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Engineering manual - SAB 193-233-283 S A-frame (including ATEX)
008831 en 2022.02

173/175

Kracht oil pump ..........................................................................................................................

66

L

Legend .......................................................................................................................................

73

Lifting the unit ...........................................................................................................................

159

Liquid injection............................................................................................................................

50

Liquid injection adjustment.........................................................................................................

50

Liquid injection oil cooling ..........................................................................................................

59

List of components .....................................................................................................................

88

Loading.....................................................................................................................................

159

Loading range ..........................................................................................................................

125

Long-term storage ....................................................................................................................

139

Lubricating oil ..........................................................................................................

28, 55, 143, 145

M

Machine room.............................................................................................................................

93

Main components .......................................................................................................................

39

Maintenance intervals ..............................................................................................................

140

Maintenance of compressor unit..............................................................................................

138

Major overhaul..........................................................................................................................

138

Marine application ......................................................................................................................

38

Marine plant..............................................................................................................................

114

Mass damping ..........................................................................................................................

112

Motor ..........................................................................................................................................

96

Motor lubrication.......................................................................................................................

149

Mounting site ............................................................................................................................

106

Moving the equipment..............................................................................................................

160

N

Noise data ................................................................................................................................

100

O

Oil analysis .......................................................................................................................

143

–144

Oil carry-over..............................................................................................................................

54

Oil charge .................................................................................................................................

148

Oil charging ..............................................................................................................................

132

Oil cooler ...............................................................................................................

65, 118, 122, 148

Oil cooling system .................................................................................................................

50, 59

Oil filter ........................................................................................................................

118, 122, 148

Oil filter (external) .......................................................................................................................

47

Oil level switch............................................................................................................................

56

Oil pump .......................................................................................................................

66, 118, 122

Oil return system ........................................................................................................................

45

Oil return valve ...........................................................................................................................

46

Oil separation system.................................................................................................................

43

Oil separator........................................................................................................................

44, 148

Oil vessel ....................................................................................................................................

45

Operating limits ..........................................................................................................................

95

P

Periodic maintenance...............................................................................................................

138

Summary of Contents for SAB 193 S

Page 1: ...SAB 193 233 283 S A frame including ATEX Screw compressor units Engineering manual EN...

Page 2: ......

Page 3: ...rigerant cooled oil cooler Water cooled oil cooler No oil cooler Liquid injection in compressor Single port Dual port Discharge port Standard AC Low Vi port Oil pump Economiser system ECO system Econo...

Page 4: ...e accord ing to EN 13136 Vessel data Type External surface m2 Design pressure bar Condenser Evaporator Liquid separator Oil separator Oil cooler Economiser Other Pressure loss if any from safety valve...

Page 5: ...oof equipment 18 2 6 Vessel name plate 19 2 7 Unit pipe system name plate 21 2 8 Signs 23 3 Safety precautions 24 3 1 Areas of application 24 3 1 1 Application of the screw compressor 24 3 1 2 Applica...

Page 6: ...4 16 Compressor hydraulic system 48 4 17 Compressor oil cooling systems 50 4 18 Suction check valve by pass 51 4 19 Requirements for ambient temperatures and humidity 53 4 20 Oil carry over to plant...

Page 7: ...r dimension 96 6 8 Motor selection and starting torque 97 6 9 Motor compressor torque 98 6 10 Direction of rotation 99 6 11 Emergency stop 99 6 12 Other emergency stop requirements 99 6 13 Noise data...

Page 8: ...ly on the foundation 111 7 22 Mass damping between unit and building 112 7 23 Damping using vibration dampers 112 7 24 VSD equipment 115 7 25 Calculation of centre of gravity support reactions and tip...

Page 9: ...13 Service instructions 156 14 Transport instructions 157 14 1 Safety precautions 157 14 2 Transport data 158 14 3 Personnel requirements 158 14 4 Handling of compressor and unit 158 14 5 Loading inst...

Page 10: ...SAB 193 233 283 S A frame including ATEX 10 175 008831 en 2022 02 16 Spare parts list 167 17 Spare parts drawings 168 18 Final disposal 169 18 1 Safety precautions 169 18 2 Waste disposal 169 19 Appen...

Page 11: ...al is primarily intended for sales service and contracting purposes All compressor intervention within the warranty period must be performed by competent per sonnel only If not the warranty no longer...

Page 12: ...VSD equipment has been revised Minor updates 2020 06 Version 5 New section added 7 19 Alignment of compressor and motor Minor updates 2019 08 Version 4 BPU coupling mounting procedure has been added D...

Page 13: ...ls Denmark ApS Christian X s Vej 201 8270 H jbjerg Denmark Phone 45 87 36 70 00 CVR No 19 05 61 71 www sabroe com Copyright Johnson Controls Denmark This manual must not be copied without the written...

Page 14: ...pment and or minor injury Note Indicates an operating procedure practice or portion thereof which is essential to highlight 1 7 Requirements for competent persons Personnel working on the unit must be...

Page 15: ...on Controls Denmark 2 1 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 Con trols...

Page 16: ...0A90000015Z Plant Decade Month Year Global seq no Additional remarks 1024 0 A 9 0000015 Z Month A JAN B FEB C MAR D APR E MAY F JUN G JUL H AUG K SEP L OCT M NOV N DEC Additional remarks R Remanufactu...

Page 17: ...TEX compressor The ATEX compressor name plate contains this information Model no Manufacturer type designation Part no Manufacturer part number Serial no Compressor manufacturing number Max driver spe...

Page 18: ...use in areas with possible occurrence of explosive gasses G Hazardous environment G indicates that the equipment is suitable for use in potentially explosive gas vapour and fog atmospheres T3 T4 Temp...

Page 19: ...proval no of the vessel issued by the relevant 3rd party notified body For EC PED approval CAT Category 1 2 3 or 4 according to the PED directive Side For heat exchangers only Refers to the columns Sh...

Page 20: ...3 S A frame including ATEX 20 175 008831 en 2022 02 Signs and warnings Note Depending on the supplier of the pressure vessel heat exchanger the layout and con tent of the vessel name plate may differ...

Page 21: ...tian X s Vej 201 8270 H jbjerg Denmark www sabroe com Fig 6 Name plate for standard unit Scope Design code Approval No Refrigerant Supply voltage Test pressure Allowable pressure Category Pressure sys...

Page 22: ...ressure system The low pressure side of the unit piping system is referred to as the LP side The high pressure side of the unit piping system is referred to as the HP side Category For EC PED approval...

Page 23: ...ssor blocks and units are usually delivered without refrigerant and oil To protect the compressors against internal corrosion they are delivered evacuated of all atmospheric air and charged with dry N...

Page 24: ...ive humidity RH may exceed 90 Johnson Controls Denmark further accept no liability of any kind for damage to com pressor unit and plant parts caused by torsional oscillation or the like which is attri...

Page 25: ...ection when operating the compressor unit Use safety equipment Wear appropriate gloves as well as eye and face protection when working with parts containing refrigerant and or lubricating oil Use prop...

Page 26: ...ted with an effective biological treatment programme 3 2 4 Safety during maintenance and service Personnel must be competent according to national safety rules and regulations and perform the maintena...

Page 27: ...st also be in conformity with the ATEX directive For equipment not supplied by Johnson Controls Denmark it is the contractor who is responsi ble for ensuring that the equipment is in conformity with t...

Page 28: ...aware that large amounts of leaking or released refrigerant entail a risk of asphyxiation If in direct contact with leaking liquid refrigerant there is a high risk of injuries caused by frostbite 3 2...

Page 29: ...ts with a GWP over 2500 are banned from new stationary systems after 2020 Existing systems can be serviced with reclaimed refrigerant until 2030 provided that proper quality refrigerant is available R...

Page 30: ...it is mandatory for the member states to establish certification and training programs for personnel involved in leakage inspections and the recovery recy cling reclamation and destruction of fluorina...

Page 31: ...ear all bulk installations with ammonia When applying first aid the persons assisting must be duly protected to avoid further injuries First aid measures Inhalation Immediately move affected personnel...

Page 32: ...cted persons are moved from low lying or poorly ventilated rooms where high gas concentrations are suspected the rescuer must wear a lifeline and be under constant observa tion from an assistant outsi...

Page 33: ...aled they will attack the human nervous system When halogenated gases come into contact with open flame or hot surfaces over approxi mately 300 C they will decompose to produce poisonous chemicals The...

Page 34: ...d at the lowest possible level in case of leaks Carbon dioxide CO2 Carbon dioxide CO2 is a greenhouse gas with a GWP Global Warming Potential fac tor of 1 It is found in the atmosphere in a concentrat...

Page 35: ...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...

Page 36: ...the operating conditions Fig 9 SAB 193 front Fig 10 SAB 193 back SAB 193 on oil separator OHU 04123 shown Design Construction A description of the components which form part of the unit is given belo...

Page 37: ...echnical data contains a list of tables of the screw compressors indicating weight dimensions and geometric swept volume among other things The compressor type is stated on the name plate shown in Fig...

Page 38: ...this direction will cause problems with the oil separator in terms of oil level shutdown for instance The requirements are stated in Table 4 Fig 14 Front of unit athwartships Fig 15 Side of unit fore...

Page 39: ...fit all Johnson Controls Denmark s Sabroe reciprocating and screw compressors meaning the same UniSAB III unit is used for both compressor types Once compressor type refrigerant and a few other functi...

Page 40: ...hutdown values through the straightfor ward menu system Besides monitoring the compressor pressures and temperatures UniSAB III also calculates the suction pressure vapour overheating monitors the cap...

Page 41: ...of the compressor to reduce axial loads on the axial load bearings and increase bearing life 4 Moveable slide valve to provide fully modulating capacity control from 100 to approx 10 of full load cap...

Page 42: ...ns may appear as structural vibrations in for instance frames piping and in strumentation or as torsional vibrations in rotating equipment compressor shaft coupling and motor rotor 4 7 Compressor lubr...

Page 43: ...pump oil system This system is designed to provide adequate compressor lubrication when the oil differential pressure across the compressor suction and discharge side is low It applies to high stage a...

Page 44: ...the bottom In the oil separator the oil is separated from the dis charge gas and taken to the oil reservoir Both vessels are firmly connected to pipes which cannot be separated Oil separator As illus...

Page 45: ...ts two oil return pipes will be fitted on the unit See piping diagram The oil separator is fitted with an automatic oil return valve see subsection 4 13 Oil vessel As already mentioned the lubricating...

Page 46: ...uently the pressure loss of the gas flow through the nozzle pos 7 is unable to move the piston pos 7 However the pressure loss of the oil flow through the nozzle pos 7 is able to move the piston pos 7...

Page 47: ...filter cartridges depending on compressor size Fig 24 External oil filter The filter is a horizontal filter through which the oil must pass the filter cartridge from the out side in This way dirt will...

Page 48: ...ingle acting mode high stage TC 15 C Close the valve at SC2 Open the valve at BP by pass High stage compressor loading The compressor loads when the MSV solenoid valve YY2 is energised and oil flows f...

Page 49: ...the MSS solenoid valve YY3 is energised and oil flows from the oil manifold through the valve ports P and A to the compressor port SC3 enters the increase side of the cylinder and overcomes the decrea...

Page 50: ...temperature control valve TCV See Fig 27 and Fig 28 Dual port liquid injection The dual port liquid injection system is designed to obtain the most efficient compressor per formance at high and low c...

Page 51: ...ator to slowly bleed down to approximately system suction pressure when the unit is stopped having this valve cracked open allows the compressor drive motor to have an easier start and the dis charge...

Page 52: ...oid the possibility of back feeding to a shutdown compressor from a common economiser vessel On booster systems the check valve CV 4 should be installed with a 1 7 bar 25 psi spring to avoid the possi...

Page 53: ...sor units Heating element s in the crankcase on all reciprocating compressors These heating elements are normally capable of keeping the oil temperature at least 10K above the ambient temperature Desp...

Page 54: ...rmula with good conformity to practice experience Alternatively use steam pressure from oil company Dalton s law for partial pressure of two substances in vapour form gives good conformity with practi...

Page 55: ...ndstill period the oil re ceiver has one or two built in heating rods Before start up the heating rods must have been activated for six to eight hours to ensure that there is only a minimum of refrige...

Page 56: ...the plant between several units 4 25 Cold start system The unit is equipped with a special cold start discharge valve This valve ensures a rapid de velopment of oil pressure at initial start up in or...

Page 57: ...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 Booster applications For booster applicat...

Page 58: ...n valve In the chamber above the piston pos 5 there is the same pressure P1 as under the valve cone pos 2 since the piston rod pos 3 is pierced When the main valve is closed the pres sure P2 in the ch...

Page 59: ...s mounted on the unit with the oil piping connected Water connections and con trols are field installed Thermosyphon oil cooling The optional thermosyphon cooler is a plate and shell design Vahterus o...

Page 60: ...g 35 uses two dip tubes in the receiver The liquid tube is below the evaporator tube to ensure continued oil cooling when the receiver level is low Fig 35 Dual dip tube method The level control method...

Page 61: ...S and L 3 4 250 5 113 7 4 0 113 2 SAB 233 S L and E 1 500 5 227 2 8 1 229 2 SAB 283 S L and E 1 1 4 726 5 329 8 11 7 331 1 SAB 283 X 1 1 4 994 0 451 2 16 0 452 8 R507 Booster SAB 193 S and L 3 8 41 5...

Page 62: ...mp out connections The arrangement of component placement and fluid flow requirements must be designed to suit the individual refrigeration sys tem layout with consideration given to piping safety pra...

Page 63: ...ver must be sized to handle the volume of both vessels Then the safety valve on the cooler vent liquid refrigerant side can be eliminated 3 The system receiver must be below the thermosyphon receiver...

Page 64: ...n closed loop fluids are analysed regularly and as necessary and maintained at a pH of 7 4 but not less than 6 0 for proper heat exchanger life After initial start up of the com pressor unit the strai...

Page 65: ...ng tables Keep these values in mind when designing your system It is also recommended to minimise connection loads when designing piping systems See Fig 38 Fig 38 AlfaNova oil cooler Fx Fy Fz F N Mx M...

Page 66: ...ting the response pressure using the adjusting screw and then securing the adjust ing screw with the hexagon nut Fig 40 The by pass valve serves two purposes To protect against overheating by allowing...

Page 67: ...condensing temperatures fluctuate into the shaded area only occasionally during the winter the demand pump avoids unnecessary consumption of pump horsepower Fig 43 Standard lubrication system limits...

Page 68: ...back pressure regulator valve is not used on a flash econo miser it is possible that no pressure difference will exist to drive liquid from the flash vessel to the evaporators since the flash vessel p...

Page 69: ...tion The electric shutoff feature is necessary to prevent flow from the common economiser vessel to the suction side of a stopped compressor through the suction check valve bypass line if the other co...

Page 70: ...83 S A frame including ATEX 70 175 008831 en 2022 02 Technical description Fig 47 Shell and coil economiser system Fig 48 Direct expansion economiser system Fig 49 Flash economiser system Fig 50 Multi...

Page 71: ...anual SAB 193 233 283 S A frame including ATEX 008831 en 2022 02 71 175 Technical description 4 34 General piping diagram 4809 052_9 Fig 51 General piping diagram SAB 193 with OHU 04123 oil separator...

Page 72: ...ription Delivered and installed by customer Strainer with mesh 500 m to be installed in water line Valves for CIP cleaning recommended Additional part flow filtration is recommended for particle rich...

Page 73: ...tor SV 1 Vapour injection tongue and groove PDSL L Compressor low diff pressure cut out SD 1 Coalescer bleed str trh O ring port TW 1 Thermowell PE Pressure transducer Pressure transducers indicate PI...

Page 74: ...is in use 124 Regulating valve oil flow Open partly Adjusted according to manual 126 Cold start discharge valve Opens automatically 127 Compressor protection valve Closed Controlled by pilot valve 12...

Page 75: ...igh level indicator 165 Liquid stop valve Open 170 Stop valve Open 172 Stop valve Open 173 Stop valve Open 175 Stop valve Closed 181 Slide valve unload 182 Slide valve load 183 Moveable slide stop 184...

Page 76: ...and pressure sensors on the unit The UniSAB III control system is described in a separate manual Fig 53 and Fig 54 show the positions of sensors valves etc See also the general piping diagram in subse...

Page 77: ...cluding ATEX 008831 en 2022 02 77 175 Technical description Fig 54 Positions of valves and components SAB 193 with OHU 04123 155 192 124 157 127 128 136 196 138 191 146 144 PM 1 193 ZI 3 ZI 2 YY3 4 YY...

Page 78: ...lange design etc Electrical connection must be carried out so that it complies with current legislation within the area in question Electric cables must be dimensioned on the basis of the maximum powe...

Page 79: ...5 25 34 34 34 1 25 25 25 25 34 34 34 1 5 50 40 40 68 54 54 2 100 70 70 136 95 95 3 250 175 175 339 237 237 4 400 200 200 542 271 271 5 425 400 400 576 542 542 6 1000 750 750 1356 1017 1017 8 1500 1000...

Page 80: ...discs in the check valve to strike against the stop pin and eventually damage the inside of the check valve If installing an elbow near the check valve make sure that the plate is stressed evenly If...

Page 81: ...1737 1 68 39 2000 6 78 76 1979 7 77 94 2078 8 81 84 2382 5 93 80 2500 9 98 46 B mm In 698 5 27 50 712 2 28 04 726 4 28 60 757 7 29 83 759 2 29 89 881 6 34 71 900 7 35 46 1346 2 35 53 C mm In 253 5 9 9...

Page 82: ...poses only Configurations of other compressor sizes vary slightly Model 19xx 28xx has an integrated suction strainer with side access on left or right Refrigeration suction side On the compressor suct...

Page 83: ...IN SE 1 ELECTRICAL CONNECTOR SC 8 CLOSED THREAD DRAIN SB 3 COMPRESSOR OIL SUPPLY SC 14 LIQUID INJECTION BLEED SC 5 INLET PRESSURE SD 1 COALESCER BLEED SM 1 MAIN OIL INJECTION COMPRESSOR PORT LOCATIONS...

Page 84: ...Vi LIQUID INJECTION SV 1 VAPOR INJECTION SC 8 CLOSED THREAD DRAIN SM 1 MAIN OIL INJECTION SC 13 OIL DRAIN CYCLINDER SC 11 CLOSED THREAD DRAIN SC 9 INLET HOUSING DRAIN SC 7 SEAL WEAPAGE PORT THREAD SI...

Page 85: ...14 9 16 18 UNF 2B 980A0012K60 SD 1 1 12 UN 2B 980A0012K66 SL 1 1 12 UN 2B 980A0012K69 SL 2 1 12 UN 2B 980A0012K69 SM 1 1 12 UN 2B 980A0012K69 SC 6 DISCHARGE PRESSURE SM 1 MAIN OIL INJECTION SV 1 VAPOR...

Page 86: ...2B 980A0012K60 SD 1 1 12 UN 2B 980A0012K66 SL 1 1 12 UN 2B 980A0012K69 SL 2 1 12 UN 2B 980A0012K69 SM 1 1 12 UN 2B 980A0012K71 COMPRESSOR PORT LOCATIONS SAB 283 E X SGC 2821 AND 2824 SC 14 LIQUID INJE...

Page 87: ...e 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 62 Positions of electrical connect...

Page 88: ...ch control 160 LSLL Low level shutdown 161 HTR 1 Heater 163 High level transmitter ZI2 Capacity linear transmitter slide valve ZI3 Volumizer transmitter slide stop YY 1 Solenoid valve Energise unload...

Page 89: ...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 w...

Page 90: ...ssor Noise level data Vibration data Test pressure for compressors This chapter is primarily intended for designers service engineers sales personnel and pro spective customers 6 1 Data for compressor...

Page 91: ...0 2300 5200 Table 16 Unit dimension data Oil separator OHU 04136 Compressor type 4 HH Width mm Length mm Height mm Max net weight kg SAB 233 OHU 04136 1800 3660 2200 4800 SAB 283 S OHU 04136 1800 3660...

Page 92: ...730 1609 785 1731 1000 2205 IEC 315L 1050 2315 1200 2646 830 1830 1050 2315 IEC 355S 1500 3307 IEC 355M 1790 3946 1600 3527 855 1885 IEC 355L 2095 4619 1750 3858 1510 3329 IEC 355L LA 1900 LA 1900 15...

Page 93: ...0 SAB 233 E SGC 2321 3300 1500 SAB 283 S SGC 2813 4100 1860 SAB 283 L SGC 2817 4400 2000 SAB 283 E SGC 2821 4700 2136 SAB 283 X SGC 2824 5100 2315 Table 21 Compressor weight without coupling 6 3 Plann...

Page 94: ...metry and its op erating 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 Unit Minimum flo...

Page 95: ...its depend on various factors such as the specific compressor the compressor cooling meth od whether there is an economiser and which refrigerant is used The relevant diagram can be obtained from the...

Page 96: ...ing factors 1 Air conditioning plant factor 1 10 2 Other refrigeration plants factor 1 15 b Consider which type of plant the compressor is going to work on The motor must be di mensioned in accordance...

Page 97: ...specific torque data for the motor used Unit Starting torque 1 multiplier Breakaway torque ft lb Breakaway torque Nm 2 3 Mass mo ment of iner tia lb ft2 2 3 Mass mo ment of iner tia kg m2 SAB 193 S 0...

Page 98: ...that will be experienced during normal starting Note Star delta and auto transformer reduced voltage motor starting methods drastically ef fect the starting torque available from motors as indicated A...

Page 99: ...the unit The emergency device must be adjusted in such a way that after a stop instruction it stays in its stop position until it is deliberately reset It must not be possible to block the emergency...

Page 100: ...AB 193 L 104 84 SAB 233 S 105 86 SAB 233 L 106 86 SAB 233 E 107 86 SAB 283 S 106 88 SAB 283 L 107 88 SAB 283 E 108 88 SAB 283 X 108 88 Table 24 Noise data Noise data for other operating conditions can...

Page 101: ...III Based on the design and decades of experience with it the evaluation criteria given for measured values belonging to Zone II is deemed as ac ceptable for rms values up to 11 2 mm s Measured values...

Page 102: ...quirements 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 tr...

Page 103: ...Sabroe compressors at an additional price Please contact your local sales representative for further information When pressure testing compressors and vessels components must first prove their streng...

Page 104: ...n or C 2 bubble test by liquid application in accordance with EN 1779 This ensures a leak rate below 10 4Pa m3 s Hence there will be some refrigerant leaking from the equipment and it is the obligatio...

Page 105: ...y with safety precautions may cause death or injury to personnel It may also cause damage to or destruction of the equipment 7 3 Installation data The physical data of the compressor is included in ch...

Page 106: ...and materials necessary to perform the installation correctly Ordinary hand tools Tools for installing pipes including welding tool The following can be ordered Tools for alignment of coupling Tools...

Page 107: ...lling the unit make sure that the plant can be serviced without problems i e always make sure that there is enough space around the plant See subsection 6 3 Planning the ma chine room 7 13 Lifting and...

Page 108: ...ng of coupling 8 Imbalance in compressor and motor The service engineer who installs the unit is responsible for 1 to 4 whereas 5 to 8 must be checked by the compressor or motor manufacturer prior to...

Page 109: ...e measuring pin to the flange using feeler gauges This change is called x Measure the distance b between the motor feet as shown in Fig 75 Measure the dis tance a from the centre of the pin pos 2 to t...

Page 110: ...hickness equal to half the value of z under all four feet After securing the motor repeat the measurement and compare the result to the values in Table 26 pos 1 vertical Achieving parallel shafts in v...

Page 111: ...To make sure that the foundation plates are kept close to the base frame during the casting process secure the foundation plates to the base frame by means of steel wire The concrete used for the foun...

Page 112: ...ng is part of the cast building construction the foundation block can be cast on a vi bration mat with a suitable bearing capacity This should be taken into account by the supplier The dead weight of...

Page 113: ...not rest with the same weight on all supports Consequently vibration dampers with different bearing capacities will be used on a unit and these must be placed correctly in accordance with the Mounting...

Page 114: ...ur in the foundation level Vibration dampers for marine use however cannot be adjusted which makes a level foundation even more important Read more about this below under Marine plant Fig 80 Vibration...

Page 115: ...nter resonance causing critical vibrations During selection an assessment of equipment feasibility for variable speed must be carried out based on the risk chart below The table values are based on re...

Page 116: ...ex pected when combining refrigerants in this group with VSD On site remediation of critical vibrations may be required including Skip of speed ranges with high vibration levels as described in the Vi...

Page 117: ...ue is based on J 140 mm 2 Fill in edit Table 32 with the values from the tables above corresponding to the unit in question 3 Calculate M X M Y M Z and M X 4 Calculate centre of gravity 5 Calculate su...

Page 118: ...ravity of compressor in relation to dist flange zg motor h Shaft height z J z h zi J Shaft height z dist discharge flanges z to drive shaft j height of discharge flange from dimension sketch zi from T...

Page 119: ...rious 49 733 1000 914 35 917 49 000 44 786 Oil 120 934 702 320 112 080 84 240 38 400 See Table 29 Compressor 1206 2080 457 1358 2 508 480 551 142 1 637 748 See Table 31 Motor 1140 800 377 1323 912 000...

Page 120: ...tions Reactions Unit to be seen from top F1 710 F3 950 x 0 Y 906 b x 2268 L y 906 Motor Compressor F2 832 F4 1112 x 0 y 0 x 2268 l y 0 Filter Oil cooler Table 35 Calculation of tipping angle Tipping a...

Page 121: ...unit Column 7 Column 8 Column 9 x flange Yg motor zg motor Shaft height z zi M comp X Y z SAB 283 S 1058 425 1574 387 406 2383 2060 532 1593 SAB 233 E 2393 444 1514 327 372 1703 2063 569 1559 SAB 233...

Page 122: ...er 2 upper 535E0013EU 127 2960 180 727 Suction stop valve DN 150 50 2040 1100 1800 DN 200 90 2100 1200 1850 DN 250 180 2150 1300 2142 Fixed values Calculated and or edited values Table 38 The parts ha...

Page 123: ...00 108 000 166 500 See Table 39 Motor 1140 800 377 1320 912 000 429 780 1 504 800 See Table 38 Oil filter 1 lower 97 2550 180 240 247 350 17 460 23 280 See Table 38 Oil filter 2 upper 97 2550 180 727...

Page 124: ...Oil cooler Table 43 Calculation of tipping angle Tipping angle atan YK ZG where YK YG if YG b 2 or YK b YG if YG b 2 Calculated tipping angle YK YG 519 26 1 degrees Fig 81 Type Dimensions in mm Overa...

Page 125: ...onents such as the shafts or the coupling parts a special toolset has been designed The toolset part no 3083 398 is shown in Fig 82 and is available from the Johnson Controls In dustrial Refrigeration...

Page 126: ...molibdenum bisulphite or high pressure additives and do not use grease These substances notably reduce the friction coefficient 3 With the clamp bolts loose and the set screw slightly unscrewed instal...

Page 127: ...upling installation and performance it is recommended if possible at this stage to rotate the assembly a few times while repeatedly rapping the spacer flange OD with a soft dead blow hammer to relieve...

Page 128: ...SAB 233 S 177 SGC 2313 M20 x 2 5 217 M20 x 2 5 298 SAB 233 L 222 SGC 2317 M20 x 2 5 217 M20 x 2 5 350 SAB 233 E 270 SGC 2321 M20 x 2 5 217 M22 x 2 5 350 SAB 283 S 316 SGC 2813 M22 x 2 5 312 M22 x 2 5...

Page 129: ...he equipment Before connecting make sure that there is no power on the cables you are about to connect the power cannot be connected accidentally Lock the switches or place a sign indicat ing that con...

Page 130: ...008831 en 2022 02 Installation instructions 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 descr...

Page 131: ...stop valves must also be closed during pressure testing Plant safety valves must normally be blanked off during pressure testing as their opening pres sure is lower than the test pressure Danger Durin...

Page 132: ...mercury column and must be fitted with a gas ballast valve This valve should be used wherever possible to prevent water vapour condensing in the vacuum pump Important Never use the refrigeration comp...

Page 133: ...installation OK 1 Level foundation Check that the foundation is level 2 Position of vibration dampers Measure the flexion 3 Position of the motor on the foundation Check that the motor rests on all fo...

Page 134: ...ng conditions The motor size can be determined on the basis of the calculations in the calculation program COMP1 See also sub section 6 6 Selecting electric motor Transmission system The power transmi...

Page 135: ...TE7 See chapter 5 Physical and connection data Heating element The function of the heating element is to boil out refrigerant from the oil see subsection 4 23 Heating rod element for oil heating pos 3...

Page 136: ...y 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 manua...

Page 137: ...frame including ATEX 008831 en 2022 02 137 175 Operating instructions 10 Operating instructions This chapter is included in the separate Operating manual Please consult this manual if you need inform...

Page 138: ...operating personnel Other maintenance and service tasks which require the refrigeration system to be opened must be performed by com petent personnel Maintenance can be divided into three groups 1 Da...

Page 139: ...plant is stopped for a long period of time follow this procedure 1 Close the main shut off valve after the receiver 2 Pump down evaporators It might be necessary to adjust low pressure cut out to a lo...

Page 140: ...hen leak rate exceeds 7 8 drops per minute a Check bolts shim packs centre inserts keys and all bolt torque b Check and torque all terminals in the processor and starter panel per the specification po...

Page 141: ...tion Listen for any knocking or other ab normal noise caused by poorly clamped pipes or faulty valves Evaporating pressure and condensing pressure No special requirements are imposed regarding equipme...

Page 142: ...ensing pressure In the condenser the absorbed heat energy in the refrigerant is released to the surroundings The heat energy in the refrigerant is the sum of the heat energy absorbed in the evaporator...

Page 143: ...f all the oil in a container is not used at once the container should be tightly sealed and stored in a warm place to prevent moisture absorption Note It is inadvisable to reuse oil which has been dra...

Page 144: ...e all oil makes This will mean a uniform reporting of the results The analysis will determine the following Whether or not the oil can still be used if necessary after filtering Whether solid particle...

Page 145: ...mpiled for every sample received This report will describe whether the oil can still be used without taking any further action whether the oil can be used after it has been filtered through a very fin...

Page 146: ...d to the unit stop the pump and close the service valve pos 106 6 Open the ball valve pos 9 carefully to equalise the pressure The hoses can now be dismantled 7 Loosen the non return valve carefully t...

Page 147: ...Engineering manual SAB 193 233 283 S A frame including ATEX 008831 en 2022 02 147 175 Maintenance instructions Fig 87 Piping diagram for oil charging 5 20 2 1 B 9 7 12 M A 106...

Page 148: ...e middle of the upper sight glass and down to the lowest level where it is still visible in the lower sight glass However in the latter situation a recharge is required The oil level difference betwee...

Page 149: ...e Litres Single Litres Double Litres 180 34 2 7 120 21 33 66 50 100 66 5 1 222 40 116 9 146 15 Table 51 Optional Note Always keep approximately 25 extra oil available to refill at first start up 11 14...

Page 150: ...er repairs For example after replacement of a damaged component to find external reasons why a component failed Systematic faultfinding Faultfinding should be carried out systematically Experienced pe...

Page 151: ...tion line loss Check valves strainers etc Malfunction of evaporator Check evaporator fouling accumu lated oil etc liquid expansion valve system filter in liquid line re frigerant charge insufficient D...

Page 152: ...too low Insufficient oil cooling function re frigerant cooled Check drain accumulated oil in the oil cooler Check that the gravity fed refrigerant system is full flooded Insufficient oil cooling func...

Page 153: ...Contaminated oil damaged or not seated coalescer elements Replace oil charge and coalescers Coalescer return valve closed Open return valve Coalescing oil return line strainer blocked Clean strainer R...

Page 154: ...alibra tion over or under compression Calibrate Coupling loose on shaft Tighten coupling Replace if damaged Refrigerant flood back Liquid slugging Correct system problem Capacity slide valve and or sl...

Page 155: ...jection throttling valve too wide open or oil pressure regulating valve improperly adjusted Readjust both valves Oil pressure fluctuates Liquid injection overfeeding or re frigerant flood back from sy...

Page 156: ...ng manual SAB 193 233 283 S A frame including ATEX 156 175 008831 en 2022 02 Service instructions 13 Service instructions Please contact your local Johnson Controls representative about service relate...

Page 157: ...equipment Danger Risk of injury to personnel and damage to equipment Always read the safety precautions be longing to this equipment before start Failure to comply with safety precautions may cause d...

Page 158: ...her data 14 3 Personnel requirements Personnel who will be handling the unit during loading transport and unloading must have tak en the necessary courses in crane operation 14 4 Handling of compresso...

Page 159: ...added motor weight Adjustment of the lifting point must also be made for any extra weight added to the standard unit such as an external oil cooler The extra weight will affect the centre of balance F...

Page 160: ...the following parts are included Vibration dampers and the drawing indicating the position of the dampers Parts for coupling series 52 intermediate piece inner and outer screen and perhaps loose coup...

Page 161: ...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 When stored the unit must be inspected at regular intervals E...

Page 162: ...It may also cause damage to or destruction of the equipment 15 2 Preparations for commissioning Final check of installation Before the plant is put into operation the installation must be checked one...

Page 163: ...nsulation has been carried out correctly the paint is acceptable the screens have been mounted correctly and so on Commissioning instructions Please see the Commissioning guide controls 005202 which i...

Page 164: ...p and dismount the main fuses to ensure that the motor does not start unintentionally Important Note the procedures for reducing the evaporating pressure 15 6 Commissioning set As impurities in the pi...

Page 165: ...eck that the heating element in the oil has been on for 6 8 hours before start Take a sample of the primary refrigerant must be free from water air etc Check that the motor rotation direction is corre...

Page 166: ...re C Oil pressure compressor bar Oil pressure filter bar Oil temperature C Oil temperature separator C Oil collection from shaft seal ml Oil level 0 1 4 1 2 3 4 Full Charged oil Litre Motor 1 1 load a...

Page 167: ...Engineering manual SAB 193 233 283 S A frame including ATEX 008831 en 2022 02 167 175 Spare parts list 16 Spare parts list 16 1 Please see separate spare parts manual...

Page 168: ...Engineering manual SAB 193 233 283 S A frame including ATEX 168 175 008831 en 2022 02 Spare parts drawings 17 Spare parts drawings 17 1 Please see separate spare parts manual...

Page 169: ...anger Be very careful when using cutting tools such as angle grinders or flame cutters during the dismantling process as pipes and the like contain oil residue and refrigerant which may be toxic and o...

Page 170: ...agram order specific Dimension sketch order specific Placing of vibration dampers order specific 4 Electric motor Instruction for motor order specific Torque for screws and bolts Metric thread ISO 5 6...

Page 171: ...rigerant 163 Checklist 133 Cold start system 56 Combustion engines application 24 Commissioning 162 COMP1 calculation program 54 Competent persons requirements 14 Compressor 40 Compressor description...

Page 172: ...ing pressure 141 F F gas regulation 29 Faultfinding 150 Final check 163 First aid HFC HCFC 32 First aid for ammonia accidents 31 First start up 105 Flange loads 79 Foundation block 112 Frick 11 G Grav...

Page 173: ...intervals 140 Maintenance of compressor unit 138 Major overhaul 138 Marine application 38 Marine plant 114 Mass damping 112 Motor 96 Motor lubrication 149 Mounting site 106 Moving the equipment 160 N...

Page 174: ...ce and service 26 Safety equipment 106 Safety precaution definitions 14 Safety signs 23 Shaft rotation 41 Signs and warnings 15 Space requirements 107 Start up 164 Stopping routine 139 Storage 160 Suc...

Page 175: ...ing ATEX 008831 en 2022 02 175 175 V Variable speed drive 42 Vessel name plate 19 Vi 49 Vibration dampers 112 117 124 Vibration data 101 Visual inspection 141 W Water cooled oil cooling 59 63 Weight 1...

Page 176: ...Johnson Controls Denmark ApS Sabroe Factory Christian X s Vej 201 8270 H jbjerg Denmark Phone 45 87 36 70 00 www sabroe com Version 7...

Page 177: ...ressor model Torque Nm All See torque table Mount the cutting ring and union nut correctly in the fitting Press the pipe all the way to the bottom Turn the union nut until it reaches its fixture point...

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