Johnson Controls Sabroe SAB 233 S - Service Instructions

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Engineering manual - SAB 193-233-283 S A-frame (including ATEX)

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008831 en 2020.10

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 Equipment14
Compressor Name Plate15
Compressor Name Plate - ATEX16
Labelling of Explosion-Proof Equipment17
Vessel Name Plate18
Unit/Pipe System Name Plate19
Signs21
Safety Precautions22
Areas of Application22
Application of the Screw Compressor22
Application of Combustion Engines22
Safety Precautions23
General Precautions23
Work Area Safety23
During Operation23
Safety During Maintenance and Service24
Electrical Installations25
Power Supply25
Lubricating Oils26
Refrigerants26
Purging a Refrigeration Plant26
F-Gas Regulation (Fluorinated Greenhouse Gases)27
First Aid for Accidents with Ammonia29
First Aid for Accidents with HFC/HCFC30
Protecting the Operator as Well as the Environment31
Technical Description34
Description of the Screw Compressor34
Marine Application36
Description of Main Components and Systems37
Control System37
Compressor38
Variable Speed Drive (VSD)39
Compressor Lubrication System40
Oil Injection Valve40
No Pump Oil System41
Demand Pump Oil System41
Flow Security41
Compressor Oil Separation System41
Automatic Oil Return Valve44
External Oil Filter45
Unit with Double Oil Filter46
Compressor Hydraulic System46
Compressor Oil Cooling Systems48
Suction Check Valve By-Pass49
Requirements for Ambient Temperatures and Humidity51
Oil Carry-Over to Plant52
Selecting Lubricating Oil for Sabroe Screw Compressors53
Oil Charge53
Heating Rod Element for Oil Heating, Pos. 3053
Oil Level Switch54
Cold-Start System54
Compressor Protecting System, Pos. 220 and 22156
Oil Cooling System and General Piping Layout57
Liquid Injection Oil Cooling57
Thermosyphon Oil Cooling59
Water-Cooled Oil Cooling61
Connection to Alfanova Oil Cooler62
KRACHT Oil Pump63
Economiser, High-Stage (Optional)64
General Piping Diagram68
Key to Piping Diagram71
Instrumentation73
Physical and Connection Data75
Physical Data75
Allowable Flange Loads76
Mounting of Suction Isolation Valve77
Connection Data78
Connections to Compressor Unit78
Electrical Connections84
List of Components85
Technical Data87
Data for Compressor Units87
Other Data88
Planning the Machine Room89
Minimum Compressor Flow at 3550 Rpm90
Operating Limits91
Selecting Electric Motor92
Motor Dimension92
Motor Selection and Starting Torque93
Motor/Compressor Torque94
Direction of Rotation95
Emergency Stop95
Other Emergency Stop Requirements95
Noise Data96
Noise Data for SAB 193-233-28396
Vibrations and Test Pressure Levels97
Vibration Data for Compressors (All Compressor Types)97
Test Pressure Levels for Standard Compressors and Components99
Installation Instructions100
Installation100
Safety Precautions100
Installation Data100
Installation and First Start-Up Procedure100
Installation Drawings100
Personnel Requirements101
Preparing the Installation101
Tools and Accessories101
Safety Equipment101
Local Regulations101
Preparing the Mounting Site101
Space Requirements102
Lifting and Loading Instructions102
Unpacking and Inspection102
Disposal of Non-Reusable Materials102
Moving the Equipment to the Mounting Site102
Alignment of Compressor and Unit103
Alignment of Unit against Foundation103
Alignment of Compressor and Motor103
Laying the Unit Foundation106
Mounting Directly on the Foundation106
Mass Damping between Unit and Building107
Damping Using Vibration Dampers107
VSD Equipment110
Calculation of Centre of Gravity, Support Reactions and Tipping Angle112
Sab 193 S113
Sab 193 L113
Sab 233 S116
Sab 233 L116
Sab 233 E116
Sab 283 S116
Sab 283 L117
Sab 283117
Instruction for Mounting of Coupling120
BPU Coupling Installation Procedure121
Piping Connections123
Connecting Electricity Supply124
Pressure Testing125
Evacuation of the Refrigeration Plant126
Oil Charging126
Final Installation Check127
Components128
Unisab III129
Settings130
Control System130
Operating Instructions131
Maintenance Instructions132
Safety Precautions132
Maintenance of Compressor Unit132
Stopping Routine133
Long-Term Storage133
Visual Inspection135
Measures to be Taken135
General Rules for Use of Lubricating Oil in Refrigeration Compressors137
Assessing the Oil137
Visual Assessment138
Analytical Evaluation138
Analysing the Oil138
Charging Compressor with Lubricating Oil139
Oil Charge142
Motor143
Faultfinding Instructions144
How to Carry out Faultfinding144
Troubleshooting145
Service Instructions150
Transport Instructions151
Safety Precautions151
Transport Data152
Personnel Requirements152
Handling of Compressor and Unit152
Loading Instructions153
Preparations before Lifting153
Loading153
Transport Instructions154
Transport Regulations154
Unpacking and Inspecting the Unit154
Moving the Equipment to the Mounting Site154
Storage154
Commissioning Instructions156
Safety Precautions156
Preparations for Commissioning156
Preparations on the Mounting Site157
Evacuation and Charging of Refrigerant157
Start-Up158
Commissioning Set158
Commissioning Checklist159
Spare Parts List160
Spare Parts Drawings161
Final Disposal162
Safety Precautions162
Waste Disposal162
Appendices163
Index164

Johnson Controls Sabroe SAB 233 S - Service Instructions

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