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Operating manual - HPC Mk 4 LL & Mk 5 (including ATEX)
001752 en 2023.05

41/48

Maintenance instructions

Oil level

Check the oil level in the compressor. It is of vital importance for the service life of the compres-
sor that an optimal lubrication is maintained. The oil level must always be visible in the oil level
glass. If the oil level is below the lowest part of the oil level glass, oil must be recharged.

Recharging of oil (“topping up”) can be carried out during operation, either by means of a
hand-operated oil pump or as described in subsection

4.10 Charging the compressor with lu-

bricating oil

. Use recommended oil type only.

Remember to write down drained or recharged amount of oil.

4.10

Charging the compressor with lubricating oil

As all Sabroe reciprocating compressors are supplied with a special oil charging valve on the
crankcase, lubricating oil may be charged while the compressor is operating.

For this purpose, use a hand-operated oil pump as mentioned earlier, or follow the procedure
below.

See oil charge in Table 12 and oil level in Table 13.

Note:

When charging for the first time, use the oil pump. Never start the compressor, if it is not

charged with oil.

•

Reduce pressure in the crankcase, e.g. by throttling the suction stop valve until the suc-
tion pressure gauge shows a pressure slightly below atmospheric.

•

Fill the pipe connected to the oil charging valve with lubricating oil, and place the free
end of the pipe in a receptacle containing fresh lubricating oil.

•

Open the oil charging valve carefully. External air pressure will force oil into the
crankcase.

•

Avoid air or other impurities being sucked into the compressor.

Note:

In order to achieve pressure below atmospheric, it will sometimes be necessary to set

the low-pressure cut-out so that the compressor can operate down to this pressure. Remem-
ber to reset the pressure cut-out to its normal setting after oil charging. During operation, the
compressor can be recharged with oil by means of the hand-operated oil pump.

Note:

As halocarbon refrigerants are miscible with lubricating oils, there will always be a good

portion of oil blended with the refrigerant in the plant. Therefore, it is often necessary to re-
charge with lubricating oil after starting up for the first time, and after charging with fresh
refrigerant.

Watch the oil level in the compressor closely after start-up.

Содержание HPC 100 Mk 4 LL

Страница 1: ...HPC 100 Mk 4 LL Mk 5 including ATEX Reciprocating compressor unit Operating manual EN...

Страница 2: ......

Страница 3: ...her ______ Control UniSAB None Other Compressor cooling Water cooled top and side covers Air cooled top and side covers Air cooled top covers and water cooled side covers Air cooled top and side cover...

Страница 4: ...13136 Vessel data Type External surface m2 Design pressure bar Condenser Evaporator Liquid separator Oil separator Oil cooler Economiser Desuperheater Subcooler Other Pressure loss if any from safety...

Страница 5: ...Signs 18 2 4 2 Emergency stop 19 2 4 3 Safety during maintenance and service 19 2 4 4 Electrical installations 20 2 4 5 General precautions 21 2 4 6 During operation 21 2 4 7 Cooling water system 22...

Страница 6: ...nd service 34 4 2 Safety measures 34 4 3 Basis for maintenance 34 4 4 Service intervals 35 4 5 Service interval diagrams for HPC 35 4 6 Annual service 38 4 7 Regular service schedule refrigeration pla...

Страница 7: ...liarise themselves with the contents of this manual in order to ensure proper and efficient operation Johnson Controls Denmark is not li able for damage occurring during the warranty period where this...

Страница 8: ...rsion 6 The regular service schedule Table 11 and the Annual service section have been updated New noise data tables showing 1500 and 1800 rpm Updated versions of declarations of conformity Unit and A...

Страница 9: ...nd or minor injury Note Indicates an operating procedure practice or portion thereof which is essential to highlight 1 3 Requirements for competent persons Personnel working on the unit must be compet...

Страница 10: ...ustomer after delivery ATEX The compressor is approved for application in potentially explosive atmos pheres provided it is fitted with explosion proof equipment If it is ATEX approved there will be a...

Страница 11: ...equipment re sulting from using the equipment for other purposes than the ones stated above 2 3 Identification 2 3 1 Identification of equipment All equipment from Johnson Controls Denmark can be iden...

Страница 12: ...erant charge Max Allowable temp Min Max Year Fluid Group Control V Hz kg bar g bar g C LP side HP side 1000010127 Main Serial Type No Johnson Controls Denmark ApS Christian X s Vej 201 8270 H jbjerg D...

Страница 13: ...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 categ...

Страница 14: ...volume Speed bar g bar g rpm m h 3 1000010132 Max Serial Type No Johnson Controls Denmark ApS Christian X s Vej 201 8270 H jbjerg Denmark www sabroe com MADE IN DENMARK Fig 7 Name plate for ATEX compr...

Страница 15: ...ume of the compressor at nominal speed Pressure system The low pressure side of the compressor is referred to as the LP side The high pressure side of the compressor is referred to as the HP side Allo...

Страница 16: ...eas 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 Temperature cl...

Страница 17: ...ansparent Material 0 5 mm AISI 304 plate Anvendte fonte Used fonts Hvor where Font Eksempel Example 1 Tekst i isbj rn logo Text in polar bear logo Arial 2 vrig tekst Remaining text Arial Narrow SABROE...

Страница 18: ...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...

Страница 19: ...ess It must be able to stop any dangerous situation as quickly as possible without this caus ing any additional danger 2 4 3 Safety during maintenance and service Personnel must be qualified according...

Страница 20: ...Controls Denmark must not be replaced by unspeci fied parts that are not ATEX approved Warning On ATEX executions the limits in Table 2 must always be respected Temp class Max surface temp Max oil tem...

Страница 21: ...t and or lubricating oil Use proper electrical safety protection Note These instructions only provide general information The owner of the refrigeration plant is responsible for ensuring that all code...

Страница 22: ...recommendation for the recommended type of oil Warning When charging oil follow the safety instructions given by the oil supplier MSDS Material Safety Data Sheet Always avoid direct contact with the o...

Страница 23: ...regulation No 517 2014 about reduction of harmful gases in the at mosphere the European Parliament EU has established guidelines for the regulation of cer tain fluorinated greenhouse gases The follow...

Страница 24: ...utting in place arrangements for the proper recovery of fluori nated greenhouse gases by competent personnel to ensure recycling reclamation or destruction Certification of personnel According to dire...

Страница 25: ...he compressor motor cannot start up inadvertently When performing service where the motor is dismantled from the base frame follow the in structions for coupling alignment in the Installation instruct...

Страница 26: ...densing temperature TC 74 C 165 F Refrigerant R717 Speed 1500 rpm Compressor block SWL SPL HPC 104 S 97 82 HPC 106 S 99 83 HPC 108 S 100 84 Table 3 Noise data for HPC and HPX 1500 rpm Evaporating temp...

Страница 27: ...materials the actual SPL will be approximately 14 dBA higher than the stated SPL free field value Checking the actual SPL must therefore always be accompanied by measurements of the acoustic environme...

Страница 28: ...he plant Danger Body contact with leaking liquid refrigerant entails high risk of injuries caused by intense cold The safety sheets supplied by the supplier of the plant also explain the risks general...

Страница 29: ...sight glass Normally it must be turned off when the compressor is in operation Remember to turn off the heating element before draining the oil through the compressor serv ice valve and before opening...

Страница 30: ...ion the button must be in its outermost position If the plant does not start check that the fuses are intact that the valves are open according to Table 6 that direction of rotation is correct Check t...

Страница 31: ...You can use the items listed in the Start up log which is page 2 of the Checklist illustrated in Fig 15 The service engineer will need this information in connection with for ex ample error reports In...

Страница 32: ...Operating manual HPC Mk 4 LL Mk 5 including ATEX 32 48 001752 en 2023 05 Operating instructions Fig 15 The checklist which MUST be filled in during commissioning and start up...

Страница 33: ...pheric pressure Close the suction and discharge stop valves and the stop valve in the oil return line Follow the plant instructions which indicate how to stop and close down the plant correctly Shut o...

Страница 34: ...any maintenance please study carefully the general safety instructions regulations that apply to this series of compressor units Failure to follow these instructions regulations may cause personal inj...

Страница 35: ...le operation under non specified conditions water acid or solid par ticles in the lubricating oil or refrigerant forced starts and stops part load using an unsuitable oil type and failure to monitor t...

Страница 36: ...1460 rpm correct the service interval ac cording to Table 7 40 30 20 10 0 10 20 30 90 80 70 60 50 40 30 20 10 0 C C 7 000 8 000 9 000 10 000 11 000 12 000 50 68 32 86 Condensing temperature Evaporati...

Страница 37: ...con trol lamp or UniSAB Standard service inspections will be performed in cycles consisting of four preventive mainte nance service visits 1 x service interval Use service set A 2 x service interval U...

Страница 38: ...hange gaskets for covers that have been opened Perform functional test of safety devices Check for correct operation and working order of all safety controls all measuring devices all alarm systems Ch...

Страница 39: ...Safety switching devices emergency signals and alarm systems X Perform leak test X Check and perform leak test of safety valves bursting discs and fusible plugs X Perform functional test of safety dev...

Страница 40: ...ents and system X Re Re Re Re Analyse oil Re Re Re Re Re Check vibration dampers for cracks and adjustment Re Re Re Re Re Check for abnormal noises and or vibrations Re Re Re Re Re Check crankcase hea...

Страница 41: ...for the first time use the oil pump Never start the compressor if it is not charged with oil Reduce pressure in the crankcase e g by throttling the suction stop valve until the suc tion pressure gaug...

Страница 42: ...peration the compressor must be recharged with oil as part of the oil has been absorbed by the refrigerant This particularly applies to HFC and HCFC refrigerants Fig 17 Oil level glass Oil must be cha...

Страница 43: ...ve must be open Check the oil level in the crankcase The oil level must always be visible in the oil sight glass A hand operated oil pump connected to the oil charging valve pos B can be used for the...

Страница 44: ...s 4 14 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 o...

Страница 45: ...e 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 or flamm...

Страница 46: ...and a translated version of the declaration of conformity however not filled in with the specific data for your unit The translated version is also included in the operat ing manual available for down...

Страница 47: ...application 10 Competent persons requirements 9 Compliance 46 Compressor name plates 14 Cooling water system 22 D Declaration of conformity 46 E Emergency stop 19 F F gas regulation 23 Final disposal...

Страница 48: ...22 R Refrigerants 22 S Safety during maintenance and service 19 Safety precaution definitions 9 Safety signs 18 Service intervals 35 Service schedule 39 T Temperature class T1 T6 16 20 Troubleshootin...

Страница 49: ......

Страница 50: ...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 8...

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