Sabroe SAB 283-355 A-Frame OHU 6042 and OHU 7650 Operating instructions

Form Number: 004059 en 2023.09

Supersedes: 004059 en 2019.11

Operation Guide

Issue Date: 2023-09-21

SAB 283-355 A-Frame OHU 6042 and

OHU 7650 (including ATEX) Screw

Compressor Unit

2 SAB 283-355 A-Frame OHU 6042 and OHU 7650 (including ATEX) Screw Compressor Unit

Contents

ContentsManual for SAB 283 and 355 screw compressors.........................................................................................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..................................................................................................................... 20

Compressor name plate - ATEX................................................................................................................ 22

Labelling of explosion-proof equipment.......................................................................................... 23

ATEX............................................................................................................................................................. 23

Geometrical swept volume.................................................................................................................24

Vessel name plate................................................................................................................................24

Safety precautions..........................................................................................................................................27

Signs...................................................................................................................................................... 27

General..................................................................................................................................................28

During operation................................................................................................................................. 28

Ventilation................................................................................................................................................... 29

Rotating parts.............................................................................................................................................29

Vibration and noise....................................................................................................................................29

Pressure.......................................................................................................................................................29

Cooling water system................................................................................................................................ 29

Safety during maintenance and service........................................................................................... 29

ATEX............................................................................................................................................................. 30

Electrical installations..........................................................................................................................30

ATEX............................................................................................................................................................. 30

Power supply.............................................................................................................................................. 31

Lubricating oils.....................................................................................................................................31

Refrigerants................................................................................................................................................ 31

Purging a refrigeration plant............................................................................................................. 32

F-gas regulation (fluorinated greenhouse gases)...........................................................................32

Bans on GWP.............................................................................................................................................. 33

Labelling...................................................................................................................................................... 33

Leakage test................................................................................................................................................33

Recovery of refrigerant..............................................................................................................................33

Certification of personnel..........................................................................................................................33

Record keeping...........................................................................................................................................33

SAB 283-355 A-Frame OHU 6042 and OHU 7650 (including ATEX) Screw Compressor Unit 3

Sound and noise data......................................................................................................................... 34

Noise data................................................................................................................................................... 34

Noise data for SAB 283 and SAB 355....................................................................................................... 34

Installation...................................................................................................................................................... 35

ATEX.......................................................................................................................................................36

Operating instructions.................................................................................................................................. 37

Description of the unit........................................................................................................................ 37

Control system........................................................................................................................................... 37

Principle drawing....................................................................................................................................... 37

General P&I diagram...........................................................................................................................40

P&I diagram - liquid injection............................................................................................................ 43

Valve positions during operation.............................................................................................................44

Descriptions of main components and systems............................................................................. 45

Compressor..........................................................................................................................................45

Compressor lubrication system.........................................................................................................46

No pump oil system............................................................................................................................ 47

Demand pump oil system.................................................................................................................. 47

Compressor oil separation system....................................................................................................47

Automatic oil return valve.................................................................................................................. 48

Function.......................................................................................................................................................48

Cold-start system.................................................................................................................................49

High-stage units.........................................................................................................................................50

Booster applications.................................................................................................................................. 50

Compressor hydraulic system............................................................................................................51

Single-acting mode, high-stage (> 10 bar pressure differential)......................................................... 52

High-stage compressor loading...............................................................................................................52

High-stage compressor unloading.......................................................................................................... 52

Double-acting mode, booster (< 10 bar pressure differential)............................................................ 52

Booster compressor loading.................................................................................................................... 53

Booster compressor unloading................................................................................................................53

Volumizer volume ratio (VI) control.................................................................................................. 53

Compressor VI increase......................................................................................................................53

Compressor VI decrease.....................................................................................................................54

Compressor oil cooling systems........................................................................................................54

Liquid injection........................................................................................................................................... 54

Suction check valve by-pass............................................................................................................... 54

Balance piston pressure regulator.................................................................................................... 55

Low ambient temperature operation............................................................................................... 57

Heating element.................................................................................................................................. 57

ATEX............................................................................................................................................................. 57

Start-up................................................................................................................................................. 57

Preparations before start-up....................................................................................................................57

SAB 283-355 A-Frame OHU 6042 and OHU 7650 (including ATEX) Screw Compressor Unit4

Initial start-up procedure................................................................................................................... 58

Motorised oil injection valve.....................................................................................................................58

Correct setting at first start-up.................................................................................................................58

Method selection........................................................................................................................................59

Initial start-up guidelines..........................................................................................................................59

Normal start-up procedure.......................................................................................................................60

Restarting the compressor unit after control power interruption, plant power failure................... 60

Stopping routine..................................................................................................................................60

Brief stop.....................................................................................................................................................60

Shut down for long periods...................................................................................................................... 60

Long term storage...............................................................................................................................60

Secondary system.......................................................................................................................................... 61

General information............................................................................................................................61

Guidelines for the control of secondary sides................................................................................. 61

Off condition operation.............................................................................................................................61

Cleaning in place..................................................................................................................................61

Temperature and flow control........................................................................................................... 62

Water and brine treatment................................................................................................................ 62

R717 detector....................................................................................................................................... 62

Troubleshooting............................................................................................................................................. 63

Refrigeration plant, general issues................................................................................................... 63

Compressor unit, general issues....................................................................................................... 63

Compressor unit - oil separation.......................................................................................................65

Compressor block................................................................................................................................65

Demand oil pump system, optional.................................................................................................. 66

Maintenance instructions............................................................................................................................. 67

Maintenance of compressor unit...................................................................................................... 67

Daily maintenance, perform a minimum of twice a week.................................................................... 67

Periodic maintenance................................................................................................................................67

Major overhaul........................................................................................................................................... 67

Monitoring of operation..................................................................................................................... 69

Checklist...................................................................................................................................................... 69

Oil..................................................................................................................................................................... 71

Oil change.............................................................................................................................................71

Charging the compressor with lubricating oil................................................................................. 71

Sampling the oil................................................................................................................................... 73

Motor.....................................................................................................................................................75

Motor lubrication....................................................................................................................................... 75

Replacing the motor bearings..................................................................................................................75

Final disposal.................................................................................................................................................. 76

Safety precautions...............................................................................................................................76

Waste disposal..................................................................................................................................... 76

5SAB 283-355 A-Frame OHU 6042 and OHU 7650 (including ATEX) Screw Compressor Unit

Machine parts.............................................................................................................................................76

Oil and refrigerant..................................................................................................................................... 76

Electric components.................................................................................................................................. 76

Batteries...................................................................................................................................................... 76

Compliance..................................................................................................................................................... 77

Declaration of conformity...................................................................................................................77

SAB 283-355 A-Frame OHU 6042 and OHU 7650 (including ATEX) Screw Compressor Unit6

Manual for SAB 283 and 355 screw compressors

Table 1: Manual for SAB 283 and 355 screw compressors

Unit no.

Compressor r283 r355

Compressor type rSrLrErX

Bearing

configuration

(355 only)

rSGCB/SGXBrSGCH/SGXH

Oil separator type rOHU 7650/6050 rOHU 6042/5030

Refrigerant rR717 rHFC/HCFC __________ Other: _________________________

Oil type Oil type:

_________________________________________

Evap temp:

________________

Cond temp:

_________________

Control rUnisab III rNone rOther

Oil filter rSingle rDual

rRefrigerant-cooled oil cooler rWater-cooled oil cooler

Oil cooling rLiquid injection in compressor rSingle port

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 filter rpcs.

Unisab setting values Separator velocity ref. _______________ Separator velocity ref. CR________________

7SAB 283-355 A-Frame OHU 6042 and OHU 7650 (including ATEX) Screw Compressor Unit

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 283-355 A-Frame OHU 6042 and OHU 7650 (including ATEX) Screw Compressor Unit8

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 a spare part lists.

For more information, go to http://www.sabroe.com.

This manual covers the following types of units:

• SAB 283 S

• SAB 283 L

• SAB 283 E

• SAB 283 X

• SAB 355 S

• SAB 355 L

• SAB 355 E

• SAB 355 X

Note: This compressor range has two different oil separators. The OHU 6042/5030, referred

to as the OHU 6042 in this manual, and the OHU 7650/6050 which is a bigger compressor,

referred as the OHU 7650 in this manual.

Both the SAB 283 and the SAB 355 compressors can use either oil separators depending on the

operating conditions.

All P&I diagrams in this manual use American standards.

9SAB 283-355 A-Frame OHU 6042 and OHU 7650 (including ATEX) Screw Compressor Unit

Compressor name, SABROE and Frick

The compressor in a SABROE SAB 283 and 355 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 283 S SGC 2813

SAB 283 L SGC 2817

SAB 283 E SGC 2821

SAB 283 X SGC 2824

SAB 355 S SGC 3511

SAB 355 L SGC 3515

SAB 355 E SGC/SGX 3519

SAB 355 X SGC/SGX 3524

SAB 283-355 A-Frame OHU 6042 and OHU 7650 (including ATEX) Screw Compressor Unit10

Amendments to the manual

2023.09 Version 3

• Added bearing configuration information to the section.

• Update to 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 Geometrical swept volume table in the Geometrical swept volume section.

• Update to oil types in the Lubricating oils section.

• Updated the noise data table in the Noise data section.

• Updated the principle drawings in the Description of the unit section.

• Updated general P&I drawings in the General P&I diagram and P&I diagram - liquid injection

sections.

• Updated the valve positions during operation table in the P&I diagram - liquid injection

section.

• Updated the Compressor section.

• Updated the Compressor lubrication system section.

• Updated the Compressor oil separation system section.

• Updated the Compressor hydraulic system section.

• Updated the Compressor oil cooling systems section.

• Updated the Balance piston pressure regulator section.

• Added new Secondary system section.

• Updated the torque requirements table in the Maintenance of compressor unit section.

• Updated the oil charging table in the Oil change section.

• Added new Sampling the oil procedure.

• Implemented various style and document improvements throughout document.

2019.11 Version 2

• Added information about motorised oil injection valve in the ‘Initial start-up procedure’

section.

• Updated general piping diagram.

• New compressor name plates.

• The copies of the declarations of conformity (Unit and ATEX) are now only contained in the

printed manual delivered with the unit and the PDF version uploaded with the order specific

documentation.

• Various minor changes.

2017.12 Version 1

• ATEX information has been added, for example table with temperature classes.

• Name plates with EurAsian Conformity mark (EAC) have been added.

• ‘F-gas regulation’ section has been updated.

• ‘Monitoring of operation’ section has been added, including copy of checklist for

commissioning and start-up.

• ‘Requirements for competent persons’ section has been added.

• ‘Noise data’ section has been updated.

• Declarations of conformity, unit and ATEX, have been added.

• And more.

11SAB 283-355 A-Frame OHU 6042 and OHU 7650 (including ATEX) Screw Compressor Unit

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

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 283-355 A-Frame OHU 6042 and OHU 7650 (including ATEX) Screw Compressor Unit12

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/unit according to EN 13313.

• Operators and maintenance personnel must carefully read, understand, and fully comply with

all alarms and instructions.

13SAB 283-355 A-Frame OHU 6042 and OHU 7650 (including ATEX) Screw Compressor Unit

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:

• You must 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.

• You must only use the compressor with the refrigerant(s) and number of revolutions per

minute, as shown on the compressor name plate. You must only use other refrigerants in

accordance with Johnson Controls Denmark's instructions. You must 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 1: 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 a 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 283-355 A-Frame OHU 6042 and OHU 7650 (including ATEX) Screw Compressor Unit14

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 283-355 A-Frame OHU 6042 and OHU 7650 (including ATEX) Screw Compressor Unit

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 2: Name plate for standard unit, with CE mark

SAB 283-355 A-Frame OHU 6042 and OHU 7650 (including ATEX) Screw Compressor Unit16

Figure 3: Name plate for ATEX unit

Figure 4: Name plate for standard unit, without CE mark

17SAB 283-355 A-Frame OHU 6042 and OHU 7650 (including ATEX) Screw Compressor Unit

Figure 5: Name plate for unit with EurAsian Conformity mark (EAC)

The unit name plate is positioned on the frame and contains the following information:

Table 4: Unit and pipe name plate 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

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.

SAB 283-355 A-Frame OHU 6042 and OHU 7650 (including ATEX) Screw Compressor Unit18

Table 4: Unit and pipe name plate information

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.

Sabroe SAB 283-355 A-Frame OHU 6042 and OHU 7650 Operating instructions

Sabroe SAB 283-355 A-Frame OHU 6042 and OHU 7650 Operating instructions

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