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Sabroe SMC/TSMC/HPC/HPX Mk 4 LL and Mk 5 Installation Operation and Maintenance Guide

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SMC/TSMC/HPC/HPX Mk 4 LL & Mk 5
Reciprocating compressor units
Engineering manual (including installation and service) EN
Engineering manual - SMC/TSMC/HPC 100 Mk 4 LL & Mk 5 and HPX 700 Mk 4 LL & Mk 5
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Manual for SMC/TSMC/HPC/HPX Mk 4 LL & Mk 5 compressors
Compressor
type
SMC TSMC HPC S L E
104 106 108 112 116
HPX 704 706 708 712 716
Compressor no.
Refrigerant R717 R22 R134a
R404A R507 R744 Other ________
Control UniSAB III None Other
Compressor
cooling
Thermopump
Water-cooled top and side covers
Air-cooled top and side covers
Air-cooled top covers and water-cooled side covers
Air-cooled top and side covers + oil cooling (refrigerant-cooled)
Drive type Fixed speed Variable speed (VSD)
Ex-execution
(ATEX) T3 T4 Other ________
Oil return on
parallel
systems
Oil separator Sabroe OVUR Sabroe OHUR
Intermediate
cooling system
With internal intermediate cooling system
With external intermediate cooling system
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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
Desuperheater
Subcooler
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......................................................................................... 15
1.1 Introduction to manual................................................................ 15
1.1.1 Main users .........................................................................15
1.1.2 Models covered .................................................................. 15
1.1.3 Amendments to the manual ................................................. 15
1.1.4 Manufacturer's information .................................................. 18
1.1.5 Safety precaution definitions used in this manual................... 19
1.1.6 Requirements for competent persons ................................... 19
2. Signs and warnings............................................................................. 20
2.1 Main users ................................................................................20
2.2 Identification of equipment ..........................................................20
2.3 Unit/pipe system name plate.......................................................21
2.4 Compressor name plates............................................................ 23
2.5 Labelling of explosion-proof equipment........................................25
2.6 Vessel name plate...................................................................... 26
2.7 Signs .......................................................................................27
3. Safety precautions .............................................................................. 28
3.1 Areas of application.................................................................... 28
3.2 Application of combustion engines .............................................. 29
3.3 Safety precautions .....................................................................29
3.3.1 Emergency stop.................................................................. 29
3.3.2 General precautions............................................................ 30
3.3.3 Work area safety.................................................................30
3.3.4 During operation .................................................................30
3.3.5 Transmission safety ............................................................ 31
3.3.6 Cooling water system..........................................................31
3.3.7 Safety during maintenance and service ................................ 31
3.3.8 Electrical installations..........................................................33
3.3.9 Power supply...................................................................... 33
3.3.10 Lubricating oils ................................................................... 33
3.3.11 Refrigerants ....................................................................... 34
3.3.12 Purging a refrigeration plant................................................. 34
3.3.13 F-gas regulation (fluorinated greenhouse gases)................... 34
3.3.14 First aid for accidents with ammonia..................................... 37
3.3.15 First aid for accidents with HFC/HCFC .................................38
3.3.16 First aid for accidents with carbon dioxide (CO2).................... 39
3.3.17 Protecting the operator as well as the environment ................ 40
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4. Technical description .......................................................................... 43
4.1 Description of compressor ..........................................................43
4.1.1 Compressor types............................................................... 43
4.1.2 SMC-TSMC compressors.................................................... 43
4.1.3 HPC compressors............................................................... 44
4.1.4 HPX compressors............................................................... 45
4.1.5 Compressor type and version .............................................. 45
4.1.6 Marine application............................................................... 46
4.2 Single-stage compressor............................................................ 47
4.2.1 General.............................................................................. 47
4.2.2 Cylinder liners .................................................................... 47
4.2.3 Pistons............................................................................... 48
4.2.4 Suction valve...................................................................... 49
4.2.5 Discharge valve and safety spring........................................49
4.2.6 Connecting rod ................................................................... 50
4.2.7 Suction filter and filter bag ...................................................52
4.2.8 Relief valve ........................................................................52
4.2.9 Crankshaft .........................................................................55
4.2.10 Oil pump ............................................................................55
4.2.11 Oil pressure regulating valve................................................ 56
4.2.12 Oil suction strainer (internal oil filter)..................................... 56
4.2.13 External oil filter .................................................................. 57
4.2.14 Monitoring of external oil filter .............................................. 59
4.2.15 Shaft seal........................................................................... 61
4.2.16 Heating element .................................................................61
4.2.17 Oil draining valve ................................................................ 62
4.2.18 Oil level glass .....................................................................62
4.2.19 Evacuating valve ................................................................ 62
4.2.20 Stop valves ........................................................................63
4.2.21 Cooling of compressor and oil.............................................. 63
4.3 Two-stage compressors type TSMC 100...................................... 65
4.3.1 Description of two-stage compressor....................................65
4.3.2 Compressor block TSMC 100 .............................................. 65
4.3.3 Piston pin bearing TSMC 100 .............................................. 65
4.3.4 Suction filters, TSMC 100 .................................................... 67
4.4 Conversion of TSMC from two-stage to single-stage..................... 68
4.5 Oil consumption.........................................................................68
4.5.1 CVS - Crankcase Ventilation System....................................69
4.6 Oil separator.............................................................................. 73
4.6.1 Oil separator type OHUR..................................................... 73
4.6.2 Function of the OHUR oil separator ...................................... 74
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4.7 Oil return to the compressor........................................................ 74
4.7.1 Solenoid valve controlled oil return ....................................... 74
4.7.2 Oil return in connection with parallel operation ......................75
4.8 Capacity regulation of the compressor, SMC/HPC 100..................79
4.8.1 Capacity regulation and unloading of the compressor ............ 79
4.8.2 Mechanism of capacity regulation system .............................79
4.8.3 Unloaded compressor start.................................................. 81
4.8.4 Solenoid valves for capacity regulation .................................81
4.8.5 "Standard unloading" capacity regulation.............................. 82
4.8.6 "Total unloading" capacity regulation ....................................84
4.8.7 "Extended unloading" capacity regulation .............................85
4.8.8 Variable speed drive (VSD).................................................. 88
4.9 Capacity regulation of the compressor, HPX 700 .......................... 90
4.9.1 Capacity regulation and unloading of the compressor ............ 90
4.9.2 Mechanism of capacity regulation system .............................90
4.9.3 Unloaded compressor start.................................................. 91
4.9.4 Solenoid valves for capacity regulation .................................91
4.9.5 “Standard unloading” capacity regulation .............................. 92
4.9.6 “Total unloading” capacity regulation ....................................93
4.9.7 Variable speed drive (VSD).................................................. 94
4.10 Compressor unit ........................................................................95
4.11 Instrumentation.......................................................................... 97
4.11.1 Analogue reading and safety system ....................................97
4.11.2 UniSAB III reading, safety and capacity regulating
system ............................................................................. 100
4.12 Cooling of the intermediate discharge gas on TSMC
compressors............................................................................ 101
4.12.1 Intermediate cooling system with intermediate cooler type
DVEA, R717..................................................................... 101
4.12.2 Intermediate cooling system with liquid injection into the in-
termediate discharge gas, R22 and R717 ........................... 102
4.12.3 Automatic regulation of intermediate pressure IP................. 103
4.12.4 Determining the intermediate pressure, IP .......................... 104
4.13 Cooling systems for compressors.............................................. 105
4.13.1 Air-cooled top and side covers with refrigerant-cooled oil
cooler R717 (1a)............................................................... 105
4.13.2 Water-cooled top and side covers - R717 (1b)..................... 108
4.13.3 Cooling with thermopump - R717 (1c)................................. 115
4.13.4 Air-cooled top and side covers - R22, R134a, R404A,
R507 (2a)......................................................................... 123
4.13.5 Air-cooled top covers and water-cooled side covers -
R717, R22, R134a, R404A, R507 (1d + 2b) ........................ 123
4.13.6 Air-cooled top and side covers and refrigerant-cooled oil
cooler
R22, R134a, R404A, R507 (2c).......................................... 124
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4.14 Selecting lubricating oil for Sabroe recip. compressors................ 124
4.14.1 Oil charge ........................................................................ 124
5. Physical and connection data ........................................................... 125
5.1 Safety precautions ................................................................... 125
5.2 Physical data ........................................................................... 125
5.3 Connection data ...................................................................... 125
5.4 Connections to the compressor................................................. 126
5.5 Connections on HPC-SMC-TSMC-HPX..................................... 128
5.6 Connections for HPC-SMC-TSMC-HPX .................................... 130
5.7 Electrical connections .............................................................. 132
5.8 Control of the unit..................................................................... 134
6. Technical data ................................................................................... 135
6.1 Technical data for SMC, TSMC, HPC and HPX .......................... 136
6.2 Planning the machine room ...................................................... 138
6.3 Requirements for ambient temperatures and humidity ................ 139
6.4 Operating limits........................................................................ 141
6.4.1 Operating limits diagrams .................................................. 141
6.4.2 List of operating limits diagrams ......................................... 145
6.4.3 R717 Single-stage compressor CMO and SMC................... 146
6.4.4 R717 Single-stage compressor SMC 100 E ........................ 147
6.4.5 R717 Single-stage compressor HPX 700............................ 148
6.4.6 R717 Two-stage compressor TCMO and TSMC.................. 149
6.4.7 R717 Single-stage compressor HPC .................................. 150
6.4.8 R22 Single-stage compressor CMO and SMC..................... 151
6.4.9 R22 Two-stage compressor TCMO and TSMC.................... 152
6.4.10 R23 Single-stage compressor CMO and SMC..................... 153
6.4.11 R134a Single-stage compressor SMC................................ 154
6.4.12 R134a Single-stage compressor CMO ............................... 155
6.4.13 R134a Two-stage compressor TCMO and TSMC 100 S-
L...................................................................................... 156
6.4.14 R290 Single-stage compressor CMO and SMC................... 157
6.4.15 R290 Two-stage compressor TCMO and TSMC.................. 158
6.4.16 R404A Single-stage compressor CMO and SMC ................ 159
6.4.17 R404A Two-stage compressor TCMO and TSMC................ 160
6.4.18 R407C Single-stage compressor SMC ............................... 161
6.4.19 R407C Two-stage compressor TCMO and TSMC ............... 162
6.4.20 R507 Single-stage compressor CMO and SMC................... 163
6.4.21 R507 Two-stage compressor TCMO and TSMC.................. 164
6.4.22 R600 Single-stage compressor SMC.................................. 165
6.4.23 R600 Two-stage compressor TCMO and TSMC.................. 166
6.4.24 R600a Single-stage compressor SMC................................ 167
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6.4.25 R600a Two-stage compressor TCMO and TSMC ................ 168
6.4.26 R1270 Single-stage compressor CMO and SMC................. 169
6.4.27 R1270 Two-stage compressor TCMO and TSMC ................ 170
6.4.28 R744 Single-stage compressor HPC .................................. 171
6.4.29 LPG Single-stage compressor CMO and SMC .................... 172
6.4.30 LPG Two-stage compressor TCMO and TSMC ................... 173
6.5 Motor ...................................................................................... 174
6.5.1 Direction of rotation of the compressor ............................... 174
6.5.2 Choice of electric motor..................................................... 175
6.5.3 Starting torque of the compressor ...................................... 177
6.5.4 Moment of inertia .............................................................. 180
6.5.5 Direction of rotation of electric motor .................................. 181
6.5.6 Handling of compressor and unit ........................................ 181
6.5.7 Compressor shaft ............................................................. 182
6.5.8 Coupling .......................................................................... 183
6.6 Noise and vibration .................................................................. 185
6.6.1 Vibration data for compressors - all compressor
types................................................................................ 185
6.6.2 Unbalanced forces and moments ....................................... 186
6.6.3 Noise data........................................................................ 189
6.6.4 Noise data specifications................................................... 189
6.7 Materials and pressure levels.................................................... 193
6.7.1 Specification of compressor materials ................................ 193
6.7.2 Test pressure levels for standard compressors and
components ..................................................................... 194
6.7.3 Tightness of Sabroe equipment.......................................... 194
7. Installation instructions..................................................................... 196
7.1.1 Safety precautions ............................................................ 196
7.1.2 Installation data ................................................................ 196
7.1.3 Installation and first start-up procedure ............................... 196
7.1.4 Installation drawings ......................................................... 196
7.1.5 Personnel requirements .................................................... 196
7.1.6 Tools and accessories....................................................... 196
7.1.7 Safety equipment.............................................................. 197
7.1.8 Preparing the mounting site ............................................... 197
7.1.9 Laying the unit foundation.................................................. 198
7.1.10 Mounting directly on the foundation .................................... 200
7.1.11 Damping using vibration dampers ...................................... 201
7.1.12 Mass damping between unit and building............................ 203
7.1.13 Marine installation............................................................. 204
7.1.14 VSD equipment ................................................................ 204
7.1.15 Installation instructions...................................................... 205
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7.2 Alignment................................................................................ 205
7.2.1 Alignment of unit against foundation ................................... 205
7.2.2 Mounting directly on foundation ......................................... 205
7.2.3 Alignment of compressor on base frame ............................. 206
7.2.4 Alignment of motor on base frame...................................... 206
7.2.5 Coupling alignment and fitting ............................................ 206
7.2.6 Preliminary installation of coupling ..................................... 208
7.2.7 Alignment......................................................................... 210
7.2.8 Achieving correct centre height .......................................... 211
7.2.9 Achieving parallel shafts in vertical plane ............................ 212
7.2.10 Final installation of coupling............................................... 212
7.3 Piping connections................................................................... 213
7.4 Connecting electricity supply..................................................... 213
7.5 Pressure testing....................................................................... 215
7.5.1 Final installation check ...................................................... 217
8. Components...................................................................................... 218
8.1 Motors .................................................................................... 219
8.2 Transmission systems.............................................................. 219
8.3 Direct driven ............................................................................ 219
8.4 Oil separators .......................................................................... 220
8.5 Oil coolers ............................................................................... 220
8.6 Electromechanical control......................................................... 220
8.7 UniSAB III ............................................................................... 221
9. Settings............................................................................................. 222
9.1 Extended discharge gas temperatures....................................... 224
10. Operating instructions ...................................................................... 226
11. Maintenance instructions .................................................................. 227
11.1 Safety precautions ................................................................... 227
11.2 Maintenance of compressor unit ............................................... 227
11.3 Stopping routine ...................................................................... 229
11.4 Service intervals ...................................................................... 230
11.5 Service interval diagrams for SMC-TSMC-HPC-HPX.................. 230
11.6 Annual service......................................................................... 235
11.7 Regular service schedule - refrigeration plant............................. 236
11.8 Regular service schedule - compressor unit ............................... 237
11.9 Visual inspection...................................................................... 238
11.10 Measures to be taken............................................................... 238
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11.11 General rules for use of lubricating oil in refrigeration
compressors............................................................................ 240
11.12 Assessing the oil...................................................................... 240
11.13 Analytical evaluation ................................................................ 240
11.14 Charging the compressor with lubricating oil .............................. 242
11.15 Oil charge................................................................................ 243
11.16 Compressor prelubrication........................................................ 244
11.17 Shaft seal................................................................................ 245
11.18 Motor lubrication ...................................................................... 245
12. Faultfinding instructions ................................................................... 246
12.1 How to carry out faultfinding...................................................... 246
12.2 Remedying malfunctions .......................................................... 249
13. Service instructions .......................................................................... 256
13.1 General preparations before service.......................................... 256
13.2 Servicing the compressor ......................................................... 257
13.2.1 Pressure drop test ............................................................ 258
13.2.2 Removing refrigerant from the compressor ......................... 259
13.3 Servicing the refrigeration plant................................................. 260
13.3.1 General guidelines............................................................ 260
13.4 Maintenance of the compressor ................................................ 262
13.4.1 Preparing for maintenance ................................................ 262
13.4.2 If the compressor is operational ......................................... 262
13.4.3 If the compressor is inoperative.......................................... 263
13.5 Service guide........................................................................... 263
13.5.1 Service parts for SMC, TSMC, HPC and HPX ..................... 263
13.5.2 Inspection of thermostats .................................................. 265
13.5.3 Inspection of thermopump ................................................. 265
13.5.4 Inspection of shaft seal...................................................... 266
13.5.5 Inspection of safety controls .............................................. 267
13.5.6 Inspection of heating rod ................................................... 270
13.5.7 Inspection of compressor stop valves ................................. 270
13.5.8 Inspection of coupling ....................................................... 271
13.5.9 Storage of rubber elements ............................................... 272
13.5.10 Inspection of crank main bearings ...................................... 273
13.5.11 Inspection of connecting rod bearings ................................ 273
13.5.12 How to determine the usability of cylinder liners................... 275
13.5.13 Inspection of connecting rod .............................................. 277
13.5.14 Inspection of safety springs ............................................... 279
13.5.15 Inspection of piston pin...................................................... 279
13.5.16 Inspection of pistons ......................................................... 280
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13.5.17 Inspection of valve seats ................................................... 281
13.5.18 Inspection of unloading mechanism.................................... 283
13.6 Dismantling and assembly ........................................................ 284
13.6.1 Water covers .................................................................... 284
13.6.2 Fitting water covers........................................................... 284
13.6.3 Top covers ....................................................................... 285
13.6.4 Fitting top cover ................................................................ 285
13.6.5 Mounting top and water covers .......................................... 286
13.6.6 Discharge valve................................................................ 287
13.6.7 Discharge valve types ....................................................... 287
13.6.8 Suction valve types ........................................................... 288
13.6.9 Service life of discharge and suction valves ........................ 288
13.6.10 Cylinder lining with suction valve ........................................ 289
13.6.11 Extracting cylinder lining.................................................... 289
13.6.12 Dismantling suction valve .................................................. 289
13.6.13 Mounting suction valve...................................................... 289
13.6.14 Inserting cylinder lining...................................................... 290
13.6.15 Monitoring cylinder lining insertion...................................... 290
13.6.16 Connecting rod ................................................................. 293
13.6.17 Procedure for removing piston and connecting rod .............. 293
13.6.18 Fitting bearings................................................................. 294
13.6.19 Fitting connecting rod ........................................................ 294
13.6.20 Piston .............................................................................. 295
13.6.21 Shaft seal......................................................................... 296
13.6.22 Assembling and mounting shaft seal .................................. 298
13.6.23 Coupling .......................................................................... 299
13.6.24 Crankshaft ....................................................................... 299
13.6.25 Dismantling crankshaft ...................................................... 300
13.6.26 Inspection ........................................................................ 300
13.6.27 Refitting crankshaft ........................................................... 300
13.6.28 Main bearings................................................................... 301
13.7 Lubricating system ................................................................... 302
13.7.1 Compressor lubricating system .......................................... 302
13.7.2 Oil pump .......................................................................... 303
13.7.3 Dismantling oil pump......................................................... 307
13.7.4 Oil pressure valve ............................................................. 307
13.7.5 Strainer............................................................................ 308
13.7.6 Oil filter ............................................................................ 308
13.8 Suction filter and relief valve ..................................................... 310
13.8.1 Suction filters.................................................................... 310
13.8.2 Relief valve, pos. 24.......................................................... 310
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13.9 Pressure gauges...................................................................... 311
13.9.1 Description....................................................................... 311
13.9.2 Adjustment to other temperature ranges ............................. 312
13.9.3 Cleaning and refilling glycerine-filled gauges....................... 312
13.10 Refrigeration plant ................................................................... 313
13.10.1 Refrigeration plant maintenance ........................................ 313
13.10.2 Dismantling plant .............................................................. 315
13.10.3 Tightness testing and pump down of refrigeration
plant ................................................................................ 315
13.11 Spare parts ............................................................................. 315
13.11.1 How to order spare parts ................................................... 315
14. Transport instructions....................................................................... 317
14.1 Transport data ......................................................................... 317
14.2 Personnel requirements ........................................................... 317
14.3 Loading instructions ................................................................. 317
14.4 Transport instructions............................................................... 318
14.5 Unloading instructions .............................................................. 319
14.6 Storage ................................................................................... 319
15. Commissioning instructions ............................................................. 320
15.1 Safety precautions ................................................................... 320
15.2 Preparations for commissioning ................................................ 320
15.3 Preparing the installation site .................................................... 321
15.4 Commissioning instructions ...................................................... 321
15.5 Checklist for commissioning...................................................... 323
16. Spare parts list .................................................................................. 325
16.1 Please see separate Spare parts manual................................... 325
17. Spare parts drawings ........................................................................ 326
17.1 Please see separate Spare parts manual................................... 326
18. Final disposal.................................................................................... 327
18.1 Safety precautions ................................................................... 327
18.2 Waste disposal ........................................................................ 327
19. Appendices ....................................................................................... 328
19.1 Torque for screws and bolts ...................................................... 328
19.2 Connecting rods ...................................................................... 329
19.3 General torque ........................................................................ 329
19.4 Coupling data .......................................................................... 332
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19.5 Sundry clearances and check dimensions ................................. 333
19.6 Capacity diagrams, SMC and TSMC compressors ..................... 335
19.7 Capacity diagrams, HPC compressors ...................................... 354
19.8 Capacity diagrams, HPX compressors....................................... 362
Index ................................................................................................. 370
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Introduction
1. Introduction
1.1 Introduction to manual
The Sabroe reciprocating compressor and unit can be configured with various types of equip-
ment 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 all-in-one manual provides all compressor information needed for sales, installation, main-
tenance and service. Operating instructions and spare parts data are not included, but can be
found in the operating and spare parts manuals respectively.
The manual includes:
• Description of all component parts
• Description of all important technical functions to ensure a thorough understanding of
the product functionality
• Refrigerant safety
• Connecting data
• Installation, maintenance, service instructions
• and much more.
1.1.1 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 per-
sonnel only. If not, the warranty no longer applies.
1.1.2 Models covered
• SMC 104 - 106 -108- 112 -116 and TSMC 108 - 116
• HPC 104 - 106 - 108 - 112 - 116
• HPX 704 - 706 - 708 -712 - 716.
1.1.3 Amendments to the manual
2023.04 Version 10
• The compressor, vessel and unit pipe system name plates have been updated.
• Updated operating limits diagrams, see sections: 6.4.5 R717 Single-stage compressor HPX
700,6.4.22 R600 Single-stage compressor SMC and 6.4.24 R600a Single-stage compressor
SMC.
• Updated section: 4.13.2 Water-cooled top and side covers - R717 (1b).
• Various minor changes.
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Introduction
2021.12 Version 9
• Coupling data changes in Table 44 and Table 78.
• Subsection 6.7.3: Tightness of Sabroe equipment added.
• Subsection 15.5 Checklist for commissioning added - the list can be filled in electronically.
• Various minor changes.
2021.04 Version 8
• Oil charging instructions changed, see section 11.15 Oil charge,Table 57: Oil charge and Table 58: Oil level.
• Capacity diagrams for HPC 112 and HPC 116 have been added, section 19.7
• Principle diagram in section 4.7.2 Oil return in connection with parallel operation has been updated.
• Various minor changes.
2019.11 Version 7
• Section 6.3 Requirements for ambient temperatures and humidity has been updated in accordance with the latest
WHC (Water Heating and Cooling system) updates.
• Updated instructions in section 7.2.6 Preliminary installation of coupling.
• Min. rpm for TSMC compressors changed from 500 to 700 in all operating limits tables in section 6.4.2 List of operating
limits diagrams.
• Various minor corrections.
2019.06 Version 6
• Section about ‘Water-cooled top and side covers, R717’ has been updated.
• New section about the Crankcase Ventilation System (CVS).
• Various minor corrections.
2018.10 Version 5
• The regular service schedule, Table 56, and the ‘Annual service’ section have been updated.
• Lists of service parts have been updated.
• Two tables showing ‘Unbalanced forces and moments’ have been added
• Various minor corrections.
2018.06 Version 4
• Drawings of SMC units have been updated – now showing single-beam units.
• Drawings of SMC compressors have been updated - now showing Mk 5 design.
• Noise data for 1800 rpm have been added.
• The ‘Storage’ section in the ‘Transport instructions’ chapter has been revised.
• Operating limits and more for R410A have been removed as the refrigerant has been phased out.
• Cooling of side covers: the max. permissible cooling water pressure changed from 8 to 10 bar.
• Declarations of conformity (unit and ATEX) have been removed. They can be found in the operating manuals.
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Introduction
2018.01 Version 3
• The manual now covers version Mk 4 LL as well as Mk 5.
• HPC 112-116 and HPX 712-HPX 716 have been added.
• Added information about ATEX, for example table with temperature classes.
• Name plates with EurAsian Conformity mark (EAC) have been added.
• ‘Requirements for competent persons’ section has been added.
• New operating limits diagram for R717 single-stage HPC compressor
• Compressor weights changed.
• Correction in connections table, pos. AC.
• ‘F-gas regulation’ section has been updated.
• Updated versions of declarations of conformity: Unit and ATEX.
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Introduction
1.1.4 Manufacturer's information
This manual is produced by:
Johnson Controls Denmark ApS
Christian X's Vej 201
8270 Højbjerg, Denmark
Phone +45 87 36 70 00
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
1.1.5 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 dam-
age to equipment and/or minor injury.
Note: Indicates an operating procedure, practice, or portion thereof, which is essential to
highlight.
1.1.6 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 and all machine functions to oper-
ate or service the compressor/unit according to EN 13313.
• Operators and maintenance personnel must carefully read, understand and fully com-
ply 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 Con-
trols Denmark products.
Before a compressor/unit is put into operation, it must be fitted with the warning signs belong-
ing to the type of compressor/unit in accordance with the rules and regulations in force.
2.2 Identification of equipment
All equipment from Johnson Controls Denmark can be identified by one or several name plates
positioned as illustrated in Fig. 1.
Fig. 1: Position of name plates
Unit pipe system name plateVessel name plate Compressor name plate
/