Johnson Controls SABROE SVER User manual

SVER-type economiser
Installation, operation and maintenance manual
en

Installation, operation and maintenance manual - SVER-type economiser
0005708 en 2017.01 3/7
Design
Design
SVER is a closed flash economiser. In principle, the economiser consists of a shell with domed
ends. Nozzles are welded in the shell and end.
On delivery, the nozzles are blanked off with seal caps protecting against moisture and dirt during
transport and storage.
Option Float valve Level switch
1) Danfoss HFI080 Endress + Hauser FTL51
2) Danfoss SV4 Danfoss AKS 38
N1 To economiser connection
N2 Liquid to evaporator
N3 Liquid from condenser
N6 Safety valve
N7 2) Level connection, SV4
N9 1) Level switch, FTL51
Application
The function of the economiser is to cool the liquid refrigerant (subcooling) from the condenser
before it is led to the evaporator. The flash gas side is connected to the economiser port of the
screw compressor, where the intermediate pressure gas from SVER is added to the suction gas.
The liquid will be subcooled to improve the efficiency of the refrigeration plant.
Product Description
By connecting the economiser to the economiser port of the compressor, gas of intermediate
pressure is led to the compressor resulting in increased COP. The refrigeration capacity of the
economiser appears as subcooling of the liquid from the high-pressure side to the low-pressure
side of the refrigeration plant.
N1
N6
N7 N3
N9
N2
Name plate
Sight glass

Installation, operation and maintenance manual - SVER-type economiser
4/7 0005708 en 2017.01
Design
Option 1 Float valve Level switch
Danfoss HFI080 Endress + Hauser FTL51
Option 2 Float valve Level switch
Danfoss SV4 Danfoss AKS38
Thread nozzle, G1 ISO 228/1 I=28 mm
2321.705
Mark at top
Level switch, Liquiphant FTL51
Nozzle for level switch, ø42.2x5
Level switch, N9
Economiser
HFI080
FTL51
To evaporator
Liquid level by rimy
pipe free of insulation

Installation, operation and maintenance manual - SVER-type economiser
0005708 en 2017.01 5/7
Shipping
Connection
nominal diameter Connection
external diameter
OD
Standard
connection
thickness
DIN 2448
Connection possibilities
DN inch ANSI SCH40
x cut off
ANSI SCH80
y cut off
15 1/2 21.3 2.3 7 11
20 3/4 26.9 2.3 7 11
25 1 33.7 2.6 8 13
32 1 1/4 42.4 2.6 9 14
40 1 1/2 48.3 2.6 9 15
50 2 60.3 2.9 9 16
65 2 1/2 76.1 2.9 20 22
80 3 88.9 3.2 14 23
100 4114.3 3.6 15 25
Shipping
The economiser must be blanked off and primed on delivery. The primer is not intended for out-
door storage. If the economiser is not put into immediate service, take precautions against corro-
sion or contamination.
Only lift the economiser when it is empty, and make sure it is not subjected to strokes or bumps
during transport. When lifting the economiser before it is built into the unit, always use straps
around the shell.
The weight is stated in the technical data.
A shipping description can be made when the economiser is built together with the unit.
Installation
The site and personal protection must be in accordance with EN 378-3 or national requirements.
Check the economiser immediately upon receipt for any damage occurred during transport. If the
economiser is damaged, it must not be installed and started.
When placing the economiser, make sure there is enough space for inspection, maintenance, es-
cape and emergency.
Foundations must be sufficiently robust, as their purpose is to provide permanent support without
settling and to absorb any normal vibrations from outside causes.
The SVER-type economiser is for horizontal installation.
Temporary seal cap.
OD
Cut off = Standard marking line
X Cut off = SCH 40
Y Cut off = SCH 80
Std. thickness
DIN 2448

Installation, operation and maintenance manual - SVER-type economiser
6/7 0005708 en 2017.01
Safety equipment
Blanked off branches must be cut off at the cutting groove depending on metal thickness on ad-
joining tubes. Make sure that no dirt or other unknown elements enter the economiser during
installation.
Do not remove protective plugs and covers until immediately before installation.
The entire system must be clean before starting the operation. When fitting the tube connections,
make sure that stress in the economiser during test, operation and standstill does not exceed the
allowable values. Vibrations must be minimised, possibly by means of vibration dampers.
Apart from branch connections, welding must not be carried out on the economiser.
The economiser must be secured against exceeding the allowable pressures and temperatures.
All outer surfaces must have a corrosion-resistant surface coating to allow the economiser to be
installed in certain environments without it causing corrosion.
Safety equipment
Before the economiser is put into operation, it must be provided with safety equipment. The man-
ufacturer of the refrigeration plant is responsible for the safety equipment as it is not included in
the economiser delivery.
Bolted connections
Normal relaxing of the gasketed joints may occur in the interval between testing at the manufac-
turer’s and installation on site. Therefore, all external bolted joints may require retightening after
installation and, if necessary, after the economiser has reached operating temperature.
It is important that all bolted joints are tightened evenly and in a diametrically staggered pattern.
All bolts must be tightened to the same torque using a torque wrench.
Maintenance
The economiser should be inspected at the inspection intervals stated in the compressor specifi-
cation. Only qualified personnel must carry out inspection.
Operating experience will determine how often inspection of the economiser is needed. It de-
pends on the operating conditions. Johnson Controls Denmark recommends inspection to be car-
ried out in monthly intervals during the running-in period. After a running-in period of six months,
a maintenance plan must be made. Johnson Controls Denmark recommends inspection to be car-
ried out every third month as a minimum.
Do not disconnect or tighten connections when the equipment is under pressure.
Periodic inspection during the service life of the economiser must meet the requirements of na-
tional legislation or EN 378-2. Correspondingly, a visual inspection of connections, outer surfaces,
bases, the vibration damper and safety equipment must be carried out.

Installation, operation and maintenance manual - SVER-type economiser
0005708 en 2017.01 7/7
Gasket connections
If corrosion, erosion or other weaknesses in the economiser are found, the economiser must be
inspected by a qualified authorised third party, who will provide the necessary permission to con-
tinue using it. If repair is requested, approved personnel together with a qualified third party and
Johnson Controls Denmark will carry this out. If permission to continue using the economiser is
not granted, it must be scrapped.
Gasket connections
Gasket and gasket surface should be thoroughly cleaned and free of scratches and other defects.
The gasket should be properly positioned before attempting to retighten bolts. When an econo-
miser is dismantled for any cause, it must be reassembled with new gaskets. This will prevent fur-
ther leaks and/or damage to the gasket-seating surface of the economiser.
Spare parts and replacement parts
Spare parts and replacement parts can be ordered directly from Johnson Controls Denmark.
When ordering parts, please provide the name of the needed part as well as the economiser serial
number, type, size and other information from the name plate.
Environmentally correct removal
The economiser does not contain environmentally damaging material such as asbestos, mercury
or heavy metals.
All parts of the economiser can be re-used after being scrapped.
• Refrigerant and oil must be drained off before destruction
• All steel materials can be used again after remelting
• During the re-melting process, coating will disappear without damaging the environment
Start-up and operation
Before start-up, make sure that all connections are tight.
To avoid accidents or personal injury, the person responsible for the plant must make sure that
the operating staff is duly trained and instructed before the refrigeration plant is started. The in-
struction should be based on the unit instruction manuals and should include instructions in con-
struction, supervision, operation and maintenance of the system as well as the handling of used
refrigerant.
Evacuation and charging with refrigerant must be carried out in accordance with the description
in the unit instruction manual.
Before operation, the refrigeration plant must be leak tested and inspected by an authorised
person.
Local safety and health regulations must be observed.
The authorised person makes a certificate which must be kept by the user.

Johnson Controls Denmark ApS
Sabroe Factory
Christian X's Vej 201 ∙ 8270 Højbjerg
Denmark
Phone [phone]
Fax [phone]
www.sabroe.com