Sabroe SAB 193/233/283 Operating instructions

Brand
Sabroe
Model
SAB 193/233/283
Type
Operating instructions
Form Number: 0000347 en 2023.11
Supersedes: 0000347 en 2019.05
Operation Guide
Issue Date: 2023-11-15
SAB 193-233-283 OHU 09135, OHU 10737,
and OHU 07633 HP (including ATEX)
Screw Compressor Units
2 SAB 193-233-283 OHU 09135, OHU 10737, and OHU 07633 HP (including ATEX) Screw Compressor Units
Contents
ContentsManual for SAB 193, 233, and 283 screw compressor units, including ATEX............................................ 7
Introduction to operating manual................................................................................................................. 9
Compressor name, SABROE and Frick.............................................................................................. 10
Amendments to the manual.............................................................................................................. 11
Safety precaution definitions used in this manual..........................................................................13
Requirements for competent persons..............................................................................................13
Areas of application of the screw compressor........................................................................................... 14
Application of the screw compressor................................................................................................14
Application of combustion engines...................................................................................................14
Identification...................................................................................................................................................16
Unit and pipe name plate................................................................................................................... 16
Compressor name plate..................................................................................................................... 19
Compressor name plate - ATEX................................................................................................................ 20
Labelling of explosion-proof equipment.......................................................................................... 21
ATEX............................................................................................................................................................. 21
Geometrical swept volume.................................................................................................................22
Vessel name plate................................................................................................................................23
Safety precautions..........................................................................................................................................25
Signs...................................................................................................................................................... 25
General..................................................................................................................................................26
During operation................................................................................................................................. 26
Ventilation................................................................................................................................................... 27
Rotating parts.............................................................................................................................................27
Vibration and noise....................................................................................................................................27
Pressure.......................................................................................................................................................27
Cooling water system................................................................................................................................ 27
Safety during maintenance and service........................................................................................... 27
ATEX............................................................................................................................................................. 28
Electrical installations..........................................................................................................................28
ATEX............................................................................................................................................................. 28
Power supply.............................................................................................................................................. 29
Lubricating oils.....................................................................................................................................29
Refrigerants................................................................................................................................................ 29
Purging a refrigeration plant............................................................................................................. 30
F-gas regulation (fluorinated greenhouse gases)...........................................................................30
Bans on GWP.............................................................................................................................................. 31
Labelling...................................................................................................................................................... 31
Leakage test................................................................................................................................................31
Recovery of refrigerant..............................................................................................................................31
Certification of personnel..........................................................................................................................31
Record keeping...........................................................................................................................................31
SAB 193-233-283 OHU 09135, OHU 10737, and OHU 07633 HP (including ATEX) Screw Compressor Units 3
Sound measurement and noise data.......................................................................................................... 32
Noise data.............................................................................................................................................32
Noise data for SAB 193, 233, and 283................................................................................................32
Installation...................................................................................................................................................... 34
ATEX.......................................................................................................................................................35
Operating instructions.................................................................................................................................. 36
Positions of valves and components.................................................................................................36
Control system........................................................................................................................................... 36
Principle drawing....................................................................................................................................... 36
Principle P&I diagram......................................................................................................................... 39
P&I diagrams - liquid injection...........................................................................................................45
Valve positions during operation.............................................................................................................46
Descriptions of main components and systems............................................................................. 47
Compressor..........................................................................................................................................47
Compressor lubrication system.........................................................................................................48
No pump oil system............................................................................................................................ 49
Demand pump oil system.................................................................................................................. 49
Compressor oil separation system....................................................................................................49
Automatic oil return valve.................................................................................................................. 51
Function.......................................................................................................................................................51
Cold-start system.................................................................................................................................52
High-stage units.........................................................................................................................................53
Booster applications.................................................................................................................................. 53
Compressor hydraulic system............................................................................................................54
Single-acting mode, high-stage (> 10 bar pressure differential)......................................................... 55
High-stage compressor loading...............................................................................................................55
High-stage compressor unloading.......................................................................................................... 55
Double-acting mode, booster (< 10 bar pressure differential)............................................................ 56
Booster compressor loading.................................................................................................................... 56
Booster compressor unloading................................................................................................................56
Volumizer volume ratio (VI) control.........................................................................................................57
Compressor VI increase............................................................................................................................ 57
Compressor VI decrease........................................................................................................................... 57
Compressor oil cooling systems........................................................................................................57
Liquid injection.....................................................................................................................................57
Liquid injection adjustment...................................................................................................................... 57
Suction check valve by-pass............................................................................................................... 58
Balance piston pressure regulator.................................................................................................... 59
Low ambient temperature operation............................................................................................... 60
Heating element.................................................................................................................................. 60
ATEX............................................................................................................................................................. 61
Start-up................................................................................................................................................. 61
SAB 193-233-283 OHU 09135, OHU 10737, and OHU 07633 HP (including ATEX) Screw Compressor Units4
Preparations before start-up....................................................................................................................61
Starting and stopping......................................................................................................................... 61
Initial start-up procedure..........................................................................................................................61
Motorised oil injection valve.....................................................................................................................62
Correct setting at first start-up.................................................................................................................62
Method selection........................................................................................................................................62
Initial start-up guidelines..........................................................................................................................63
Normal start-up procedure.......................................................................................................................63
Restarting the compressor unit after control power interruption, plant power failure................... 63
Stopping routine........................................................................................................................................ 63
Shut down for long periods...................................................................................................................... 63
Long term storage..................................................................................................................................... 64
Secondary system.......................................................................................................................................... 65
General information............................................................................................................................65
Guidelines for the control of secondary sides................................................................................. 65
Off condition operation.............................................................................................................................65
Cleaning in place..................................................................................................................................65
Temperature and flow control........................................................................................................... 66
Water and brine treatment................................................................................................................ 66
R717 detector....................................................................................................................................... 66
Troubleshooting............................................................................................................................................. 67
Refrigeration plant, general issues................................................................................................... 67
Compressor unit, general issues....................................................................................................... 67
Compressor unit - oil separation.......................................................................................................69
Compressor block................................................................................................................................69
Demand oil pump system, optional.................................................................................................. 70
Maintenance instructions............................................................................................................................. 71
Maintenance of compressor unit...................................................................................................... 71
Daily maintenance, perform a minimum of twice a week.................................................................... 71
Periodic maintenance................................................................................................................................71
Major overhaul........................................................................................................................................... 71
Monitoring of operation..................................................................................................................... 73
Checklist...................................................................................................................................................... 73
Oil...........................................................................................................................................................74
Oil change.............................................................................................................................................74
Oil charge....................................................................................................................................................75
Charging the compressor with lubricating oil................................................................................. 75
Sampling the oil................................................................................................................................... 78
Motor.....................................................................................................................................................79
Motor lubrication....................................................................................................................................... 79
Replacing the motor bearings..................................................................................................................79
Final disposal.................................................................................................................................................. 80
5SAB 193-233-283 OHU 09135, OHU 10737, and OHU 07633 HP (including ATEX) Screw Compressor Units
Safety precautions...............................................................................................................................80
Waste disposal..................................................................................................................................... 80
Machine parts.............................................................................................................................................80
Oil and refrigerant..................................................................................................................................... 80
Electric components.................................................................................................................................. 80
Batteries...................................................................................................................................................... 80
Compliance..................................................................................................................................................... 81
Declaration of conformity...................................................................................................................81
SAB 193-233-283 OHU 09135, OHU 10737, and OHU 07633 HP (including ATEX) Screw Compressor Units6
Manual for SAB 193, 233, and 283 screw compressor
units, including ATEX
Table 1: Manual for SAB 193, 233, and 283 screw compressor units, including ATEX
Unit no.
Compressor r193 r233 r283
Compressor type rSrLrErXrHP
Oil separator
type
rOHU 09135 I rOHU 09135
II
rOHU 10737 rOHU 07633HP II
Refrigerant rR717 rHFC/HCFC _____________ Other: _________________________
Oil type Oil type:
__________________
Evap temp:
_______________________
Cond temp:
_______________________
Control rUnisab III rNone rOther
Oil filter rSingle rDual
Oil cooling rRefrigerant-
cooled oil
cooler
rWater-cooled oil cooler rLiquid injection in
compressor
Discharge port rStandard rAC (Low Vi port)
Oil pump r
Economiser
system
(ECO-system)
rEconomiser
connection
rEconomiser type: ______________________________________
Ex-execution
(ATEX) rT3 rT4 Other: ________________________________
Motor 3 x ____________________ V / ____________________Hz
Control 1 x ____________________V / ____________________ Hz
Supply voltage
Heating elements (phasing) 1 x ____________________V / ____________________ Hz
rIP23 rIP55
Power ____________________ kw Size IEC _______________________
Motor
rAnti-condensation heater
Drive type rFixed speed rVariable speed (VSD)
Coalescer
element rpcs.
Unisab setting
values Separator velocity ref. _______________ Separator velocity ref. CR________________
7SAB 193-233-283 OHU 09135, OHU 10737, and OHU 07633 HP (including ATEX) Screw Compressor Units
Table 2: 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:
Data for calculation
of downstream line
according to EN 13136
Safety valve type:
rBack-pressure dependent
rBack-pressure independent
SAB 193-233-283 OHU 09135, OHU 10737, and OHU 07633 HP (including ATEX) Screw Compressor Units8
Introduction to operating manual
You can configure the SABROE® screw compressor and the unit 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:
• The 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 respond when problems occur during operation.
• The scheduled maintenance tasks for the equipment and when and how to carry them out
safely.
• The 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 manual
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
personnel only. If not, the warranty no longer applies.
This manual does not describe the following:
• The control systems. A specific operating manual is delivered with the compressor.
• Safety information when handling refrigerants and oils.
• Installation procedures.
• Service and repair information including spare part lists.
For more information, go to http://www.sabroe.com.
This manual covers the following types of units:
• SAB 193 S
• SAB 193 L
• SAB 193 HP
• SAB 233 S
• SAB 233 L
• SAB 233 E
• SAB 233 HP
• SAB 283 S
• SAB 283 L
• SAB 283 E
• SAB 283 X
All P&I diagrams in this manual use American standards.
9SAB 193-233-283 OHU 09135, OHU 10737, and OHU 07633 HP (including ATEX) Screw Compressor Units
Compressor name, SABROE and Frick
The compressor in a SABROE SAB 193, 233, and 283 screw compressor unit is manufactured by
Frick®. The following table and image indicates how the SABROE and Frick compressor names are
made and how they correspond to each other.
Table 3: Compressor overview
SABROE name Frick name
SAB 193 S SGC 1913
SAB 193 L SGC 1918
SAB 193 HP SGC 1913
SAB 233 S SGC 2313
SAB 233 L SGC 2317
SAB 233 E SGC 2321
SAB 233 HP SGC 2313
SAB 283 S SGC 2813
SAB 283 L SGC 2817
SAB 283 E SGC 2821
SAB 283 X SGC 2824
Figure 1: Compressor overview
SAB 193-233-283 OHU 09135, OHU 10737, and OHU 07633 HP (including ATEX) Screw Compressor Units10
Amendments to the manual
Table 4: Amendments to the manual
2023.11 Version 4
• Update to the oil separator types in Manual for SAB 193, 233, and 283 screw compressor units,
including ATEX.
• Update to the list of units that this manual covers in the Introduction to operating manual
section.
• Update to compressor naming convention according to SABROE and Frick in the Introduction
to operating manual section.
• Update to the unit and pipe name plate examples in the Identification section.
• Update to the compressor oil types table in the Lubricating oils section.
• Update to the noise data table in the Sound measurement and noise data section.
• Added new SAB 193 - 233 HP with oil separator drawings in the Positions of valves and
components section.
• Added new general P&I drawings and update to the legend in the Principle P&I diagram
section.
• Update to the P&I diagram and the valve positions during operation table in the P&I diagrams
- liquid injection section.
• Update to the Compressor section.
• Update to the Compressor lubrication system section.
• Update to the Compressor hydraulic system.
• Update to the Compressor oil cooling systems.
• Update to the Balance piston pressure regulator section.
• Added new Secondary system section.
• Update to the torque requirements table in the Maintenance of compressor unit section.
• Update to the tables in the Oil change section.
• Added new Sampling the oil section.
• Implemented various style and document improvements throughout document.
2019.05 Version 3
• Added information about motorised oil injection valve in the Initial start-up procedure section.
• Added section about Balance piston pressure regulator.
• Updated P&I diagram, SAB 233.
• New compressor name plates.
• Overview of Frick compressors in SABROE units.
• 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 changes.
11SAB 193-233-283 OHU 09135, OHU 10737, and OHU 07633 HP (including ATEX) Screw Compressor Units
Table 4: Amendments to the manual
2017.11 Version 2
• Compressor SAB 193 HP has been added.
• 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).
• More ATEX information has been added, for example table with temperature classes.
• Updated versions of declarations of conformity: Unit and ATEX.
• And more.
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 purposes.
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
language, the English version will prevail.
SAB 193-233-283 OHU 09135, OHU 10737, and OHU 07633 HP (including ATEX) Screw Compressor Units12
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.
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 operate or
service the compressor and unit according to EN 13313.
• Operators and maintenance personnel must carefully read, understand, and fully comply with
all alarms and instructions.
13SAB 193-233-283 OHU 09135, OHU 10737, and OHU 07633 HP (including ATEX) Screw Compressor Units
Areas of application of the screw compressor
You must adhere to the following application of the screw compressor and application of
combustion engine guidelines.
Application of the screw compressor
To prevent unintentional application of the compressor, which could injure personnel or damage
equipment, you must observe the following guidelines:
• Only use the compressor as a refrigeration compressor and within the operating limits specified
in the manuals or in a written agreement with Johnson Controls Denmark.
• Only use the compressor with the refrigerant or refrigerants and number of revolutions per
minute, as shown on the compressor name plate. Only use other refrigerants in accordance
with Johnson Controls Denmark's instructions. Only use all other types of gas with written
permission from Johnson Controls Denmark.
• Johnson Controls Denmark further accept no liability of any kind for damage to the compressor
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.
Important: You must use special non-sparking tools for all maintenance work on the
compressor.
Figure 2: EX name plate example
Important: You must not use the compressor to complete the following actions:
• To evacuate the refrigeration plant of air and moisture.
• To put the refrigeration plant under air pressure in view of pressure testing.
• As an air compressor.
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
destroy the pumps. However, check with the local authorities as exemptions to this rule may be
granted.
SAB 193-233-283 OHU 09135, OHU 10737, and OHU 07633 HP (including ATEX) Screw Compressor Units14
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 previously.
15SAB 193-233-283 OHU 09135, OHU 10737, and OHU 07633 HP (including ATEX) Screw Compressor Units
Identification
All Johnson Controls Denmark equipment can be identified by one or several name plates as shown
in the following sections.
Unit and pipe name plate
Figure 3: Name plate for standard unit, with CE mark
Figure 4: Name plate for ATEX unit
SAB 193-233-283 OHU 09135, OHU 10737, and OHU 07633 HP (including ATEX) Screw Compressor Units16
Figure 5: Name plate for standard unit, without CE mark
Figure 6: Name plate for unit with EurAsian Conformity mark (EAC)
The unit name plate is positioned on the frame and contains the following information:
Table 5: Unit and pipe name plate information
Serial No: Unique identification number.
Year Year of manufacturing.
Type Manufacturer's type designation.
17SAB 193-233-283 OHU 09135, OHU 10737, and OHU 07633 HP (including ATEX) Screw Compressor Units
Table 5: Unit and pipe name plate information
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 third 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 maximum 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
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 the 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 number of the
notified body or third 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
TheEurAsian Conformity mark (EAC) indicates that the unit
is in compliance with all relevant technical regulations of the
Eurasian Customs Union.
SAB 193-233-283 OHU 09135, OHU 10737, and OHU 07633 HP (including ATEX) Screw Compressor Units18
Note: Locate the main supply voltage on the motor and/or electrical name plate.
Compressor name plate
Figure 7: Compressor name plate
Figure 8: Refrigerant plates
Note: The compressor is fitted with a name plate, as shown in Figure 7, and one of the two
refrigerant name plates, as shown in Figure 8.
The rotary screw compressor serial numbers contain the following information:
19SAB 193-233-283 OHU 09135, OHU 10737, and OHU 07633 HP (including ATEX) Screw Compressor Units
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 the following information:
Table 6: Compressor name plate 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.
Compressor name plate - ATEX
Figure 9: Name plate for an ATEX compressor
The ATEX compressor name plate contains the following information:
SAB 193-233-283 OHU 09135, OHU 10737, and OHU 07633 HP (including ATEX) Screw Compressor Units20
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Sabroe SAB 193/233/283 Operating instructions

Brand
Sabroe
Model
SAB 193/233/283
Type
Operating instructions
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