SABROE SAB 202 Bedienungsanleitung

Operating manual

SAB 202

Screw compressor unit

0175-168 ENG

1/380175-168 - ENG

Rev. 2005.09

Operating Manual - SAB 202

Manual for SAB 202

The screw compressor and the unit may be fitted

with different equipment, depending on their func-

tions and requirements.

Part of this equipment is described in this manual

although it may not be fitted on your particular

unit.

In the table, the x mark indicates which equipment

is fitted on your particular unit with the compressor

number stated below.

Compressor SM ❏LM ❏SF ❏LF ❏

Compressor no.

Refrigerant ❏R717 ❏HFC/HCFC: ______ ❏Other: ______

Control

Transducers and manual regulation of Vi slide

UNISAB II and manual regulation of Vi slide

UNISAB II and automatic regulation of Vi slide

Oil filter

Internal

External

Oil cooling

Water cooled oil cooler

❏ OWRF ❏ OWTF Other: ______

Refrigerant cooled oil cooler OOSI

Refrigerant injection in compressor ❏ HLI ❏ BLI

Oil separator

With 1 discharge valve

With 2 discharge valves

Oil temp.reg. Thermostatic oil valve

Economizer

system

(ECO-system)

With vessel type HESS

With closed system and vessel type EOSE

With open system and vessel type SVER

Ex-execution Compressor and unit are safeguarded

Introduction to operating manual

2/38 0175-168 - ENG

Rev. 2005.09

Operating Manual - SAB 202

Introduction to operating manual

The purpose of this manual is to describe:

•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 act when problems occur during

operation.

•Scheduled maintenance tasks for the

equipment and when/how to carry them

out safely.

This manual is primarily intended for operators

and service engineers.

In order to prevent accidents, assembly and dis-

assembly of components should be carried out by

authorised personnel only.

•It is important that the operating personnel

familiarize themselves with the contents of

this manual in order to ensure proper and

efficient operation. Sabroe Refrigeration

(YORK Denmark ApS) - hereafter referred

to as Sabroe Refrigeration - is not liable for

damage occurring during the warranty peri-

od where this is attributable to incorrect op-

eration.

Sabroe Refrigeration's manual concept covers six

standard manuals: Engineering, Operating, Serv-

ice, Installation and commissioning, Transport,

and Spare parts.

Therefore, reference may be made to sections

which are not part of this manual.

This manual is produced by:

Sabroe Refrigeration (YORK Denmark ApS)

Chr. X’s Vej 201, P.O. Box 1810

8270 Højbjerg, Denmark

Phone +45 87 36 70 00

Fax +45 87 36 70 05

www.sabroe.com

Reg. No 19 05 61 71

This manual must not be copied without the writ-

ten permission of Sabroe Refrigeration and the

contents must not be imparted to a third party nor

be used for any unauthorised purposes.

Contravention will be prosecuted.

In the space below you may enter the name and address of your local Sabroe representative

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Rev. 2005.09

Operating Manual - SAB 202

Contents

Manual for SAB 202 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

Introduction to operating manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

Contents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Areas of application of screw compressor unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

Application . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

Application of combustion engines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

Signs and Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

Identification of Sabroe Refrigeration equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

Unit pipe system name plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

Compressor name plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

Vessel name plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

Signs in instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

The sign: CAUTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

The sign: HIGH VOLTAGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

The sign: The temperature of tangible surfaces . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

The sign: Internal protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

Other warning signs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

Emergency stop . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

Safety at service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

Warnings in instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

Texts marked with Danger! . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

Texts marked with Warning! . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

Texts marked with Caution! . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

Safety precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

General safety instructions and considerations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

Personal safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

Work area safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

Tool safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

Operation safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

Maintenance safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

Lubricating oils . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

Refrigerants . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

Cooling water systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

Noise data for screw compressors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

Operating instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

Safety precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

Ventilation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

Hot and cold surfaces . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

UNISAB II reading, safety and capacity regulating system . . . . . . . . . . . . . . . . . . . . . . . . 19

Valves for operating the compressor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

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Preparations before start . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

Starting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

Principle drawing - position during operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

Checks to be performed during operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

Operations log . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

Stopping routine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26

Brief stop . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26

Shutting down for long idle period . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26

Problems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26

Fault finding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26

Maintenance instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27

Maintenance of the compressor unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27

General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27

Major service intervals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .28

Checking the oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29

Visual inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30

Oil level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30

Oil level glass . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30

Oil change . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30

Oil charging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31

Motor lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34

Replacing motor bearings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34

Major overhaul of the compressor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34

Final disposal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35

Safety precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35

Disposal of machine parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35

Disposal of oil and refrigerant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35

Disposal of electrical components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35

Disposal of batteries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35

Appendices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36

References to instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36

Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37

Areas of application of screw compressor unit

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Operating Manual - SAB 202

Areas of application of screw compressor unit

Application

To prevent unintentional application of the com-

pressor, which could injure personnel or damage

the equipment, the following must be observed:

•The compressor must only be used as a re-

frigeration compressor with the number of

revolutions per minute and within the oper-

ating limits specified in the manuals or in a

written agreement with

Sabroe Refrigeration.

•The compressor must only be used with the

following refrigerants: R717, R22, R134a,

R404A, R507, R600, R600A, R290 and

LPG. Other HFC refrigerants must only be

used in accordance with

Sabroe Refrigeration's instructions. All oth-

er types of gas must only be used with a

written permission from

Sabroe Refrigeration.

•The compressors are approved for applica-

tion in potentially explosive atmospheres

provided they have been fitted with explo-

sion-proof equipment. This can be seen

from the Ex name plates fixed on each unit.

See Fig. 1.

Fig. 1

Please note that special tools which do not cause

any sparks must be used for ALL maintenance

work on the compressor.

WWarning!

Sabroe Refrigeration is not liable for injuries to

personnel or damage to equipment resulting from

using the equipment for other purposes than the

ones stated above.

Application of combustion engines

If combustion engines are installed in rooms con-

taining refrigeration machinery or rooms where

there are pipes and components containing refrig-

erant, make sure that in case of leakage the com-

bustion air for the engine comes from an area in

which there is no refrigerant gas.

Failure to do so involves a risk of lubricating oil

from the combustion engine mixing with refriger-

ant. At worst this may lead to corrosion and dam-

age of the engine.

WWarning!

The compressor must NOT be used:

•For evacuating the refrigeration plant of

air and moisture.

•For putting the refrigeration plant under

air pressure in view of a pressure test-

ing.

•As an air compressor.

Signs and Warnings

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Operating Manual - SAB 202

Signs and Warnings

Identification of Sabroe Refrigeration equipment

All Sabroe Refrigeration equipment can be identified by one or several name plates positioned as illus-

trated in the following drawing:

Fig. 2 SAB 202 screw compressor unit, position of name plates

1. Compressor name plate

2. Vessel name plate

3. Unit pipe system name plate

Signs and Warnings

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Operating Manual - SAB 202

Unit pipe system name plate

Fig. 3 Unit pipe system name plate

The unit pipe system name plate is positioned on

the frame. The name plate contains the following

information:

•Type

Manufacturer's type designation.

•Year

Year of manufacture.

• Identification no.

Individual no. for identification of supplied

pipe system.

• Design code

For PED orders: EN 378-2

If the unit has been approved by an author-

ity, the design code will be shown here.

• Approval no.

If the unit has been approved by an author-

ity, the approval no. will be shown here.

• Pressure system

Low pressure side of compressor piping is

referred to as LP.

High pressure side of compressor piping is

referred to as HP.

• Fluid/Group

Refrigerant designation according to

ISO817 or fluid group according to directive

67/548/EEC.

• Max. allowable pressure, PS

Shows max allowable pressure relative to

atmospheric pressure for which the pipe

system has been designed.

• Leak test pressure, PT

Shows the pressure with which the pipe sys-

tem has been leak tested.

• Design temperature, TS

Shows min and max temperatures for which

the pipe system including components has

been designed.

• CE xxxx

The four digits compose the registration no.

of the notified body in charge of the assess-

ment modules for the vessel.

Signs and Warnings

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Operating Manual - SAB 202

Compressor name plate

Fig. 4 Compressor name plate

The compressor name plate is positioned on the

compressor. The plate contains the following in-

formation:

• Compressor no.

Compressor manufacturing number.

• Year

Year of manufacture.

•Type

Manufacturer's type designation.

• Nominal speed

Shows rotational speed of drive shaft at typ-

ical running condition.

• Swept volume

Shows swept volume of compressor in m3/h

at nominal speed.

• Max allowable pressure, Ps

Shows max. working pressure of compres-

sor.

• Max allowable pressure, Pss

Shows max allowable pressure at compres-

sor standstill.

Signs and Warnings

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Vessel name plate

Fig. 5 Vessel name plate

The vessel name plate is positioned on the shell

of the vessel. The name plate contains the follow-

ing information:

• Vessel no.

Vessel number stated by

Sabroe Refrigeration.

•Year

Year of manufacture.

•Type

Manufacturer's type designation.

• Design code

Shows the design code according to which

the vessel was manufactured.

• Approval no./CAT

Shows the approval no. of the vessel issued

by the relevant authority as well as the cat-

egory according to PED 97/23/EEC,

Article 9.

•Side

Refers to the columns “Shell” and “Tube”.

• Fluid

Shows the refrigerant designation accord-

ing to ISO817.

• Allowable pressure, PS

Shows min and max pressure relative to at-

mospheric pressure for which the vessel or

vessel part has been designed.

• Allowable temperature, TS

Shows min and max temperatures for which

the vessel has been designed.

• Volume

Shows volume of the vessel in litres.

• CE xxxx

The four digits compose the registration no.

of the notified body in charge of the assess-

ment modules for the vessel.

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