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SABROE SAB 283, Руководство по эксплуатации

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Table 25: Maintenance intervals

Maintenance intervals

Hours operation (maximum)

Maintenance

schedule

200

1000

5000

8000

10000

15000

20000

25000

30000

35000

40000

45000

50000

55000

60000

65000

70000

75000

80000

85000

90000

95000

Change oil

As directed by oil analysis

Oil analysis

x

Every 6 months

Change filters

x

x

x

x

x

x

x

x

x

x

x

Clean oil

strainers

x

x

x

x

x

x

x

x

x

x

x

Clean liquid

strainers

x

x

x

x

x

x

x

x

x

x

x

Change

coalescers (d)

x

x

x

x

x

x

Check and clean

suction screen

x

x

x

x

x

x

x

x

x

x

x

x

Check

alignment (e)

x

x

x

x

x

x

x

x

x

x

x

Check

coupling (a)

x

Annually regardless of operating hours

Check electrical

connections (b) x

x

x

x

x

x

x

x

x

x

x

x

x

x

x

x

x

x

x

x

Check sensor

calibration (c)

x

x

x

x

x

x

x

x

x

x

x

x

x

x

x

x

x

x

x

x

x

Vibration

analysis (f)

x

Every 6 months, more frequently if levels increase

Replace

shaft seal

When leak rate exceeds 7 to 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 measurement must be carried out continuously to obtain optimum preventive control on bearings. If not

continuously controlled then every 6 months, more frequently if levels increase. Alternatively, major overhaul after

maximum 30000 h.
(g) Verify tightness of bolts on suction and discharge flanges on a daily basis. See for torque requirements.
Leak test: According to national rules or as a minimum according to 

EN 378-2

 (Minimum annually if leak rate < 1% year)

Safety equipment: Check of safety equipment (Safety switch devices, pressure relief valve) according to national rules.

Minimum requirement according to 

EN 378

, annual check of safety switch devices and every 5 years for pressure relief valve.

Table 26: Torque requirements

Discharge flange to separator

flange

Suction flange

EU

designation

Compressor

model

Bolt size

Torque (Nm)

Bolt size

Torque (Nm)

SAB 283 S

SGC 2813

M22 x 2.5

312

M22 x 2.5

350

SAB 283 L

SGC 2817

M22 x 2.5

312

M24 x 3.0

400

SAB 283 E

SGC 2821

M22 x 2.5

312

M24 x 3.0

400

SAB 283 X

SGC 2824

M22 x 2.5

325

M24 x 3.0

400

SAB 355 S

SGC 3511

M24 x 3.0

400

M30 x 3.5

678

SAB 355 L

SGC 3515

M24 x 3.0

400

M30 x 3.5

678

SAB 283-355 A-Frame OHU 6042 and OHU 7650 (including ATEX) Screw Compressor Unit

68

Содержание SAB 283

Страница 1: ...Form Number 004059 en 2023 09 Supersedes 004059 en 2019 11 Operation Guide Issue Date 2023 09 21 SAB 283 355 A Frame OHU 6042 and OHU 7650 including ATEX Screw Compressor Unit ...

Страница 2: ...2 SAB 283 355 A Frame OHU 6042 and OHU 7650 including ATEX Screw Compressor Unit ...

Страница 3: ...X 22 Labelling of explosion proof equipment 23 ATEX 23 Geometrical swept volume 24 Vessel name plate 24 Safety precautions 27 Signs 27 General 28 During operation 28 Ventilation 29 Rotating parts 29 Vibration and noise 29 Pressure 29 Cooling water system 29 Safety during maintenance and service 29 ATEX 30 Electrical installations 30 ATEX 30 Power supply 31 Lubricating oils 31 Refrigerants 31 Purgi...

Страница 4: ...High stage units 50 Booster applications 50 Compressor hydraulic system 51 Single acting mode high stage 10 bar pressure differential 52 High stage compressor loading 52 High stage compressor unloading 52 Double acting mode booster 10 bar pressure differential 52 Booster compressor loading 53 Booster compressor unloading 53 Volumizer volume ratio VI control 53 Compressor VI increase 53 Compressor ...

Страница 5: ...ol 62 Water and brine treatment 62 R717 detector 62 Troubleshooting 63 Refrigeration plant general issues 63 Compressor unit general issues 63 Compressor unit oil separation 65 Compressor block 65 Demand oil pump system optional 66 Maintenance instructions 67 Maintenance of compressor unit 67 Daily maintenance perform a minimum of twice a week 67 Periodic maintenance 67 Major overhaul 67 Monitorin...

Страница 6: ...Machine parts 76 Oil and refrigerant 76 Electric components 76 Batteries 76 Compliance 77 Declaration of conformity 77 SAB 283 355 A Frame OHU 6042 and OHU 7650 including ATEX Screw Compressor Unit 6 ...

Страница 7: ...mpressor r Single port Discharge port r Standard r AC Low Vi port Oil pump r Economiser system ECO system r Economiser connection r Economiser type ______________________________________ Ex execution ATEX r T3 r T4 Other _________________________ Motor 3 x ____________________ V ____________________Hz Control 1 x ____________________V ____________________ Hz Supply voltage Heating elements phasing...

Страница 8: ... if any from safety valve to customer connection based on design pressure bar ______________________________________________________ Safety valve Data for calculation of downstream line according to EN 13136 Safety valve type r Back pressure dependent r Back pressure independent SAB 283 355 A Frame OHU 6042 and OHU 7650 including ATEX Screw Compressor Unit 8 ...

Страница 9: ...mage occurring during the warranty period where this is attributable to incorrect operation All compressor intervention within the warranty period must be performed by competent personnel only If not the warranty no longer applies This manual does not describe the following The control systems A specific operating manual is delivered with the compressor Safety information when handling refrigerant...

Страница 10: ...SABROE and Frick compressor names are made and how they correspond to each other Table 3 Compressor overview SABROE name Frick name SAB 283 S SGC 2813 SAB 283 L SGC 2817 SAB 283 E SGC 2821 SAB 283 X SGC 2824 SAB 355 S SGC 3511 SAB 355 L SGC 3515 SAB 355 E SGC SGX 3519 SAB 355 X SGC SGX 3524 SAB 283 355 A Frame OHU 6042 and OHU 7650 including ATEX Screw Compressor Unit 10 ...

Страница 11: ...gulator section Added new Secondary system section Updated the torque requirements table in the Maintenance of compressor unit section Updated the oil charging table in the Oil change section Added new Sampling the oil procedure Implemented various style and document improvements throughout document 2019 11 Version 2 Added information about motorised oil injection valve in the Initial start up pro...

Страница 12: ...on Controls Denmark and the contents must not be imparted to a third party nor be used for any unauthorised purposes 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 translated into another language the English version will prevail SAB 283 355 A Fr...

Страница 13: ...of which is essential to highlight 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 supported by evidence of appropriate training Assign only competent personnel instructed in safety...

Страница 14: ...le to built in VSD solutions initiated by 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 Important You must use special non sparking tools for all maintenance work on the compressor Figure 1 EX name plate exam...

Страница 15: ...k is not liable for injuries to personnel or damage to equipment resulting from using the equipment for other purposes than the ones stated previously 15 SAB 283 355 A Frame OHU 6042 and OHU 7650 including ATEX Screw Compressor Unit ...

Страница 16: ...uipment can be identified by one or several name plates as shown in the following sections Unit and pipe name plate Figure 2 Name plate for standard unit with CE mark SAB 283 355 A Frame OHU 6042 and OHU 7650 including ATEX Screw Compressor Unit 16 ...

Страница 17: ...Figure 3 Name plate for ATEX unit Figure 4 Name plate for standard unit without CE mark 17 SAB 283 355 A Frame OHU 6042 and OHU 7650 including ATEX Screw Compressor Unit ...

Страница 18: ...pplies to the piping system only and it is the sole responsibility of the owner to ensure and declare that the complete unit is in conformity with the provisions of all relevant rules Design code Design code used for the unit and piping system Approval no If the unit manufacture has been approved by a third party notified body Refrigerant Fluid Refrigerant of the unit Refrigerant designation accor...

Страница 19: ...mum allowable pressure depending on the operating conditions and safety equipment settings Test pressure The test pressure that the unit piping system has been strength tested with Allowable temperature min max The minimum and the maximum temperatures that the unit piping system has been designed for at the indicated maximum allowable pressures CE xxxx The CE mark appears on the name plate for EC ...

Страница 20: ...Compressor name plate Figure 6 Compressor name plate SAB 283 355 A Frame OHU 6042 and OHU 7650 including ATEX Screw Compressor Unit 20 ...

Страница 21: ...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 the following information Table 5 Compressor name plate 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 allowabl...

Страница 22: ...on 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 SAB 283 355 A Frame OHU 6042 and OHU 7650 including ATEX Screw Compressor Unit 22 ...

Страница 23: ...he equipment is suitable for use in potentially explosive gas vapour and fog atmospheres T3 T4 Temperature class Indicates the surface temperatures that may occur on the compressor WARNING On ATEX executions the limits in Table 7 must always be respected Table 7 Temperature classes screw compressors Temp class Max surface temp Max temperature of oil to shaft seal Min ignition temperature of oil T1...

Страница 24: ...7 1000 3600 0 66115 0 018711 3312 SGC 2821 283 2 1 1000 3600 0 79546 0 022512 3985 SGC 2824 283 2 4 1000 3600 0 89858 0 025430 4501 SGCH B 3511 355 1 1 1000 3600 0 82248 0 023276 4120 SGCH B 3515 355 1 5 1000 3600 1 12154 0 031739 5618 SGCH B 3519 355 1 9 1000 3600 1 42748 0 040398 7150 SGCB 3524 355 2 4 1000 3600 1 80328 0 051033 9033 Vessel name plate Figure 9 Name plate for vessel SAB 283 355 A...

Страница 25: ... number of the vessel issued by the relevant third party or 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 refrigerant s For EC PED approval Designation of the refrigerant s and or the highest fluid group Group 1 or ...

Страница 26: ...its make up the registration number of the notified body or the third party in charge EAC The EurAsian Conformity mark EAC indicates that the vessel is in compliance with all relevant technical regulations of the Eurasian Customs Union Note Depending on the supplier of the pressure vessel or heat exchanger the layout and content of the vessel name plate may differ from the previous SABROE name pla...

Страница 27: ...tric shock High voltage High pressure High surface temperature about 70 C Thecompressor may be top heavy Internal overpressure Hazardous substance Cold surfaces Dangerous noise level use hearing protectors Do not step on surface No open flame Flammable gas The unit IS filled with refrigerant R290 27 SAB 283 355 A Frame OHU 6042 and OHU 7650 including ATEX Screw Compressor Unit ...

Страница 28: ... and unit Local plant and shop safety rules and codes National safety rules and regulations Read and understand all safety instructions before setting up operating or servicing or performing maintenance on the compressor Assign only competent personnel instructed in safety and all machine functions to operate or service this compressor Operators and maintenance personnel must carefully read unders...

Страница 29: ...y See also EN 378 and existing national legislation Cooling water system WARNING The recirculation water system may contain chemicals or biological contaminants including legionella which can be harmful if inhaled or ingested Water systems should only be operated with an effective biological treatment programme Safety during maintenance and service Personnel must be competent according to national...

Страница 30: ... not ATEX approved WARNING On ATEX executions the limits in Table 10 must always be respected Table 10 Temperature classes screw compressors 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 Electrical installations ATEX On ATEX ex...

Страница 31: ...neral oil on paraffinic base PAO Synthetic oils based on poly alfa olefin POE Synthetic oils based on polyol esters PAG Synthetic oils based on polyalkylene glycols AN Synthetic oils based on alkylated naphthalene For the recommended type of oil refer to SABROE oil WARNING When charging oil follow the safety instructions given by the oil supplier MSDS Material Safety Data Sheet Always avoid direct...

Страница 32: ... to prevent and minimise leakage of refrigerant from 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 F gas regulation fluorinated greenhouse gases In the Europea...

Страница 33: ...s For equipment that contains fluorinated greenhouse gases in quantities of 500 tonnes of CO2eq or more at least every 3 months or where a leakage detection system is installed at least every 6 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 Recovery of refrigerant Operators are responsible for putting in...

Страница 34: ... 355 S 112 89 SAB 355 L 112 89 SAB 355 E 112 89 SAB 355 X 112 89 Johnson Controls Denmark can provide noise data for other operating conditions 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 machine room without any noise absorbing materials the actual SPL will be approximately 14 dBA higher...

Страница 35: ...n dampers according to the vibration design strategy 4 Welding on suction piping discharge piping and other oil cooling system pipings The piping design must include proper design considerations regarding function vibrations thermal 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...

Страница 36: ... 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 Specifically the contractor is responsible for equalising potential differences on the compressor SAB 283 355 A Frame OHU 6042 and OHU 7650 including ATEX Screw Compressor Unit 36 ...

Страница 37: ...nit Control system The compressor unit is controlled by an electronic control system The control system is described in a separate manual delivered with the unit Principle drawing Figure 11 SAB 283 with oil separator OHU 7650 viewed from the back 37 SAB 283 355 A Frame OHU 6042 and OHU 7650 including ATEX Screw Compressor Unit ...

Страница 38: ...12 SAB 283 with oil separator OHU 7650 viewed from the front Figure 13 SAB 355 with oil separator OHU 7650 viewed from the back SAB 283 355 A Frame OHU 6042 and OHU 7650 including ATEX Screw Compressor Unit 38 ...

Страница 39: ...Figure 14 SAB 355 with oil separator OHU 7650 viewed from the front 39 SAB 283 355 A Frame OHU 6042 and OHU 7650 including ATEX Screw Compressor Unit ...

Страница 40: ...General P I diagram Figure 15 General P I diagram SAB 355 with oil cooler dual oil filters and oil pump SAB 283 355 A Frame OHU 6042 and OHU 7650 including ATEX Screw Compressor Unit 40 ...

Страница 41: ...Figure 16 General P I diagram SAB 283 OHU 6042 or 7650 41 SAB 283 355 A Frame OHU 6042 and OHU 7650 including ATEX Screw Compressor Unit ...

Страница 42: ... High discharge pressure shutdown SL 1 Liquid injection low Vi PAL Low pressure alarm SL 2 Liquid injection high Vi PALL Low pressure shutdown SM 1 Main oil injection PDAH High pressure differential alarm SV 1 Vapour injection tongue and groove PDI Pressure differential indicator SD 1 Threaded hole for oil return from coalescer PDSLL Compressor low diff pressure cut out TW 1 Thermowell PE Pressure...

Страница 43: ...ler YY 2 Energize increase volume rate TCV Thermal control valve YY 3 Energize increase volume ratio TE Temperature element YY 4 Energize decrease volume ratio TI Temperature indicator YY 5 Solenoid valve TS Temperature switch YY 9 Dual port liquid injection solenoid TSH Temperature switch high alarm P I diagram liquid injection Figure 17 P I diagram liquid injection 43 SAB 283 355 A Frame OHU 604...

Страница 44: ... valve pressure transducer Open 123 Stop valve after oil filter Open 124 Regulating valve oil flow Open partly adjusted according to manual 125 Service valve pressure transducer Open 126 Cold start valve Open 127 Compressor protection valve Closed Controlled by pilot valve 128 Pilot valve for position 127 Closed Fixed set point 200 Stop valves oil return Open 209 Oil sample valve Closed Table 15 V...

Страница 45: ...ompressor uses mating asymmetrical profile helical rotors to provide a continuous flow of refrigerant vapour and it is designed for both high pressure and low pressure applications The compressor incorporates the following features High capacity roller bearings to carry radial loads at both the inlet and outlet ends of the compressor Heavy duty four point contact ball SG_B models or angular contac...

Страница 46: ...lubrication system The lubrication system on a screw compressor unit performs the following functions Provides lubrication to bearings and seal Provides a cushion between the rotors to minimise noise and vibrations Helps keep the compressor cool and prevents overheating Provides an oil supply to hydraulically actuate the slide valve and slide stop Provides oil pressure to the balance pistons to in...

Страница 47: ...nd the main oil injection port If this differential pressure is less than 2 5 bar 35 psi the demand pump will turn on and continue to run until obtaining a 3 bar 45 psi differential pressure Note For alarm descriptions and shutdown or cut out parameters refer to the separate control system manual Compressor oil separation system The compressor is an oil flooded screw compressor Most of the oil dis...

Страница 48: ...EVRB is to return the separated oil in the fine separator to the compressor Oil and gas from the fine separator flow into the oil return valve at position 1 through the filter position 2 and through the nozzles position 7 and 8 and back to the compressor through the outlet position 5 see Figure 21 The gas and oil flow through the nozzles position 7 and 8 is adapted to the spring force of position ...

Страница 49: ...tional view of valve structure Note The sectional view shows the valve structure Some of the internal oil channels are not visible Cold start system The unit is equipped with a special cold start discharge valve This valve ensures a rapid development of oil pressure at initial start up in order to lubricate the compressor without requiring an oil pump even in cold ambient temperatures with all pre...

Страница 50: ...n 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 Booster applications For booster applications the valve is equipped with a light spring which produces 0 5 bar 7 psi oil pressure above suction pressure before it fully powers open An oil pump is required to ensure compres...

Страница 51: ...ose It is separated by a fixed bulkhead into two sections The movable slide valve MSV section is to the left of the bulkhead and the movable slide stop MSS to the right Both sections are considered double acting hydraulic cylinders as oil pressure moves the pistons in either direction Both sections are controlled by double acting four way solenoid valves which are actuated when a signal from the a...

Страница 52: ...ads when the MSV solenoid valve YY1 is energised and oil flows from the oil manifold through the valve ports P and A to the cylinder port SC1 and enters the unloading side of the cylinder Simultaneously gas on the loading side of the cylinder is vented through the port SC2 and the valve BP to the compressor suction side Note To control the rate of loading and unloading change cycle time proportion...

Страница 53: ... ports B and T to the compressor suction side 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 the valves SC1 or SC2 Figure 24 Volumizer volume ration control CAUTION Never open valve BP and valve SC2 at the same time during compressor operation Volumizer volume ratio VI c...

Страница 54: ...t High pressure liquid refrigerant is then supplied to the temperature control valve TCV See General P I diagram Liquid injection adjustment For discharge temperature set point and PID regulator parameters refer to the operating manual for the control system The discharge temperature set point is set to the required oil temperature see Compressor oil cooling systems Suction check valve by pass The...

Страница 55: ...ump should run for long periods of time when the compressor is stopped This is important to prevent oil being pumped up the suction line Balance piston pressure regulator All SGC compressors SAB 193 233 283 and 355 have a balance piston on the male rotor inlet end Oil is fed to the balance piston to counteract a portion of the force of gas pressure For the SAB 193 233 and 283 the balance piston oi...

Страница 56: ... on the operating condition Solenoid valve Energizing or opening the solenoid valve pressurises the balance piston with full oil pressure from the oil manifold by passing the pressure regulating valve De energising or closing the solenoid valve pressurises the balance piston with oil pressure regulated by the pressure regulating valve Signals from the control panel operate the solenoid valve For a...

Страница 57: ...he heating element must not be switched on if the oil level in the reservoir is below minimum in the 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 service valve and before opening into the oil reservoir for inspection ATEX On ATEX executions the heating element s are ATEX approv...

Страница 58: ...on valve Some units usually if they have variable speed control VSD are equipped with a motorised valve that controls the amount of oil being led to the rotors This control uses the rotational speed to set the appropriate opening degree of the valve and thereby regulate the amount of oil for the rotor injection so that it follows the rpm of the compressor The motorised valve replaces the functiona...

Страница 59: ...perature is controlled by the liquid injection thermal expansion valve you will not be able to adjust for the correct oil flow by using the discharge temperature Before the initial start up of the compressor close the hand expansion valve completely Open the valve back up and count the turns that it takes to fully open the valve After the initial start up close the valve halfway If it took 10 turn...

Страница 60: ...r work you must close the necessary valves To reduce the risk of bearing damage it is recommended to rotate to a new position the motor and compressor on a monthly basis If the screw compressor unit is exposed to vibrations during a long shutdown period the interval should be changed to weekly Avoid high vibration levels 1 Complete the procedures in Brief stop 2 Disconnect the oil heater 3 Close t...

Страница 61: ...ents in Table 19 as these will maintain slow regulation and eliminate the risk of liquid slugging Off condition operation The heat pump and chiller may accidentally enter operation outside the design conditions due to rapid changes on the secondary side This increases the risk of the UniSAB going into limitation mode or even shutting down by reducing the capacity In such a case the hot and cold se...

Страница 62: ...Be aware that all cooling towers and evaporative condensers experience a constant loss of water due to evaporation To keep the concentration of impurities low a bleed system must be installed Note To obtain the correct mixture it is recommended to premix secondary refrigerants glycol or brine and to check it subsequently R717 detector Installation of R717 detectors in the room and in the secondary...

Страница 63: ...e separate safety pressure cut out High discharge line loss Check the valves and check valve Malfunctioning of condenser Check the condenser the liquid drain from the condenser the refrigerant charge too much the water and air inlet temperature too high and the water and air flow too low Discharge pressure excessively high Air or non condensable gasses in the system Purge the air from the condense...

Страница 64: ... line Oil temperature too high and high discharge temperature Compressor protection valve is open or leaking Check the discharge pressure safety cut out settings Check the pilot and main protection valve Excessive liquid in suction line or liquid slugging Check the evaporator and economiser optional and the expansion valve function Decrease the rate of the evaporator temperature pull down Discharg...

Страница 65: ...epair valve Suction check valve bypass open too far Close valve Coalescers loose or not seated properly Correct or replace On economised unit economiser check valve not working Repair or replace Rapid loss with no oil level in the coalescer section sight glass Leakage exceeds normal allowable rate of 7 drops per minute Replace seal Compressor block Table 23 Compressor block Symptom Probable cause ...

Страница 66: ...valve position 124 may be open too much Throttle the valve Oil pressure rapidly drops off when compressor starts Results in compressor differential alarm Main oil injection throttling valve open too wide or oil pressure regulating valve improperly adjusted Re adjust both valves Oil pressure fluctuates Liquid injection overfeeding or refrigerant flood back from system Make necessary adjustments or ...

Страница 67: ...ce consists of the following 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 Monitoring of operation Check that all operating values are within the permissible ranges Compare them with previous values to detect trends Check the oil level in the oil ...

Страница 68: ...ure d Booster 20 000 h High stage air conditioning 10 000 h One stage 30 000 h e Not for flange motors f Vibration measurement must be carried out continuously to obtain optimum preventive control on bearings If not continuously controlled then every 6 months more frequently if levels increase Alternatively major overhaul after maximum 30000 h g Verify tightness of bolts on suction and discharge f...

Страница 69: ... example error reports In addition to the items listed in the start up log you must enter all other activities of service maintenance or repair work into your logbook as required by EN 378 and national laws Checklist Along with this Operating manual we have provided a Checklist as shown in Figure 27 which serves as a help to the service engineer and must be filled in during commissioning and start...

Страница 70: ...Figure 27 Checklist SAB 283 355 A Frame OHU 6042 and OHU 7650 including ATEX Screw Compressor Unit 70 ...

Страница 71: ...an oil analysis shows that a change is required We advise you to let Johnson Controls Denmark s service organisation change the oil as it is recommended to replace all filters in the unit at the same time Table 27 Oil charging Total Volume Amount of oil per 10 mm Oil separator Sight glass level Volume litres Volume gallon Volume litres Volume gallon Upper 667 176 15 4 Middle 588 155 16 4 OHU 6042 ...

Страница 72: ...will now charge to the unit 5 When the necessary amount of oil has charged to the unit stop the pump and close the service valve position 106 6 Open the ball valve position 9 carefully to equalise the pressure You can now dismantle the hoses 7 Loosen the non return valve carefully to equalise the remaining pressure Remember to mount the cap nut on the charge valve and to seal the oil barrel if the...

Страница 73: ...jury or death consider gloves and eye protection About this task Sample hot active fluid while the equipment is operating Sample after 30 minutes of compressor operation 1 CAUTION Do not unthread the valve from the filter housing or uncontrolled release of oil will result Unthread the oil sampling valve cap and the locknut see Figure 30 73 SAB 283 355 A Frame OHU 6042 and OHU 7650 including ATEX S...

Страница 74: ...and the locknut Note The locknut prevents the accidental release of oil 5 Record all the necessary sample data and identification on the forms and labels and then promptly send to the lab for results When sampling oil from high pressure applications the oil might foam a lot If this occurs collect the oil in an oil jug and wait for the oil to degas before you transfer it to an oil sample bottle Fig...

Страница 75: ... lubricate the bearings correctly and use the appropriate type of grease Refer to the motor manual and the motor name plate Replacing the motor bearings Contact Johnson Controls Denmark s service organisation 75 SAB 283 355 A Frame OHU 6042 and OHU 7650 including ATEX Screw Compressor Unit ...

Страница 76: ... the dismantling process as pipes and the like contain oil residue and refrigerant which may be toxic and or flammable 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 category of iron and metal scrap must be brought to an approved scrap dealer who complies with t...

Страница 77: ...nit 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 declaration of conformity is required all relevant individual declarations will be contained in a ...

Страница 78: ... Johnson Controls All rights reserved Subject to change without notice Johnson Controls Denmark ApS SABROE Factory Christian X s Vej 201 8270 Højbjerg Denmark Phone 45 87 36 70 00 www sabroe com ...

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