    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 355 Screw compressor unit (including ATEX) 132/156 004100 en 2020.10...

  • Page 133: Fault-Finding Instructions

    Considerable changes in the operating conditions can often be produced by even very small changes in the variable pressure and temperatures. The following troubleshooting chart shows the cause and remedy for any operating disturbance. Engineering manual - SAB 355 Screw compressor unit (including ATEX) 004100 en 2020.10 133/156...

  • Page 134: Troubleshooting

    (too high), water/air flow (too low). Air/non-condensable gasses in the Purge the air from the condenser system. side. Table 35: Refrigeration plant, general issues Engineering manual - SAB 355 Screw compressor unit (including ATEX) 134/156 004100 en 2020.10...
  • Page 135 Adjust the regulating valve accord- Oil return valve fully open. capacity ing to manual. Suction strainer clogged. Clean strainer. Table 36: Compressor unit, general issues Engineering manual - SAB 355 Screw compressor unit (including ATEX) 004100 en 2020.10 135/156...
  • Page 136 Leakage exceeds normal allowable Shaft seal leakage Replace seal. rate of 7 drops per minute. Table 37: Compressor unit - oil separation Engineering manual - SAB 355 Screw compressor unit (including ATEX) 136/156 004100 en 2020.10...
  • Page 137 Cannot unload/load Malfunction of 4-way control valve of Check according to description of or both slide components. main components. Table 38: Compressor block Engineering manual - SAB 355 Screw compressor unit (including ATEX) 004100 en 2020.10 137/156...
  • Page 138 Oil is too cold. difference is too Service valve on filter outlet is parti- high Open valves fully. ally closed. Table 39: Demand oil pump system (optional) Engineering manual - SAB 355 Screw compressor unit (including ATEX) 138/156 004100 en 2020.10...

  • Page 139: Service Instructions

    Service instructions 13. Service instructions Please contact your local Johnson Controls representative about service-related issues. Engineering manual - SAB 355 Screw compressor unit (including ATEX) 004100 en 2020.10 139/156...

  • Page 140: Transport Instructions

    Fail- ure to comply with safety precautions may cause death or injury to personnel. It may also cause damage to or destruction of the equipment. Engineering manual - SAB 355 Screw compressor unit (including ATEX) 140/156 004100 en 2020.10...

  • Page 141: Transport Data

    Handling of compressor and unit The compressor is equipped with a threaded hole for mounting of the lifting eye. For compressor weight, see Table 14: Compressor weight (without coupling). Engineering manual - SAB 355 Screw compressor unit (including ATEX) 004100 en 2020.10 141/156...
  • Page 142 Fig. 87: Max. 6.5 t Fig. 86: Lifting device must be completely assembled before lifting Max. weight per lifting device: 6.5 t. The lifting devices are constructed for the crane. Engineering manual - SAB 355 Screw compressor unit (including ATEX) 142/156 004100 en 2020.10...

  • Page 143: Loading 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 144: Transport Regulations

    As far as the motor is concerned, check the lubricating nipples and lubricate them if necessary. Engineering manual - SAB 355 Screw compressor unit (including ATEX) 144/156 004100 en 2020.10...

  • Page 145: 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 146: 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 147: Start-Up

    This set includes a new filter and the necessary O-rings and gas- kets for the oil filter and suction filter. The spare parts included in the set are marked in the parts list with a *. Engineering manual - SAB 355 Screw compressor unit (including ATEX) 004100 en 2020.10 147/156...

  • Page 148: Commissioning Checklist

    Take out a representative lubricating oil sample after about 1 hour of operation, and save it for minimum 1 year from commissioning date Table 42: Commissioning checklist Engineering manual - SAB 355 Screw compressor unit (including ATEX) 148/156 004100 en 2020.10...

  • Page 149: Spare Parts List

    Spare parts list 16. Spare parts list 16.1 Please see separate spare parts manual Engineering manual - SAB 355 Screw compressor unit (including ATEX) 004100 en 2020.10 149/156...

  • Page 150: Spare Parts Drawings

    Spare parts drawings 17. Spare parts drawings 17.1 Please see separate spare parts manual Engineering manual - SAB 355 Screw compressor unit (including ATEX) 150/156 004100 en 2020.10...

  • Page 151: Final Disposal

    Batteries Used batteries, for example from the control system backup, must be disposed of in accordance with prevailing national rules and regulations. Engineering manual - SAB 355 Screw compressor unit (including ATEX) 004100 en 2020.10 151/156...

  • Page 152: Torque

    Torque 19. Torque Torque for screws and bolts Metric thread (ISO 5.6) Metric thread (ISO 8.8) Metric thread (ISO 12.9) Table 43 Engineering manual - SAB 355 Screw compressor unit (including ATEX) 152/156 004100 en 2020.10...

  • Page 153: Index

    Data for compressor........................83 Demand pump oil system......................43 Design/Construction ........................35 Direction of rotation ........................89 Documentation ........................146 Dual-port liquid injection......................51 Economiser ..........................66 Engineering manual - SAB 355 Screw compressor unit (including ATEX) 004100 en 2020.10 153/156...
  • Page 154 Lubricating oil......................27, 57, 127, 130 Main components ........................38 Maintenance intervals ......................124 Maintenance of compressor unit....................122 Major overhaul ......................... 122 Marine application ........................37 Engineering manual - SAB 355 Screw compressor unit (including ATEX) 154/156 004100 en 2020.10...
  • Page 155 Space requirements ........................96 Start-up ........................... 147 Starting torque........................... 86 Stopping routine ........................123 Storage ............................ 144 Suction check valve by-pass ...................... 52 Suction filter..........................42 Engineering manual - SAB 355 Screw compressor unit (including ATEX) 004100 en 2020.10 155/156...
  • Page 156 Vibration dampers........................99 Vibration data ..........................91 Visual inspection ........................125 Water-cooled oil cooling ......................60 Weight of electric motor ......................75 Work area safety ........................24 Engineering manual - SAB 355 Screw compressor unit (including ATEX) 156/156 004100 en 2020.10...
  • Page 158 Johnson Controls Denmark ApS SABROE Factory Christian X's Vej 201 ∙ 8270 Højbjerg Denmark Phone +45 87 36 70 00 Version 3 www.sabroe.com...

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