SABROE SAB 283 Manual de usuario
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
Este manual sirve para los siguientes modelos
1
Tabla de contenidos
Otros manuales de Compresor de aire de SABROE
