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Operating manual - SAB 120-151 A-frame (including ATEX)

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008668 en 2019.08

Operating instructions

6.5

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

•

Compressor oil cooling system.

The information in this section of the manual provides the logical step-by-step instructions to
properly start up and operate the screw compressor unit.

The following subsections must be read and understood before attempting to start or operate the
unit.

6.6

Compressor

The rotary screw compressor uses mating asymmetrical profile helical rotors to provide a continu-
ous flow of refrigerant vapour and is designed for both high-pressure and low-pressure applica-
tions. The compressor incorporates the following features:

•

Heavy-duty roller bearings to carry radial loads at both inlet and outlet ends of the
compressor.

•

Heavy-duty angular contact ball bearings to carry axial loads are mounted at the dis-
charge end of compressor.

•

Moveable slide valve to provide infinite step capacity control from 100% to 25% of full
load capacity.

•

VOLUMIZER® II adjusts to the most efficient of three volume ratios (2.2, 3.5 or 5.0) de-
pending on system requirements.

•

Hydraulic cylinders to operate the volumizer slide stop and slide valve.

•

Compressor housing suitable for 28 bar [400 PSI] pressure.

•

Most bearing and control oil is vented to closed threads in the compressor instead of suc-
tion port to avoid performance penalties from superheating suction gas.

•

The shaft seal is designed to maintain operating pressure on the seal well below discharge
pressure for increased seal life.

•

Oil is injected into the rotors to maintain good volumetric and adiabatic efficiency, even at
very high compression ratios.

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Содержание SABROE SAB 120 E

Страница 1: ...SAB 120 151 A frame including ATEX Screw compressor units Operating manual en ...

Страница 2: ......

Страница 3: ...oled oil cooler Liquid injection in compressor Single port Dual port Discharge port Standard AC Low Vi ports Oil pump Economiser system ECO system Economiser connection Economiser type _________ Ex execution ATEX T3 T4 Other _________ Supply voltage Motor 3 x _________V _________ Hz Control 1 x _________V ________ Hz Heating elements phasing 1 x _________V ________ Hz Motor IP23 IP55 Power ______ ...

Страница 4: ...ccord 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 to customer connection based on design pressure bar _____________ Safety valve type Back pressure dependent Back pressure independent ...

Страница 5: ... 3 Compressor name plate 15 3 4 Compressor name plate ATEX 16 3 5 Labelling of explosion proof equipment 17 3 7 Vessel name plate 18 4 Safety precautions 19 4 1 Signs 19 4 2 During operation 20 4 3 Safety during maintenance and service 21 4 4 Electrical installations 22 4 5 Lubricating oils 22 4 6 Purging a refrigeration plant 23 4 7 F gas regulation fluorinated greenhouse gases 23 4 8 Sound measu...

Страница 6: ...ngle port liquid injection 41 6 18 Dual port liquid injection 41 6 19 Suction check valve bypass 41 6 20 Heating element 42 6 21 Start up 42 6 22 Initial start up procedure 42 6 23 Normal start up procedure 44 6 24 Stopping routine 44 6 25 Long term storage 44 7 Troubleshooting 46 8 Maintenance instructions 51 8 1 Maintenance of compressor unit 51 8 2 Maintenance intervals 52 8 3 Monitoring of ope...

Страница 7: ...ifications This manual is primarily intended for operators and service engineers 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 All compressor intervention wi...

Страница 8: ...neral piping diagram SAB 151 Updated principle drawings of SAB 151 New compressor name plates The copies of the declarations of conformity Unit and ATEX are now only contained in the printed manual delivered with the unit and the pdf version uploaded with the order specific documentation Various minor corrections 2018 11 Version 4 New principle drawings of SAB 151 unit Overview of Frick compressor...

Страница 9: ...enmark 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 The original version of this manual is the English language version If there are any discrepancies or conflicts between the English and any other version that has been ...

Страница 10: ...o equipment and or minor injury Note Indicates an operating procedure practice or portion thereof which is essential to highlight 1 4 Requirements for competent persons Personnel working on the unit must be competent in accordance with national safety rules and regulations relating to flammable refrigerants or according to EN 13313 Maintenance work must be performed according to EN 378 or ISO 5149...

Страница 11: ... the customer after delivery ATEX The compressor is approved for application in potentially explosive atmospheres provided it is fitted with explosion proof equipment If it is ATEX approved there will be an EX name plate fixed on the unit Please note that special non sparking tools must be used for all maintenance work on the compressor The compressor must NOT be used to evacuate the refrigeration...

Страница 12: ...8 Compressor unit identification 3 Compressor unit identification 3 1 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 ...

Страница 13: ...y voltage Test pressure Allowable pressure Category Pressure system Refrigerant charge Max Allowable temp Min Max Refrigeration unit No Type Year Fluid Group Control V Hz kg bar g bar g C LP side HP side Johnson Controls Denmark ApS Christian X s Vej 201 8270 Højbjerg Denmark www sabroe com 2516 343 Main Fig 2 Name plate for ATEX unit Установка холодильная Назначение Код стандарта сертификата Хлад...

Страница 14: ...Pressure 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 The maximum category of the piping system CAT 1 2 or 3 or of the assembly unit and piping CAT 3 or 4 Allowable pressure max The max pressure pressure relative to atmospheric pressure that the unit p...

Страница 15: ...0240A90000015Z 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 Remanufactured Z Deviation from standard configuration The compressor name plate contains this information Model no Manufacturer type designation Part no Manufacturer part number Serial no Compressor manufact...

Страница 16: ...n ATEX 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 speed rpm Maximum number of revolutions allowed Max allowable pressure psig bar Maximum working pressure of compressor psig bar Assembled in Manufacturing country ...

Страница 17: ... the compressor Warning On ATEX executions the limits in Table 2 must always be respected Temp class Max surface temp Max temperature of oil to shaft seal Min ignition temperature of oil T1 450 C 380 C 500 C T2 300 C 230 C 350 C T3 200 C 130 C 250 C T4 135 C 65 C 185 C T5 100 C 30 C 150 C T6 85 C 15 C 135 C Table 2 Temperature classes screw compressors 3 6 Geometrical swept volume Compr model Roto...

Страница 18: ...elevant 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 Shell side and Tube side Fluid Designation of the primary refrigerant s and the secondary re frigerant s For EC PED approval Designation of the refrigerant s and or the highest fluid group Group 1 or 2 according to the PED directive Allowabl...

Страница 19: ...t and oil To protect the compressors against internal corrosion they are delivered evacuated of all atmospheric air and charged with dry Nitrogen N2 to an overpressure of 0 5 bar 7 3 PSI In such cases a yellow sign is affixed to a visible spot on the compressor The magnetic field on the rotor may affect pacemakers The motor rotor contains a powerful magnetic field This field may affect digital dev...

Страница 20: ...ation The owner of the refrigeration plant is responsible for ensuring that all codes regulations and industry standards are complied with 4 2 During operation Warning All safety features disengagement and interlocks must be in place and function correctly before the equipment is put in operation Never by pass or wire around any safety device Ventilation Before operating the unit always check the ...

Страница 21: ... all necessary stop valves 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 When performing maintenance the main switch must be locked Use gloves and protective goggles ...

Страница 22: ...s include the following oil types Code design Oil types M Mineral oil naphtenic base A Synthetic oils based on alkylated aromatics alkyl benzene AP Synthetic oils blended from alkyl benzene and poly alfa olefin base stocks S Semi synthetic oils hydro treated mineral oil on paraffinic base PAO Synthetic oils based on poly alfa olefin POE Synthetic oils based on polyol esters PAG Synthetic oils base...

Страница 23: ...m refrigeration and air conditioning systems to the atmosphere Note The occurrence of air is usually an indication of poor maintenance or lack of thoroughness at installation Note Ammonia systems should be purged on a regular basis to avoid atmospheric air and other non condensable gases 4 7 F gas regulation fluorinated greenhouse gases In the European F gas regulation No 517 2014 about reduction ...

Страница 24: ...e detection system is installed at least every 12 months for equipment that contains fluorinated greenhouse gases in quantities of 500 tonnes of CO2eq or more at least every three months or where a leakage detection system is in stalled at least every six months The equipment must be checked for leakage within one month after a leak has been repaired to ensure that the repair has been effective Re...

Страница 25: ...nit SWL SPL SAB 120 S 100 83 SAB 120 M 101 84 SAB 120 L 103 86 SAB 120 E 104 87 SAB 151 S 106 88 SAB 151 M 107 89 SAB 151 L 107 89 SAB 151 E 108 90 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 In a typical mac...

Страница 26: ...proper design considerations regarding function vibrations ther mal expansion and pre stress after welding in order to avoid high load on the compressor unit connections 5 Leak and pressure test according to the applied local codes and rules Isolate the com pressor unit from the test pressure or disconnect pressure transducers and safety valves Never exceed the test pressure of the unit stated on ...

Страница 27: ...e unit 6 1 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 Fig 9 Positions of valves and components shown on a SAB 151 unit EC 151 158 101 192 107 102 Not shown 126 108 163 116 154 106 161 117 103 104 105 159 160 Behind 126 114 ...

Страница 28: ...ding ATEX 28 61 008668 en 2019 08 Operating instructions Fig 10 Positions of valves and components shown on a SAB 151 unit 155 192 124 127 128 YY2 YY1 200 PM 1 193 144 145 146 135 196 123 195 138 156 120 139 119 157 182 181 106 153 121 136 137 ...

Страница 29: ... I diagram Delivered and installed by customer Strainer with mesh 500µm to be installed in water line Valves for CIP cleaning recommended Additional part flow filtration is recommended for particle rich waters 4809 053_Rev_5 Fig 11 Principle P I diagram SAB 120 151 SAB 151 with OHU 04123 oil separator is shown here ...

Страница 30: ... injection high Vi PDAH High pressure differential alarm SM 1 Main oil injection PDI Pressure differential indicator SV 1 Vapour injection tongue and groove PDSLL 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 Pressure indicator PE 1 Oil pressure manifold PIC Pressure indicator controller PE 2 Oi...

Страница 31: ...Fig 13 P I diagram liquid injection dual port Compressor Low Vi Liquid refrigerant from receiver Solenoid valve Strainer Liquid line Sight glass Motorised expansion valve Tubing line 5 170 165 Compressor Low Vi Compressor High Vi To separator Tubing line Motorised expansion valve Solenoid valve Strainer Sight glass Liquid line Liquid refrigerant from receiver Compressor suction pressure 5 170 165 ...

Страница 32: ... 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 128 Pilot valve for pos 127 Closed Fixed set point 129 Suction check valve 130 Change over valve 131 Safety valve oil cooler 132 Safety valve oil cooler 133 Safety valve oil cooler 135 Stop valve before oil filte...

Страница 33: ...hutdown 161 Heater 163 High level indicator Liquid injection optional 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 Moveable slide stop 191 Compressor 192 Electric motor 193 Oil separator 194 Oil cooler 195 Oil filter 196 Oil filter 200 Stop valves oil return Open ...

Страница 34: ... pressure applica tions The compressor incorporates the following features Heavy duty roller bearings to carry radial loads at both inlet and outlet ends of the compressor Heavy duty angular contact ball bearings to carry axial loads are mounted at the dis charge end of compressor Moveable slide valve to provide infinite step capacity control from 100 to 25 of full load capacity VOLUMIZER II adjus...

Страница 35: ...formance even at high compression ratios It provides oil pressure for development of balance load on the balance pistons to reduce bearing loading and increase bearing life 6 8 No pump oil system The screw compressor unit is designed to be self lubricating Oil supplied to the compressor from the oil separator is at system head pressure In the compressor oil from all lubricating points is returned ...

Страница 36: ... or death Warning Inside the valve there is a very heavy tight spring Provided the valve is intact the spring presents no danger when dismantling 6 11 Compressor oil separation system The oil charged to the compressor for lubrication sealing and cooling of the compressor block is mixed with the refrigerant gas and led to the oil separator collectively In the oil separator oil and gas are separated...

Страница 37: ...te Automatic oil return Open the service valves completely to keep the coalescer end of the separator free of oil The sight glass in the valve indicates flow variations Note See subsection 8 5 Oil charge for normal operating oil level Demister From the compressor To oil vessel Fine oil separator element pos 55 Oil return Oil return ...

Страница 38: ...tly 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 Thus the spring force pos 9 is equalised and a transverse bore pos 10 with a considerably larger bore than pos 7 will open Because the bore is larger oil collections at the oil return valve inlet can qu...

Страница 39: ...umizer II This allows adjust ment of the compressor volume ratio Vi while the compressor is running 6 14 Capacity control Compressor loading The compressor loads when MSV solenoid coil YY2 is energised and oil flows from the solenoid valve through the regulating valve 182 to compressor port 2 where it enters the load side of the slide valve piston This equalises the force on the slide valve piston...

Страница 40: ...so the Engineering manual for Unisab for adjustment of the slide speed Note A change in operating conditions such as winter to summer operation may require read justment of the slide valve travel time 6 15 Volumizer II Vi control The compressor is equipped with a special internal control that automatically adjusts the com pressor volume ratio to the most efficient of three available steps 2 2 3 5 ...

Страница 41: ...g injection of liquid refrigerant into one of two ports optimally located on the compressor This minimises the performance penalty incurred with liquid injection oil cooling The dual port system contains all the components of the single port system with the addition of a double acting solenoid valve and operates as outlined The liquid injection solenoid valve is energised by the microprocessor whe...

Страница 42: ...ld reactivate it 6 21 Start up Preparations before start up 1 Turn on the power voltage and the control voltage Check the emergency stop button 2 Check the oil level in the oil separator see subsection 8 5 Oil charge 3 Check that all valves are positioned in accordance with 6 4 Valve positions during opera tion including the secondary side of the oil cooler 4 Reset all alarms according to the cont...

Страница 43: ...the hand expansion valve The ideal discharge temperature is within 2 7 C or 2 7 C of the theoretical discharge temperature Adjust the valve to achieve the theoretical discharge temperature Second method If you do not have access to CoolWare Comp 1 or ScrewSelect 82 C is a good target discharge temperature for a high stage ammonia compressor Booster applications and compressors using HFC and HCFC r...

Страница 44: ...y capacity setting However under normal conditions it is recommended to reduce the capacity to a minimum before stopping the compressor Leave all valves in their in operation positions Do not turn off the power to the screw compres sor unit as the oil heater must be connected to keep the correct oil temperature Shutting down for a long period Follow the Brief stop instructions and Disconnect oil h...

Страница 45: ...uipment may lead to the deterioration of components over the period of time 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 ...

Страница 46: ...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 Discharge pressure excessively high Safety cut out set too low Check the setting of alarms and warnings control system and the separate safety pressure cut out High discharge line loss Check the valves check val...

Страница 47: ... 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 function liquid injection Check the settings in control system valves and strainer in liquid injection line Compressor protection valve is open or leaking Check the discharge pressure safety cut out settings Chec...

Страница 48: ...ated 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 Rapid loss with no oil level in the coalescer section sight glass On shutdown compressor unit suc tion check valve did not close Repair valve Suction check valve bypass open too far Close valve Coalescers loos...

Страница 49: ...ion 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 slide stop will not move Cannot unload load or both Oil pressure is not sufficient Check oil pressure Solenoid coils may be burned out Replace Incorrect setting of valves in the hy draulic system Check accordin...

Страница 50: ... 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 system Make necessary adjustments or corrections Noise and vibrations Pump strainer blocked Clean strainer Liquid refrigerant overfeed Adjust liquid injection Pump worn out Repair or replace Grease leaks from ...

Страница 51: ...to 3 groups 1 Daily maintenance minimum twice a week Daily maintenance consists of visual inspections Inspect the compressor unit and check that both noise and vibrations are normal To observe trends it is recommended to enter the observed operating data into an operations log see subsection 8 3 Monitoring of operation Check that all operat ing values are within the permissible ranges Compare them...

Страница 52: ...t seal When 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 posted in the enclosure c Check calibration of slide valve slide stop and pressure d Booster 20 000 h High stage air conditioning 10 000 h One stage 30 000 h e Not for flange motors f Vibration ...

Страница 53: ...lar basis You can use the items listed in the Start up log which is page 2 of the Checklist il lustrated in Fig 20 The service engineer will need this information in connection with for exam ple error reports In addition to the items listed in the start up log all other activities of service maintenance or re pair work must be entered into your logbook as required by EN 378 and national laws Check...

Страница 54: ... for third party components electric motors valves etc Check unit installation and vibration damper adjustment Carry out functional testing of safety equipment Read the opening pressures on all safety valves and check that they are correct Carry out vacuum test Check Unisab set up see list of settings and check VSD set up as applicable Check oil level Check that the heating element in the oil has ...

Страница 55: ... organisation change the oil as it is rec ommended to replace all filters in the unit at the same time Oil charge The necessary amount of oil depends on the composition of the specific unit You can calculate the correct amount using Table 15 and Table 16 below Operation During operation the oil level is satisfactory in the range from the middle of the upper sight glass and down to the lowest level...

Страница 56: ...pump pos 1 together with the by pass hose pos 2 in the barrel 3 Open the ball valve pos 9 and service valve pos 106 and start the pump pos 5 4 Circulate the oil until the system is free from air bubbles Close the ball valve pos 9 The oil will now be charged to the unit 5 When the desired amount of oil has been charged to the unit stop the pump and close the service valve pos 106 6 Open the ball va...

Страница 57: ... 8 7 Motor Motor lubrication 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 5 20 2 1 B 9 7 12 M A 106 ...

Страница 58: ...Be very careful when using cutting tools such as angle grinders or flame cutters during the dis mantling process as pipes and the like contain oil residue and refrigerant which may be toxic and or flammable 9 2 Waste disposal Machine parts When dismantling the plant it is important to properly sort the parts that should be disposed of The compressor frame containers and so on belonging to the cate...

Страница 59: ... lated version of the declaration however not filled in with the specific data for your unit The translated version is also included in the operating manual that is available for download with the rest of the order specific documentation The original signed declaration of conformity is sent separately in accordance with the Guide to application of the Machinery Directive If more than one declarati...

Страница 60: ...equirements 10 Compressor name 8 Compressor name plate 15 Compressor name plate ATEX 16 Compressor oil cooling system 41 Compressor oil separation system 36 Cooling water system 21 D Declaration of conformity 59 F F gas regulation 23 Frick 8 G Greenhouse gases 23 H Heating element 42 Hydraulic system 39 I Identification 12 L Logbook 53 Long term storage 44 Lubricating oil 22 56 Lubrication system ...

Страница 61: ...r 55 Oil types 22 P Piping system 55 Power supply 22 Pressure 20 Pump oil system no pump oil system 35 Purging 23 R Refrigerants 22 Rotating parts 20 S SABROE 8 Safety during maintenance and service 21 Safety precaution definitions 10 Safety signs 19 Stopping routine 44 T Temperature class T1 T6 17 21 42 Troubleshooting 46 U Unit pipe system name plate 13 V Valve positions during operation 32 Vess...

Страница 62: ...Johnson Controls Denmark ApS SABROE Factory Christian X s Vej 201 8270 Højbjerg Denmark Phone 45 87 36 70 00 www sabroe com Version 5 ...

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