Sabroe SAB 273 High-pressure screw compressor Operating instructions

Brand
Sabroe
Model
SAB 273 High-pressure screw compressor
Type
Operating instructions
SAB 273
High-pressure screw compressor
Operating manual EN
Operating manual - SAB 273 High-pressure screw compressor
0015821 en 2023.03 3/56
Manual for SAB 273 high-pressure screw compressor
Unit no.
Compressor 273
Compressor type S L
Bearing configuration HPSS HPSD
Oil separator type OHU 5040/4040
Vi range 1.3-1.96 1.7-3.0 2.2-5.0
Refrigerant R717
Oil type Oil type: _________________ Evap. temp. _____ Cond. temp. _____
Control UniSAB None Other
Oil filter Single Dual
Oil cooling Refrigerant-cooled oil cooler Water-cooled oil cooler
Economiser system
(ECO-system) Economiser connection Economiser type _________
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)
UniSAB setting
values Separator velocity ref. _______ Separator velocity ref. CR _______
Operating manual - SAB 273 High-pressure screw compressor
4/56 0015821 en 2023.03
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
Operating manual - SAB 273 High-pressure screw compressor
0015821 en 2023.03 5/56
Contents
1. Introduction to the operating manual ....................................................7
1.1 Compressor name, Sabroe/Frick...................................................7
1.2 Safety precaution definitions used in this manual............................9
1.3 Requirements for competent persons ............................................9
2. Areas of application ............................................................................10
2.1 Application of the screw compressor ...........................................10
2.2 Application of combustion engines .............................................. 10
3. Identification ....................................................................................... 11
3.1 Identification .............................................................................. 11
3.2 Unit/pipe system name plate....................................................... 12
3.3 Compressor name plate ............................................................. 14
3.4 Geometrical swept volume..........................................................15
3.5 Vessel name plate...................................................................... 16
4. Safety precautions .............................................................................. 17
4.1 Signs .......................................................................................17
4.2 During operation ........................................................................18
4.3 Safety during maintenance and service ....................................... 19
4.4 Electrical installations.................................................................19
4.5 Lubricating oils .......................................................................... 19
4.6 Purging a refrigeration plant........................................................ 20
4.7 F-gas regulation (fluorinated greenhouse gases).......................... 21
4.8 Sound measurement and noise data ...........................................23
4.8.1 Noise data.......................................................................... 23
4.8.2 Noise data for SAB 273 ......................................................23
5. Installation .......................................................................................... 24
6. Operating instructions ........................................................................25
6.1 Description of the unit.................................................................25
6.2 General piping diagram ..............................................................27
6.3 Valve positions during operation.................................................. 29
6.4 Descriptions of main components and systems ............................ 30
6.5 Compressor .............................................................................. 30
6.6 Compressor lubrication system ...................................................31
6.7 Prelubrication and start-up oil pump ............................................32
6.8 Demand pump oil system ........................................................... 32
Operating manual - SAB 273 High-pressure screw compressor
6/56 0015821 en 2023.03
6.9 Compressor oil separation system...............................................32
6.10 Automatic oil return valve ........................................................... 34
6.11 Compressor hydraulic system ..................................................... 35
6.12 Volume ratio (VI) control ............................................................. 36
6.13 Compressor oil cooling systems.................................................. 37
6.14 Equalisation .............................................................................. 37
6.15 Balance piston pressure regulator ...............................................37
6.16 Low ambient temperature operation ............................................37
6.17 Heating element ........................................................................38
6.18 Start-up..................................................................................... 38
6.19 Initial start-up procedure............................................................. 38
6.20 Stopping routine ........................................................................40
6.21 Long-term storage .....................................................................40
7. Troubleshooting.................................................................................. 41
8. Maintenance instructions .................................................................... 46
8.1 Maintenance of compressor unit ................................................. 46
8.2 Maintenance intervals ................................................................ 47
8.3 Monitoring of operation............................................................... 48
8.4 Oil............................................................................................. 50
8.5 Oil charge ................................................................................. 50
8.6 Charging the compressor with lubricating oil ................................ 50
8.7 Motor ........................................................................................ 52
9. Final disposal...................................................................................... 53
9.1 Safety precautions .....................................................................53
9.2 Waste disposal .......................................................................... 53
10. Compliance ......................................................................................... 54
10.1 Declaration of conformity ............................................................ 54
Index ................................................................................................... 55
Operating manual - SAB 273 High-pressure screw compressor
0015821 en 2023.03 7/56
Introduction to the operating manual
1. Introduction to the 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
This manual is primarily intended for operators and service engineers.
It is important that the operating personnel familiarise themselves with the contents of this
manual in order to ensure proper and efficient operation. Johnson Controls Denmark is not li-
able 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 per-
sonnel 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 type of unit:
• SAB 273 S
1.1 Compressor name, Sabroe/Frick
The compressor in a Sabroe SAB 273 screw compressor unit is manufactured by Frick. Below
is indicated how the Sabroe and Frick compressor names are made up and how they corre-
spond to each other.
Sabroe name Frick name
SAB 273 S HPS 2709
SAB 273 L HPS 2712
Table 1: Compressor overview
Operating manual - SAB 273 High-pressure screw compressor
8/56 0015821 en 2023.03
Introduction to the operating manual
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 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 discrepan-
cies or conflicts between the English and any other version that has been translated into anoth-
er language, the English version will prevail.
HPSS 09
S
R o t o r d i am e t e r
Com p r e s s o r
SAB 273
R o t o r length
S h o r t - S
Long - L
Frick name
Sabroe name
27A
Model/series
HPS = High-pressure screw
Bearing arrangement
S = Single radial bearings
D = Double radial bearings
Rotor diameter
27 = 273 mm
40 = 407 mm
Rotor length designation
09
12 Rotor length ÷ diameter x 10
Vi configuration
A = 2.2 - 5.0
B = 1.7 - 3.0
C = 1.3 - 1.96
Operating manual - SAB 273 High-pressure screw compressor
0015821 en 2023.03 9/56
Introduction to the operating manual
1.2 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.
1.3 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.
Operating manual - SAB 273 High-pressure screw compressor
10/56 0015821 en 2023.03
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 dam-
age equipment, the following must be observed:
• The compressor must only be used as a refrigeration compressor and within the oper-
ating 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 only be used with a written permission from Johnson Controls Denmark.
• Johnson Controls Denmark further accept no liability of any kind for damage to com-
pressor unit and plant parts caused by torsional oscillation, or the like, which is attribut-
able to built-in VSD solutions initiated by the customer after delivery.
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 ma-
chine room. Some refrigerant types may, to a certain extent, be absorbed by the fuel in a com-
bustion 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 destroy 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 re-
sulting from using the equipment for other purposes than the ones stated above.
Operating manual - SAB 273 High-pressure screw compressor
0015821 en 2023.03 11/56
Identification
3. Identification
3.1 Identification
All Johnson Controls Denmark equipment can be identified by one or several name plates as il-
lustrated in the following.
Operating manual - SAB 273 High-pressure screw compressor
12/56 0015821 en 2023.03
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.
Serial
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
1000010126
MADE IN DENMARK
No
Fig. 1: Name plate for standard unit, with CE mark
Scope
Design code
Approval No
Refrigerant
Supply voltage
Test pressure
Allowable pressure
Category
Pressure system
Refrigerant charge
Max.
Allowable temp.
Min./Max.
Year
Fluid
Group
Control
V/Hz
kg
bar
g
bar
g
°C
LP side
HP side
1000010127
Main
Serial
Type
No
Johnson Controls Denmark ApS
Christian X's Vej 201
8270 Højbjerg, Denmark
www.sabroe.com
MADE IN DENMARK
Fig. 2: Name plate for ATEX unit
Scope
Design code
Approval No
Refrigerant
Supply voltage
Test pressure
Allowable pressure
Category
Pressure system
Refrigerant charge
Max.
Allowable temp.
Min./Max.
Year
Fluid
Group
Control
V/Hz
kg
bar
g
bar
g
°C
LP side
HP side
1000010128
Main
MADE IN DENMARK
Serial
Type
No
Johnson Controls Denmark ApS
Christian X's Vej 201
8270 Højbjerg, Denmark
www.sabroe.com
Fig. 3: Name plate for standard unit, without CE mark
Назначение
Код стандарта
№
сертификата
Хладагент
Группа
Напряжение питания
Управ
ление
В/Гц
Заправка хладагентом
Кг
Давление
бар
бар
Допустимое давление
Давление ислытания
макс
Категория
°
С
Допустимая темп
мин/макс
1000010129
Жидкость
Сеть
Сторона НД
Сторона ВД
ммгг
Тип
Johnson Controls Denmark ApS
Christian X´s Vej 201
8270 Højbjerg, Denmark
www.sabroe.com
СДЕЛАНО В ДАНИИ
Серийный
№
Fig. 4: Name plate for unit with EurAsian Conformity mark
(EAC)
Operating manual - SAB 273 High-pressure screw compressor
0015821 en 2023.03 13/56
Identification
The unit name plate is positioned on the frame and contains this information:
Serial No. Unique identification number.
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 sys-
tem.
’Piping’ means that the CE/EAC mark applies to the piping sys-
tem only, and it is the sole responsibility of the owner to ensure
and declare that the complete unit is in conformity with the provi-
sions 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/noti-
fied 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
maximum allowable pressure depending on the operating condi-
tions 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 allow-
able 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 Eura-
sian Customs Union.
Note: Main supply voltage can be found on the motor and/or electrical panel name plate.
Operating manual - SAB 273 High-pressure screw compressor
14/56 0015821 en 2023.03
Identification
3.3 Compressor name plate
Fig. 5: Compressor name plate Fig. 6: Refrigerant plates
Note: The compressor is fitted with a name plate, Fig. 5, and one of the two refrigerant name
plates shown in Fig. 6.
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.
Operating manual - SAB 273 High-pressure screw compressor
0015821 en 2023.03 15/56
Identification
3.4 Geometrical swept volume
Screw
compr.
unit
Rotor
dia.
mm
Rotor
L/D
Min.
Speed
rpm
Max.
Speed
rpm
Geometrical
swept volume
drive shaft end
Ft3/Rev. M3/Rev.
M3/H
2950 rpm
HPS 2709 273 0.9 1,000 3,600 0.27428 0.007767 1375
HPS 2712 273 1.2 1,000 3,600 0.36570 0.010355 1833
Table 2: Geometrical swept volume
Operating manual - SAB 273 High-pressure screw compressor
16/56 0015821 en 2023.03
Identification
3.5 Vessel name plate
F
E
D
C
B
A
F
E
D
C
B
A
8765
4
32
1
8765
4
32
1
2
6
1
6
1
6646
1
6
1
6
1
6
1
6 18 3
6
1
10
12
21,6
1
422
20
20,5
52
1
13
2
2
6
6
R5
R4
105
93
105
93
6
6
R4
4
4
18,9
3
3
3
1
2
{
- -
Ø3,5
17
Logo, frame, text and square boxes
should be blank on blue (Pantone nr. 661)
Lacquer plate transparent
Material: 0,5 mm AISI 304 plate
Anvendte fonte/Used fonts
#
Hvor
where
Font Eksempel
Example
1Tekst i isbjørn logo
Text in polar bear logo
Arial
2Øvrig tekst
Remaining text
Arial Narrow
Side/Side/Seite
SABROE
WeldingProductionEngineering
Date
Date
Date
Master drw:
Date
Sheet No.
ApplicationSize:
Drawing No.
Scale:
Design std.
Checked by
Modified by
Drawn by
Type of project
Order No.
Designed by
Revision No.
ECN
Title
Rev. Revision description
© Copyright - Johnson Controls Denmark ApS - All rights reserved. PROPRIETARY AND CONFIDENTIAL.
www.sabroe.com
Christian X's Vej 201
DK-8270 Højbjerg, Denmark
Johnson Controls Denmark ApS
Quality
PED Nameplate for vessel
Danish, English, German
ABR 5-1-2009
ABR 5-1-2009
ABR 2-6-2022
2516-340
AutoCAD1:1 A3
2516-350
91/1
9 Delete material. equal with rev.6
ABR/24-5-22
Rør/Tube/Rohr
Svøb/Shell/Mantel
bar
L
PS
V
/CAT.
Volumen/Volume
Type/Typ
Beregningsnorm/Design code/
Berechnungsnorm
Godkendelsesnr./
Approval No /Abnahmenummer
Side/Seite
Tilladeligt tryk
Allowable pressure
Zulässiger Druck
2516-350
Medie/Fluid/Medium
Max./Min.
°C
TS
Tilladelig temperatur
Allowable temperature
Zulässige Temperatur Max./Min.
PT
Test tryk
Test pressure
Probedruck bar
kg
Tom vægt/
Empty weight
Leergewicht
År
Year
Jahr
Test date
Probedatum
dd/mm
Nr.
No
Serie/Serien/
Serial
Rør/Tube/Rohr
Svøb/Shell/Mantel
bar
PS
/CAT.
Volumen/Volume
Type/Typ
Beregningsnorm/Design code/
Berechnungsnorm
Tilladeligt tryk
Allowable pressure
Zulässiger Druck
Medie/Fluid/Medium
Max./Min.
Tilladelig temperatur
Allowable temperature
Zulässige Temperatur Max./Min.
Test tryk
Test pressure
Probedruck bar
kg
Nr.
No
Serie/Serien/
Serial
V
Side/Seite
°C
2516-350
PT
L
Godkendelsesnr./
Approval No /Abnahmenummer
TS
Tom vægt/
Empty weight
Leergewicht
6
25,6
25,6
/
/
/
/
/
/
/
/
/
/
8
År
Year
Jahr
Test date
Probedatum
dd/mm
Fig. 7: Vessel name plate - CE mark
1 2 3 4 5 6 7 8
1 2 3 4 5 6 7 8
A
B
C
D
E
F
A
B
C
D
E
F
1
2
{
ABR
16-4-2004
MKM
9-7-04
QualityProductionEngineering
Date
Date
Date
Master drw:
Date
Sheet No.
ApplicationSize:
Drawing No.
Scale:
Design std.
Checked by
Modified by
Drawn by
Type of project
Order No.
Designed by
Revision No.
ECN
Title
Rev.
All rights reserved by Sabroe Refrigeration
Revision description.
www.sabroe.com
DK-8270 Højbjerg, Denmark
Christian X's Vej 201, P.O. Box 1810
PED skilt for beholder Rusisk
Nameplate for vessel Russian- language PED
ABR 7-6-2022
AutoCAD1:1 A3
2516-331
14 1/1
14 Delete material; equal to rev.12
ABR/24-5-22
Logo, frame, text and square boxes
should be blank on blue (Pantone nr. 661)
Lacquer plate transparent
Material: 0,5 mm AISI 304 plate
Anvendte fonte/Used fonts
#
Hvor
where
Font
Eksempel
Example
1
Tekst i isbjørn logo
Text in polar bear logo
Arial
2
Øvrig tekst
Remaining text
Arial Narrow
SABROE
Mасса пустого cocyдa
2
6
1
6
1
66 4 6
1
6
1
6
1
6
1
6
18
3
6
1
10
12
21,6
1
422
22,5
17
52
1
13
2
2
6
6
R5
R4
105
93
105
93
6
6
4
4
18,9
3
3
3
∅3,5
17
Tpyбок
/ Tube
Oбeчaйки / Shell
л
l
PS
V
Oбъeм/Volume
Тип/Type
Пpoeкт пo cтaндapтy
Design code
Утвepждeн пoд N°
Approval No
Cтopoнa
/ Side
Paбoчee двпeниe Макс./Мин.
Allowable pressure Max./Min.
2516-331
Cpeдa/Fluid
°C
TS
Допустимая температура Макс./Мин.
Allowable temperature Мax./Min.
PT
Давление испытания
Test pressure
Mасса пустого
cocyдa
Empty weight
Дата
Test date
Cерийный №
Serial No
.
6
25,6
25,6
/
/
/
/
/
кг
Kg
год
Year
/ Кат.
/Cat.
/
/
/
/
/
Tpyбок
/ Tube
Oбeчaйки / Shell
MПа
MPa
л
l
V
Oбъeм/Volume
Тип/Type
Пpoeкт пo cтaндapтy
Design code
Утвepждeн пoд N°
Approval No
Cтopoнa
/ Side
2516-331
°C
Mасса пустого
cocyдa
Empty weight
Дата
Test date
Cерийный №
Serial No
.
/
/
/
/
/
кг
Kg
год
Year
/ Кат.
/Cat.
MПа
MPa
PS
TS
PT
MПа
MPa
MПа
MPa
Oбъeм/Volume
Paбoчee двпeниe Макс./Мин.
Allowable pressure Max./Min.
Допустимая температура Макс./Мин.
Allowable temperature Мax./Min.
Давление испытания
Test pressure
Fig. 8: Vessel name plate - EurAsian Conformity mark (EAC)
The name plate is positioned on the shell of the vessel and contains this information:
Serial no. Vessel identification no.
Empty weight The empty weight of the vessel in kg.
Test date The date of the pressure test.
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 and secondary refrigerant(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
Eurasian Customs Union.
Note: Depending on the supplier of the pressure vessel/heat exchanger, the layout and con-
tent of the vessel name plate may differ from the Sabroe name plate above.
Operating manual - SAB 273 High-pressure screw compressor
0015821 en 2023.03 17/56
Safety precautions
4. Safety precautions
4.1 Signs
All signs which may be found on your equipment are shown below. The number of signs, how-
ever, 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 refriger-
ant R290
Internal protection Pacemaker users keep out
Compressor blocks and units are usually
delivered without refrigerant and oil. To
protect the compressors against internal
corrosion, they are delivered evacuated of
all atmospheric air and charged with dry Ni-
trogen (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 af-
fect digital devices such as watches and
mobile phones.
Assembly or maintenance of the rotor must
not be carried out by people with pace-
makers 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 mi-
nutes after the drive has been turned off.
Operating manual - SAB 273 High-pressure screw compressor
18/56 0015821 en 2023.03
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/perform-
ing 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 be-
fore 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
detectors 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
system is under pressure, and never open pressurised system parts.
Note: Whenever a by-pass valve/safety valve has been activated, we recommend recalibrat-
ing it. This must be carried out by competent personnel only. See also EN 378 and existing na-
tional legislation.
Operating manual - SAB 273 High-pressure screw compressor
0015821 en 2023.03 19/56
Safety precautions
Cooling water system
Warning!
The recirculation water system may contain chemicals or biological contaminants, including le-
gionella, which can be harmful if inhaled or ingested. Water systems should only be operated
with an effective biological treatment programme.
4.3 Safety during maintenance and service
• Personnel must be competent according to national safety rules and regulations and
perform the maintenance work according to EN 378.
• Read chapter 4. Safety precautions before opening the compressor and other parts of
the refrigeration plant.
• It is recommended to remove all main fuses. Switch off all electric components on the
compressor/unit before starting the dismantling/servicing process and lock the main
switch.
• Make sure that the motor cannot start up inadvertently.
• Make sure that there is no over-pressure and no refrigerant in the part to be dismantled.
Close all necessary stop valves.
• Use the prescribed tools, and check that they are properly maintained and in good
working condition. In explosion-proof areas, use tools suited for this specific purpose.
• Use only Johnson Controls Denmark original spare parts; other parts may impair the
safety of the compressor/unit.
• When performing maintenance, the main switch must be locked.
• Use gloves and protective goggles, and make sure to have a gas mask close at hand.
Also use electrical protection equipment and tools suited for electrical operation
purposes.
4.4 Electrical installations
Power supply
Danger!
HIGH VOLTAGE!
Before removing or opening any electrical enclosures, covers, plates, doors or working on any
electrical circuits, place the main switch of the compressor/unit in the "OFF" position and lock
it. Dismantle the main fuses to the compressor unit.
An electrician must analyse the electrical system to determine the possible use of power re-
taining devices such as capacitors. Such power retaining devices must be disconnected, dis-
charged or made safe before maintenance is performed.
4.5 Lubricating oils
Compressor oils include the following oil types:
Operating manual - SAB 273 High-pressure screw compressor
20/56 0015821 en 2023.03
Safety precautions
Code design Oil types
M Mineral oil, naphtenic base
ASynthetic oils based on alkylated aromatics (alkyl-benzene)
AP Synthetic oils blended from alkyl-benzene and poly-alfa-olefin base stocks
S Semi synthetic oils (hydro-treated mineral oil on paraffinic base)
PAO Synthetic oils based on poly-alfa-olefin
POE Synthetic oils based on polyol esters
PAG Synthetic oils based on polyalkylene glycols
See the Sabroe oil recommendation for the recommended type of oil.
Warning!
When charging oil, follow the safety instructions given by the oil supplier (MSDS: Material
Safety Data Sheet). Always avoid direct contact with the oil as this may cause skin allergies.
Always use protective equipment, goggles and gloves, when charging oil.
When changing oil on the compressor or draining oil from the vessel of the refrigeration plant,
always collect the used oil in containers marked “waste oil,” and send them to an approved
hazardous waste disposal site. It is not recommended to reuse oil.
Refrigerants
Be very careful when dealing with refrigerants. For safe handling, please refer to the safety da-
ta sheets etc. delivered by the refrigerant supplier.
Danger!
Pay close attention to the fact that large amounts of escaping (or released) refrigerant entail
risk of suffocation. Body contact with leaking liquid refrigerant entails high risk of injuries
caused by intense cold.
4.6 Purging a refrigeration plant
Purging of air or other non-condensable gases is required in order to keep high system per-
formance and avoid corrosion of the equipment, which could endanger the safety of persons
and equipment.
When purging a refrigeration system, make sure to observe the following:
• Refrigerants must not be released into the atmosphere, except CO2, which can be re-
leased slowly into the atmosphere.
• When purging an ammonia system, use an approved air purger. The purged air must
pass through an open container or water for any remaining ammonia (R717) to be ab-
sorbed. The water mixture must be sent to an approved hazardous waste disposal site.
• Halocarbon refrigerants (CFC, HCFC and HFC) cannot be absorbed by water. An ap-
proved air purger must be fitted to the system. This must be checked regularly by use
of a leak detector. All precautionary measures practicable must be taken to prevent and
minimise leakage of refrigerant from refrigeration and air conditioning systems to the
atmosphere.
Note: The occurrence of air is usually an indication of poor maintenance or lack of thorough-
ness at installation.
Note: Ammonia systems should be purged on a regular basis to avoid atmospheric air and oth-
er non-condensable gases.
Page is loading ...
Page is loading ...
Page is loading ...
Page is loading ...
Page is loading ...
Page is loading ...
Page is loading ...
Page is loading ...
Page is loading ...
Page is loading ...
Page is loading ...
Page is loading ...
Page is loading ...
Page is loading ...
Page is loading ...
Page is loading ...
Page is loading ...
Page is loading ...
Page is loading ...
Page is loading ...
Page is loading ...
Page is loading ...
Page is loading ...
Page is loading ...
Page is loading ...
Page is loading ...
Page is loading ...
Page is loading ...
Page is loading ...
Page is loading ...
Page is loading ...
Page is loading ...
Page is loading ...
Page is loading ...
Page is loading ...
Page is loading ...
Page is loading ...
Page is loading ...
  • Page 1 1
  • Page 2 2
  • Page 3 3
  • Page 4 4
  • Page 5 5
  • Page 6 6
  • Page 7 7
  • Page 8 8
  • Page 9 9
  • Page 10 10
  • Page 11 11
  • Page 12 12
  • Page 13 13
  • Page 14 14
  • Page 15 15
  • Page 16 16
  • Page 17 17
  • Page 18 18
  • Page 19 19
  • Page 20 20
  • Page 21 21
  • Page 22 22
  • Page 23 23
  • Page 24 24
  • Page 25 25
  • Page 26 26
  • Page 27 27
  • Page 28 28
  • Page 29 29
  • Page 30 30
  • Page 31 31
  • Page 32 32
  • Page 33 33
  • Page 34 34
  • Page 35 35
  • Page 36 36
  • Page 37 37
  • Page 38 38
  • Page 39 39
  • Page 40 40
  • Page 41 41
  • Page 42 42
  • Page 43 43
  • Page 44 44
  • Page 45 45
  • Page 46 46
  • Page 47 47
  • Page 48 48
  • Page 49 49
  • Page 50 50
  • Page 51 51
  • Page 52 52
  • Page 53 53
  • Page 54 54
  • Page 55 55
  • Page 56 56
  • Page 57 57
  • Page 58 58

Sabroe SAB 273 High-pressure screw compressor Operating instructions

Brand
Sabroe
Model
SAB 273 High-pressure screw compressor
Type
Operating instructions
Download PDF
report

Ask a question and I''ll find the answer in the document

Finding information in a document is now easier with AI

Related papers