Johnson Controls SABROE SAB 120 S User manual

SAB 120-151 A-frame (including ATEX)
Screw compressor units
Operating manual
en

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Manual for SAB 120-151 A-frame screw compressors
Unit no.
Compressor 120 151
Compressor type S M L E
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 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 ______ kw Size IEC ______ Number of poles: 2xxxx 4
Anti-condensation heater
Drive type Fixed speed Variable speed (VSD)
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 to operating manual............................................... 7
1.1 Compressor name, SABROE/Frick.......................................... 8
1.2 Amendments to the manual.................................................... 8
1.3 Safety precaution definitions used in this manual ............... 10
1.4 Requirements for competent persons .................................. 10
2. Areas of application ...................................................................... 11
2.1 Application of the screw compressor .................................... 11
2.2 Application of combustion engines ....................................... 11
3. Compressor unit identification................................................... 12
3.1 Identification of Johnson Controls Denmark
equipment.............................................................................. 12
3.2 Unit/pipe system name plate ................................................ 13
3.3 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 measurement and noise data .................................... 25
4.8.1 Noise data....................................................................... 25
4.8.2 Noise data for SAB 120-151........................................... 25
5. Installation ..................................................................................... 26
6. Operating instructions ................................................................. 27
6.1 Description of unit ................................................................. 27
6.2 Principle P&I diagram ............................................................ 29
6.3 P&I diagrams - liquid injection, single and dual port............ 31
6.4 Valve positions during operation .......................................... 32
6.5 Description of main components and systems..................... 34

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6.6 Compressor ........................................................................... 34
6.7 Compressor lubrication system ............................................ 35
6.8 No pump oil system ............................................................... 35
6.9 Demand pump oil system...................................................... 35
6.10 Cold-start system.................................................................. 36
6.11 Compressor oil separation system ....................................... 36
6.12 Automatic oil return valve..................................................... 38
6.13 Compressor hydraulic system .............................................. 39
6.14 Capacity control..................................................................... 39
6.15 Volumizer II Vi control........................................................... 40
6.16 Compressor oil cooling system ............................................. 41
6.17 Single-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 operation ......................................................... 53
8.4 Oil ........................................................................................... 55
8.5 Oil charge............................................................................... 55
8.6 Charging compressor with lubricating oil ............................. 56
8.7 Motor...................................................................................... 57
9. Final disposal ................................................................................. 58
9.1 Safety precautions ................................................................ 58
9.2 Waste disposal....................................................................... 58
10. Compliance ..................................................................................... 59
10.1 Declaration of conformity...................................................... 59
Index................................................................................................ 60

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Introduction to operating manual
1. Introduction to operating manual
The SABROE®screw compressor and the unit can 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.
This manual describes:
• dangers resulting from failure to comply with safety precautions when operating the
equipment and performing maintenance tasks
• how to start, operate and stop the equipment safely
• how to act when problems occur during operation
• scheduled maintenance tasks for the equipment and when/how to carry them out safely
• components with ATEX-related specifications.
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 within the warranty period must be performed by competent person-
nel only. If not, the warranty no longer applies.
This manual does not describe:
• Control systems. A specific operating manual is delivered with the compressor.
• Safety when handling refrigerants and oils.
• Installation.
• Service and repair including spare part lists.
For further information, see www.sabroe.com.
This manual covers the following types of units:
• SAB 120 S
• SAB 120 M
• SAB 120 L
• SAB 120 E
• SAB 151 S
• SAB 151 M
• SAB 151 L
• SAB 151 E
American standards are used in all P&I diagrams in this manual.

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Introduction to operating manual
1.1 Compressor name, SABROE/Frick
The compressor in a SABROE SAB 120 and 151 screw compressor unit is manufactured by Frick.
Below is indicated which Frick compressor is part of the different SABROE units.
SABROE name
(compressor/unit)
Frick name
(compressor)
SAB 120 S XJF 120 S *
SAB 120 M XJF 120 M **
SAB 120 L XJF 120 L **
SAB 120 E XJF 120 S **
SAB 151 S XJF 151 A
SAB 151 M XJF 151 M
SAB 151 L XJF 151 L
SAB 151 E XJF 151 N
Table 1: SABROE units with Frick compressors - overview
* 1800 rpm
** 3600 rpm
1.2 Amendments to the manual
2019.08 Version 5
• Updated general 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 compressors in SABROE units.
• Updated versions of declarations of conformity: Unit and ATEX.
• Various minor corrections.
2017.12 Version 3
• Name plates with EurAsian Conformity mark (EAC) have been added.
• ‘Requirements for competent persons’ section has been added.
• Noise data: Add 2dBA to the values for 60 Hz compressors (used to be 3).
• ‘F-gas regulation’ section has been updated.
• Updated versions of declarations of conformity: Unit and ATEX.
• And more.
This manual is produced by:

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Introduction to operating manual
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 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 translated into another lan-
guage, the English version will prevail.

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Introduction to operating manual
1.3 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.
1.4 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 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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Areas of application
2. Areas of application
2.1 Application of the screw compressor
To prevent unintentional application of the compressor, which could injure personnel or damage
equipment, the following must be observed:
• The compressor must only be used as a refrigeration compressor and within the operating
limits specified in the manuals or in a written agreement with Johnson Controls Denmark.
• The compressor must only be used with the refrigerant(s) and number of revolutions per
minute, as shown on the compressor name plate. Other refrigerants must only be used in
accordance with Johnson Controls Denmark's instructions. All other types of gas must on-
ly be used with a written permission from Johnson Controls Denmark.
• Johnson Controls Denmark further accept no liability of any kind for damage to compres-
sor unit and plant parts caused by torsional oscillation, or the like, which is attributable 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. 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 plant of air and moisture
• to put the refrigeration plant under air pressure in view of a pressure testing
• as an air compressor.
2.2 Application of combustion engines
According to EN 378/ISO 5149, no other machinery should be installed in a refrigeration machine
room. Some refrigerant types may, to a certain extent, be absorbed by the fuel in a combustion
engine, and when the contaminated fuel reaches the fuel pumps, the refrigerant will “flash out”
(separate) and react on the increased temperature and pressure by creating acids, which will de-
stroy the pumps. However, check with the local authorities as exemptions to this rule may be
granted.
Warning!
Johnson Controls Denmark is not liable for injuries to personnel or damage to equipment resulting
from using the equipment for other purposes than the ones stated above.

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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.

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Compressor unit identification
3.2 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. 1: 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. 2: 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. 3: Name plate for unit with EurAsian Conformity
mark (EAC)

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Compressor unit identification
The unit name plate is positioned on the frame and contains this information:
Refrigeration unit No. Identification no. (serial no.)
Year Year of manufacturing.
Type Manufacturer's type designation.
Scope
For EC PED/EAC approval: ‘Unit & Piping’ means that the CE/EAC
mark applies to the complete unit including the piping system.
’Piping’ means that the CE/EAC mark applies 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 3rd party/notified
body.
Refrigerant - Fluid Refrigerant of the unit.
Refrigerant designation according to ISO 817.
Refrigerant - Group For EC PED approval:
Fluid group 1 or 2 according to the PED directive.
Supply voltage - Control Supply voltage and frequency of the control system.
Refrigerant charge
Weight of the refrigerant charge on the unit.
This is only stated if the unit includes an evaporator and/or a
condenser.
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/piping system has been designed for in terms of
pressure strength design.
The maximum practical operation pressure is lower than the maxi-
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 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 PED approval only.
The four digits make up the registration no. of the notified body/
3rd party in charge.
Ex If the unit is designed in accordance with the EC ATEX directive,
there is an Ex mark on the name plate.
EAC
The EurAsian Conformity mark (EAC) indicates that the unit is in
compliance with all relevant technical regulations of the Eurasian
Customs Union.
Note: Main supply voltage can be found on the motor and/or electrical panel name plate.

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Compressor unit identification
3.3 Compressor name plate
Fig. 4: Compressor name plate Fig. 5: Refrigerant plates
Note: The compressor is fitted with a name plate, Fig. 4, and one of the two refrigerant name
plates shown in Fig. 5.
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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Compressor unit identification
3.4 Compressor name plate - ATEX
Fig. 6: 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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Compressor unit identification
3.5 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
3.6 Geometrical swept volume
Compr.
model
Rotor
dia.
mm
Rotor
L/D
Max.
Speed
rpm
Geometrical
swept volume
drive shaft end
Ft3/Rev. M3/Rev.
CFM
3550 rpm
M3/H
2950 rpm
XJF 120 M 120 1.4 5,772 0.05065 0.001433 180 254
XJF 120 L 120 1.4 4,661 0.06272 0.001775 223 314
XJF 120 S 120 1.4 3,600 0.08234 0.002330 292 412
XJF 151 A 151 1.6 6,297 0.09623 0.002723 342 482
XJF 151 M 151 1.6 5,332 0.11366 0.003217 403 569
XJF 151 L 151 1.6 4,306 0.14075 0.003983 500 705
XJF 151 N 151 1.6 3,600 0.16833 0.004764 598 843
Table 3: Geometrical swept volume

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Compressor unit identification
3.7 Vessel name plate
Fig. 7: 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. 8: 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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Safety precautions
4. Safety precautions
4.1 Signs
All signs which may be found on your equipment are shown below. The number of signs, however,
may vary from one product to another.
Risk of electric shock High voltage/
High pressure
High surface
temperature
(about 70°C)
The compressor 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 re-
frigerant R290
Internal protection Pacemaker users keep out
Compressor blocks and units are usu-
ally delivered without refrigerant 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 devices
such as watches and mobile phones.
Assembly or maintenance of the rotor
must not be carried out by people with
pacemakers or any other implanted
medical electronic device.
The VSD contains capacitors capable
of storing electrical energy, meaning
that there is a risk of electric shock
within 15 minutes after the drive has
been turned off.
P åfyldtbesky ttelses gas
C ha rgedwithinertga s
E nthältS chutzga s
C ha rgédugazprotecteur
C ontienegas protector
N
2
0, 5 b ar
7. 3 PSI
1534 -169

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Safety precautions
General
Use these precautions as a supplement to the safety precautions and warnings included in:
• All other manuals pertaining to the compressor/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/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, understand and fully comply with all
warnings and instruction plates mounted on the machine.
• Observe the safety warnings on the compressor/unit.
• Use ear protection when operating the unit.
• Use safety equipment. Wear appropriate gloves as well as eye and face protection when
working with parts containing refrigerant and/or lubricating oil.
Note: These instructions only provide general information. 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 function of the ventilation system and refrigerant de-
tectors used in the area where the compressor unit is located (machine room).
Rotating parts
Warning!
Safety guards, shields, barriers, covers and protective devices must not be removed while the
compressor/unit is operating.
Vibration and noise
During operation, pay attention to the compressor unit process. Excessive vibration, unusual
sounds, etc. may indicate problems requiring your immediate attention.
Pressure
Danger!
A compressor unit comprises a pressurised system. Never loosen threaded joints while the sys-
tem is under pressure, and never open pressurised system parts.
Note: Whenever a by-pass valve/safety valve has been activated, we recommend recalibrating
it. This must be carried out by competent personnel only. See also EN 378 and existing national
legislation.