Johnson Controls SAB 355 - Service Instructions

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Engineering manual - SAB 355 Screw compressor unit (including ATEX)

004100 en 2020.10

139/156

Service instructions

13. Service instructions

Please contact your local Johnson Controls representative about service-related issues.

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Table of Contents5
Introduction11
Purpose11
Main Users11
Compressor Name, Sabroe/Frick11
Amendments to the Manual12
Manufacturer's Information12
Safety Precaution Definitions Used in this Manual13
Requirements for Competent Persons13
Signs and Warnings14
Main Users14
Identification of Johnson Controls Denmark Equipment15
Compressor Name Plate16
Compressor Name Plate - ATEX17
Labelling of Explosion-Proof Equipment18
Vessel Name Plate19
Unit/Pipe System Name Plate20
Signs22
Safety Precautions23
Areas of Application23
Application of the Screw Compressor23
Application of Combustion Engines23
Safety Precautions24
General Precautions24
Work Area Safety24
During Operation24
Safety During Maintenance and Service25
Electrical Installations26
Power Supply26
Lubricating Oils27
Refrigerants27
Purging a Refrigeration Plant27
F-Gas Regulation (Fluorinated Greenhouse Gases)27
First Aid for Accidents with Ammonia30
First Aid for Accidents with HFC/HCFC31
Protecting the Operator as Well as the Environment32
Technical Description35
Description of the Compressor35
Marine Application37
Description of Main Components and Systems38
Control System38
Compressor39
Variable Speed Drive (VSD)41
Suction Filter with Built-In Non-Return Valve42
Compressor Lubrication System42
No Pump Oil System43
Demand Pump Oil System43
Flow Security43
Compressor Oil Separation System43
Automatic Oil Return Valve47
External Oil Filter48
Unit with Double Oil Filter48
Compressor Hydraulic System49
Compressor Oil Cooling Systems50
Suction Check Valve By-Pass52
Requirements for Ambient Temperatures and Humidity54
Balance Piston Pressure Regulator55
Oil Carry-Over to Plant56
Selecting Lubricating Oil for Sabroe Screw Compressors57
Oil Charge57
Heating Rod Element for Oil Heating, Pos. 3057
Oil Level Switch58
Cold-Start System58
Compressor Protecting System, Pos. 220 and 22159
Oil Cooling System and General Piping Layout60
Liquid Injection Oil Cooling61
Thermosyphon Oil Cooling62
Water-Cooled Oil Cooling64
KRACHT Oil Pump64
Economiser, High-Stage (Optional)66
General Key to Piping Diagram69
General Piping Diagram71
General Key to Piping Diagram - Continued72
Instrumentation73
Physical and Connection Data75
Physical Data75
Connection Data76
Connections to the Compressor Unit76
Electrical Connections80
List of Components81
Technical Data83
Data for SAB 35583
Other Data84
Selection of Vibration Dampers84
Planning the Machine Room85
Minimum Compressor Flow at 3550 Rpm85
Operating Limits85
Motor Selection and Starting Torque86
Motor/Compressor Torque88
Direction of Rotation89
Emergency Stop89
Other Emergency Stop Requirements89
Series 52 Coupling90
Noise Data90
Vibrations and Test Pressure Levels91
Vibration Data for Compressors (All Compressor Types)91
Test Pressure Levels for Standard Compressors and Components93
Installation Instructions94
Installation94
Safety Precautions94
Installation Data94
Installation and First Start-Up Procedure94
Installation Drawings94
Personnel Requirements95
Preparing the Installation95
Tools and Accessories95
Safety Equipment95
Local Regulations95
Preparing the Mounting Site96
Space Requirements96
Lifting Accessories and Equipment96
Preparing Lifts96
Lifting and Loading Instructions96
Unpacking and Inspection96
Disposal of Non-Reusable Materials96
Moving the Equipment to the Mounting Site96
Alignment of Compressor and Unit97
Alignment of Unit against Foundation97
Laying the Unit Foundation98
Mounting Directly on the Foundation98
Mass Damping between Unit and Building99
Damping Using Vibration Dampers99
VSD Equipment102
Calculation of Centre of Gravity, Support Reactions and Tipping Angle104
Auxiliary Tools for Coupling Alignment107
Mounting of Series 52 Coupling108
Alignment Procedure for Coupling110
Piping Connections112
Connecting Electricity Supply114
Pressure Testing115
Evacuation of the Refrigeration Plant116
Oil Charging116
Final Installation Check117
Components118
Unisab III119
Settings120
Control System120
Operating Instructions121
Maintenance Instructions122
Safety Precautions122
Maintenance of Compressor Unit122
Stopping Routine123
Long-Term Storage123
Maintenance Intervals124
Visual Inspection125
Measures to be Taken125
General Rules for Use of Lubricating Oil in Refrigeration Compressors127
Assessing the Oil127
Visual Assessment128
Analytical Evaluation128
Analysing the Oil128
Oil Change129
Charging Compressor with Lubricating Oil130
Oil Charge132
Motor132
Fault-Finding Instructions133
How to Carry out Faultfinding133
Troubleshooting134
Service Instructions139
Transport Instructions140
Safety Precautions140
Transport Data141
Personnel Requirements141
Handling of Compressor and Unit141
Loading Instructions143
Preparations before Lifting143
Loading143
Transport Instructions143
Transport Regulations144
Unpacking and Inspecting the Unit144
Moving the Equipment to the Mounting Site144
Storage144
Commissioning Instructions145
Safety Precautions145
Preparations for Commissioning145
Preparations on the Mounting Site146
Evacuation and Charging of Refrigerant146
Start-Up147
Commissioning Set147
Commissioning Checklist148
Spare Parts List149
Spare Parts Drawings150
Final Disposal151
Safety Precautions151
Waste Disposal151
Torque152
Index153

Johnson Controls SAB 355 - Service Instructions

Table of Contents

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