Johnson Controls SAB 355 Installation and operation manual

SAB 355 (including ATEX)
Screw compressor unit
Engineering manual
en

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Manual for SAB 355 screw compressors
Unit no.
Compressor 355 355B
Compressor type SL E X
Oil separator type OHU 7650/6050 OHU 6042/5030
Refrigerant R717 HFC/HCFC ____ Other: _________
Oil type Oil type: __________________ . Evap. temp. _______ . Cond. temp. _______
Control UniSAB III None Other
Oil filter Single Dual
Oil cooling Refrigerant-cooled oil cooler Water-cooled oil cooler
Liquid injection in compressor Single port Dual port
Discharge port Standard AC (Low Viport)
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 ________ kw Size IEC _________
Anti-condensation heater
Drive type Fixed speed Variable speed (VSD)
Coalescer filter pcs.
UniSAB setting values Separator velocity ref. _____ Separator velocity ref. CR _____

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Safety valve:
Data for calculation of
downstream line 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 to customer connection
(based on design pressure) [bar] _____________
Safety valve type:
Back-pressure dependent
Back-pressure independent

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Contents
1. Introduction ................................................................................... 11
1.1 Purpose .................................................................................. 11
1.2 Main users.............................................................................. 11
1.3 Compressor name, Sabroe/Frick.......................................... 11
1.4 Amendments to the manual.................................................. 12
1.5 Manufacturer's information .................................................. 12
1.6 Safety precaution definitions used in this manual ............... 13
1.7 Requirements for competent persons .................................. 13
2. Signs and warnings....................................................................... 14
2.1 Main users.............................................................................. 14
2.2 Identification of Johnson Controls Denmark
equipment.............................................................................. 15
2.3 Compressor name plate ........................................................ 16
2.4 Compressor name plate - ATEX ............................................ 17
2.5 Labelling of explosion-proof equipment ............................... 18
2.6 Vessel name plate.................................................................. 19
2.7 Unit/pipe system name plate ................................................ 20
2.8 Signs ..................................................................................... 22
3. Safety precautions ........................................................................ 23
3.1 Areas of application ............................................................... 23
3.1.1 Application of the screw compressor ............................. 23
3.1.2 Application of combustion engines ................................ 23
3.2 Safety precautions ................................................................ 24
3.2.1 General precautions ....................................................... 24
3.2.2 Work area safety ............................................................ 24
3.2.3 During operation ............................................................ 24
3.2.4 Safety during maintenance and service ........................ 25
3.2.5 Electrical installations .................................................... 26
3.2.6 Power supply .................................................................. 26
3.2.7 Lubricating oils ............................................................... 27
3.2.8 Refrigerants.................................................................... 27
3.2.9 Purging a refrigeration plant .......................................... 27
3.2.10 F-gas regulation (fluorinated greenhouse
gases) ............................................................................. 27
3.2.11 First aid for accidents with ammonia ............................. 30
3.2.12 First aid for accidents with HFC/HCFC ........................... 31
3.2.13 Protecting the operator as well as the
environment ................................................................... 32

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4. Technical description ................................................................... 35
4.1 Description of the compressor .............................................. 35
4.1.1 Marine application .......................................................... 37
4.1.2 Description of main components and systems.............. 38
4.1.3 Control system ............................................................... 38
4.1.4 Compressor .................................................................... 39
4.1.5 Variable speed drive (VSD) ............................................ 41
4.1.6 Suction filter with built-in non-return valve .................. 42
4.1.7 Compressor lubrication system ..................................... 42
4.1.8 No pump oil system........................................................ 43
4.1.9 Demand pump oil system .............................................. 43
4.1.10 Flow security................................................................... 43
4.1.11 Compressor oil separation system ................................ 43
4.1.12 Automatic oil return valve.............................................. 47
4.1.13 External oil filter ............................................................. 48
4.1.14 Unit with double oil filter ................................................ 48
4.1.15 Compressor hydraulic system ....................................... 49
4.1.16 Compressor oil cooling systems .................................... 50
4.1.17 Suction check valve by-pass.......................................... 52
4.1.18 Requirements for ambient temperatures and
humidity.......................................................................... 54
4.1.19 Balance piston pressure regulator................................. 55
4.1.20 Oil carry-over to plant .................................................... 56
4.1.21 Selecting lubricating oil for Sabroe screw
compressors ................................................................... 57
4.1.22 Oil charge........................................................................ 57
4.1.23 Heating rod element for oil heating, pos. 30 ................. 57
4.1.24 Oil level switch................................................................ 58
4.1.25 Cold-start system........................................................... 58
4.1.26 Compressor protecting system, pos. 220 and
221.................................................................................. 59
4.1.27 Oil cooling system and general piping layout................ 60
4.1.28 Liquid injection oil cooling .............................................. 61
4.1.29 Thermosyphon oil cooling .............................................. 62
4.1.30 Water-cooled oil cooling................................................. 64
4.1.31 KRACHT oil pump............................................................ 64
4.1.32 Economiser, high-stage (optional) ................................ 66
4.1.33 General key to piping diagram....................................... 69
4.1.34 General piping diagram.................................................. 71
4.1.35 General key to piping diagram - continued ................... 72
4.1.36 Instrumentation ............................................................. 73

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5. Physical and connection data ..................................................... 75
5.1 Physical data.......................................................................... 75
5.2 Connection data .................................................................... 76
5.2.1 Connections to the compressor unit .............................. 76
5.2.2 Electrical connections..................................................... 80
5.2.3 List of components ......................................................... 81
6. Technical data ................................................................................ 83
6.1 Data for SAB 355 ................................................................... 83
6.2 Other data.............................................................................. 84
6.3 Selection of vibration dampers ............................................. 84
6.4 Planning the machine room .................................................. 85
6.5 Minimum compressor flow at 3550 rpm ............................... 85
6.6 Operating limits ..................................................................... 85
6.7 Motor selection and starting torque...................................... 86
6.8 Motor/compressor torque ..................................................... 88
6.9 Direction of rotation .............................................................. 89
6.10 Emergency stop..................................................................... 89
6.11 Other emergency stop requirements ................................... 89
6.12 Series 52 coupling ................................................................. 90
6.13 Noise data .............................................................................. 90
6.15 Vibrations and test pressure levels....................................... 91
6.15.1 Vibration data for compressors (all compressor
types).............................................................................. 91
6.15.2 Test pressure levels for standard compressors and
components.................................................................... 93
7. Installation instructions.............................................................. 94
7.1 Installation............................................................................. 94
7.2 Safety precautions ................................................................ 94
7.3 Installation data .................................................................... 94
7.4 Installation and first start-up procedure .............................. 94
7.5 Installation drawings............................................................. 94
7.6 Personnel requirements ........................................................ 95
7.7 Preparing the installation ...................................................... 95
7.8 Tools and accessories ............................................................ 95
7.9 Safety equipment .................................................................. 95
7.10 Local regulations ................................................................... 95
7.11 Preparing the mounting site.................................................. 96
7.12 Space requirements .............................................................. 96

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7.13 Lifting accessories and equipment ....................................... 96
7.14 Preparing lifts ........................................................................ 96
7.15 Lifting and loading instructions............................................. 96
7.16 Unpacking and inspection ..................................................... 96
7.17 Disposal of non-reusable materials ...................................... 96
7.18 Moving the equipment to the mounting site......................... 96
7.19 Alignment of compressor and unit ........................................ 97
7.20 Alignment of unit against foundation ................................... 97
7.21 Laying the unit foundation .................................................... 98
7.22 Mounting directly on the foundation..................................... 98
7.23 Mass damping between unit and building ............................ 99
7.24 Damping using vibration dampers........................................ 99
7.25 VSD equipment.................................................................... 102
7.26 Calculation of centre of gravity, support reactions and
tipping angle ........................................................................ 104
7.27 Auxiliary tools for coupling alignment ................................ 107
7.28 Mounting of series 52 coupling ........................................... 108
7.29 Alignment procedure for coupling ...................................... 110
7.30 Piping connections............................................................... 112
7.31 Connecting electricity supply .............................................. 114
7.32 Pressure testing................................................................... 115
7.33 Evacuation of the refrigeration plant .................................. 116
7.34 Oil charging.......................................................................... 116
7.35 Final installation check ........................................................ 117
8. Components ................................................................................. 118
8.1 UniSAB III ............................................................................ 119
9. Settings ......................................................................................... 120
9.1 Control system .................................................................... 120
10. Operating instructions ............................................................... 121
11. Maintenance instructions.......................................................... 122
11.1 Safety precautions .............................................................. 122
11.2 Maintenance of compressor unit......................................... 122
11.3 Stopping routine.................................................................. 123
11.4 Long-term storage .............................................................. 123
11.5 Maintenance intervals ......................................................... 124
11.6 Visual inspection.................................................................. 125

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11.7 Measures to be taken .......................................................... 125
11.8 General rules for use of lubricating oil in refrigeration
compressors ........................................................................ 127
11.9 Assessing the oil .................................................................. 127
11.10 Visual assessment ............................................................... 128
11.11 Analytical evaluation ........................................................... 128
11.12 Analysing the oil .................................................................. 128
11.13 Oil change ............................................................................ 129
11.14 Charging compressor with lubricating oil ........................... 130
11.15 Oil charge............................................................................. 132
11.16 Motor.................................................................................... 132
12. Fault-finding instructions ......................................................... 133
12.1 How to carry out faultfinding............................................... 133
12.2 Troubleshooting................................................................... 134
13. Service instructions.................................................................... 139
14. Transport instructions ............................................................... 140
14.1 Safety precautions .............................................................. 140
14.2 Transport data ..................................................................... 141
14.3 Personnel requirements ...................................................... 141
14.4 Handling of compressor and unit ........................................ 141
14.5 Loading instructions ............................................................ 143
14.6 Preparations before lifting................................................... 143
14.7 Loading ................................................................................ 143
14.8 Transport instructions ......................................................... 143
14.9 Transport regulations .......................................................... 144
14.10 Unpacking and inspecting the unit...................................... 144
14.11 Moving the equipment to the mounting site....................... 144
14.12 Storage ................................................................................ 144
15. Commissioning instructions ..................................................... 145
15.1 Safety precautions .............................................................. 145
15.2 Preparations for commissioning ......................................... 145
15.3 Preparations on the mounting site...................................... 146
15.4 Evacuation and charging of refrigerant .............................. 146
15.5 Start-up ............................................................................... 147
15.6 Commissioning set .............................................................. 147
15.7 Commissioning checklist..................................................... 148

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16. Spare parts list............................................................................. 149
17. Spare parts drawings ................................................................. 150
18. Final disposal ............................................................................... 151
18.1 Safety precautions .............................................................. 151
18.2 Waste disposal..................................................................... 151
19. Torque............................................................................................ 152
Index.............................................................................................. 153

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Introduction
1. Introduction
The Sabroe screw compressor unit may be configured with various types of equipment depending
on its function and requirements. Some of the equipment may be described in this manual even
though it is not featured on your particular unit.
1.1 Purpose
This manual provides all the data usually needed in the sales and planning phases.
• Description of all component parts
• Description of all important technical functions to increase understanding of the product
functionality
• Refrigerant safety
• Connecting data
• Installation instructions
1.2 Main users
This manual is primarily intended for sales, service and contracting purposes.
All compressor intervention within the warranty period must be performed by competent person-
nel only. If not, the warranty no longer applies.
1.3 Compressor name, Sabroe/Frick
The compressor in a Sabroe SAB 355 screw compressor unit is manufactured by Frick. Below is in-
dicated how the Sabroe and Frick compressor names are made up and how they correspond to
each other.
Sabroe name Frick name
SAB 355 S SGC 3511
SAB 355 L SGC 3515
SAB 355 E SGC/SGX 3519
SAB 355 X SGC/SGX 3524
Table 1: Compressor overview
R o t o r d i am e t e r
(first two digits)
Com p r e s s o r
SGC/SGX 3 5 1 9
R o t o r L/D
E
R o t o r d i am e t e r
Com p r e s s o r
SAB 3 5 5
R o t o r ength
S h o r t - S
Long - L
Extended - E
Extreme - X
Frick name
SABROE name
H/B
High-pressure/Booster

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Introduction
1.4 Amendments to the manual
2020.10 Version 3
• Subsection 4.1.31 KRACHT oil pump has been revised.
• Subsection 4.1.32 Economiser, high-stage (optional) has been revised.
• Subsection 7.25 VSD equipment has been revised.
• Subsection 7.29 Alignment procedure for coupling has been revised.
• Various minor corrections.
2019.11 Version 2
• Description of new KRACHT oil pump, see subsection 4.1.31.
• Updated general piping diagram, subsection 4.1.34.
• New compressor name plates, subsections 2.3 and 2.4.
• Minor corrections.
2018.08 Version 1
• This version replaces revision 2011.08.
• Many sections of the manual have been changed, for example:
• Name plates with EurAsian Conformity mark (EAC) have been added.
• ‘Requirements for competent persons’ section has been added.
• ‘Compressor port locations’ section in chapter 6. has been updated.
• ‘F-gas regulation’ section has been updated.
• Noise data: Add 2dBA to the values for 60 Hz compressors (used to be 3).
• The ‘Storage’ section in the ‘Transport instructions’ chapter has been revised.
• ATEX instructions have been included.
• European units of measurement have been added in various tables.
• And more.
1.5 Manufacturer's information
This manual is produced by:
Johnson Controls Denmark ApS
Christian X's Vej 201
8270 Højbjerg, Denmark
Phone [phone]
CVR No 19 05 61 71
www.sabroe.com
Copyright © Johnson Controls Denmark
This manual must not be copied without the written permission of Johnson Controls Denmark,
and the contents must not be imparted to a third party nor be used for any unauthorised purpo-
ses. Contravention will be prosecuted.

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Introduction
1.6 Safety precaution definitions used in this manual
Danger!
Indicates an imminently hazardous situation which, if not avoided, will result in death or serious
injury.
Warning!
Indicates a potentially hazardous situation or practice which, if not avoided, will result in death or
serious injury.
Caution!
Indicates a potentially hazardous situation or practice which, if not avoided, will result in damage
to equipment 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 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 evi-
dence of appropriate training.
• Assign only competent personnel instructed in safety and all machine functions to operate
or service the compressor/unit according to EN 13313.
• Operators and maintenance personnel must carefully read, understand and fully comply
with all alarms and instructions.

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Signs and warnings
2. Signs and warnings
This chapter describes:
• how to identify equipment from Johnson Controls Denmark
• all warning signs used on equipment delivered by Johnson Controls Denmark
• how information important to safety of personnel and equipment is presented in instruc-
tions belonging to equipment delivered by Johnson 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 Controls
Denmark products.
Before a compressor/unit is put into operation, it must be fitted with the warning signs belonging
to the type of compressor/unit in accordance with the rules and regulations in force.

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Signs and warnings
2.2 Identification of Johnson Controls Denmark equipment
All Johnson Controls Denmark equipment can be identified by one or several name plates placed
as illustrated in the following drawing:
Fig. 1
1. Compressor name plate
2. Vessel name plate
3. Unit pipe system name plate
Components placed high above the ground, the POV relief valve system and the suction strainer
with stop valve are dismounted and blanked off for transportation purposes. Each system is
marked with a name plate identical to the unit pipe system name plate, pos. 3.
When mounting the systems, check the identity and remove the name plates from the POV relief
valve system and the suction strainer with stop valve, and discard them.
3
2
1

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Signs and warnings
2.3 Compressor name plate
Fig. 2: Compressor name plate Fig. 3: Refrigerant plates
Note: The compressor is fitted with a name plate, Fig. 2, and one of the two refrigerant name
plates shown in Fig. 3.
The rotary screw compressor serial numbers contain the following information:
Example: 10240A90000015Z.
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 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.

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Signs and warnings
2.4 Compressor name plate - ATEX
Fig. 4: Name plate for an 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.

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Signs and warnings
2.5 Labelling of explosion-proof equipment
ATEX:
The compressor area of application is indicated next to the Ex-sign on the name plate.
II 2 G T3/T4
II Material group:
II indicates that the equipment is suitable for use in industrial areas above ground.
2
Material category:
2 indicates that the equipment is suitable for use in areas with possible occurrence of ex-
plosive gasses.
G
Hazardous environment:
G indicates that the 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 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

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Signs and warnings
2.6 Vessel name plate
Fig. 5: Name plate for vessel
Пpoeкт пo cтaндapтy
Design code
Утвepждeн пoд N °
Approval No
Oбъeм /Volume
Cpeдa /Fluid
Тип /Type
PS
TS
V
M асса пустого cocy д a
Empty weight
/ Кат .
/Cat.
Nº cocy д a
Vessel No
год
2516-331
кг
Cтopoнa oбeчaйки
Shell side Tube side
Cтopoнa тpyбок
п
l
MПа
MPa
°C
P a б o ч ee двп e ни e Макс ./ Мин .
Allowable pressure Max./Min.
P aбoчaя тeмпepaтypa Макс ./ Мин .
Allowable temperature Max./Min.
Kg
Year
Johnson Controls Denmark ApS
Christian X's Vej 201
8270 Højbjerg, Denmark
www.sabroe.com
Fig. 6: Name plate for vessel with EurAsian Conformity
mark (EAC)
The pressure vessel name plate is positioned on the shell of the vessel and contains this
information:
Vessel no. Identification no. (serial no.)
Empty weight The empty weight of the vessel in kg.
Year Year of manufacturing.
Type Manufacturer's type designation.
Design code Design code used for the pressure vessel.
Approval no./CAT
The approval 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 ‘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.
Allowable pressure, PS The min. and max. pressures (pressure relative to atmospheric
pressure) that the vessel or vessel part has been designed for.
Allowable temperature,
TS
The min. and max. temperatures that the vessel or vessel part has
been designed for.
Volume The volume of the vessel or vessel part.
CE xxxx
The CE mark appears on the name plate for EC PED approval.
The four digits make up the registration no. of the notified body/
3rd party in charge.
EAC
The EurAsian Conformity mark (EAC) indicates that the vessel is
in compliance with all relevant technical regulations of the Eura-
sian Customs Union.
Note: Depending on the supplier of the pressure vessel/heat exchanger, the layout and content
of the vessel name plate may differ from the Sabroe name plate above.
Johnson Controls D e n m ar k ApS
Christian X 's V e j 201
8 270 Højbj e rg, D e n m ark
www.sabro e .com

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Signs and warnings
2.7 Unit/pipe system name plate
Scope
Design code
Approval No
Refrigerant
Supply 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
2516-342 Johnson Controls Denmark ApS
Christian X's Vej 201
8270 Højbjerg, Denmark
www.sabroe.com
Fig. 7: Name plate for standard unit
Scope
Design code
Approval No
Refrigerant
Supply 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. 8: Name plate for ATEX unit
Установка холодильная
№
Назначение
Код стандарта
№ сертификата
Хладагент
Жидкость
Группа
Напряжение питания Сеть
Управ
ление В/Гц
Заправка хладагентом
Кг
Давление
бар
бар
Допустимое давление
Давление ислытания
Сторона НД
макс
Сторона ВД
Категория
° С
Допустимая темп
мин/макс
Год
Тип
2516-344
Johnson Controls Denmark ApS
Christian X's Vej 201
8270 Højbjerg, Denmark
www.sabroe.com
Fig. 9: Name plate for unit with EurAsian Conformity
mark (EAC)