SAB 151 Engineering Service and Maintenance Manual 2014.03

Engi n e e r i n g , S e r v i c e a n d Ma int e nan ce m an ual
Screw compressor unit

SAB 151 A-frame
en

Manual for SAB 151 A-frame screw compressors
Unit no.
Compressor
120 151
Compressor type
S M L E
Refrigerant
R717 HFC/HCFC ____ Other: _________
Oil type
Oil type: ______________ Evap. temp. _______ Cond. temp. _______
Control
Unisab III None Other
Oil filter
Single Dual
Refrigerant cooled oil cooler Water cooled oil cooler

Oil cooling
Liquid injection in compressor Single port Dual port
Discharge port
Standard AC/Low Vi ports
Oil pump
Economizer system
(ECO-system) Economizer connection Economizer type _________
Ex-execution (ATEX)
Motor 3 x _________V / _________ Hz
Supply voltage
Control 1 x _________V / ________ Hz
Heating elements (phasing)1 x _________V / ________ Hz
IP23 IP55
Power ______ kw Size IEC ______ Pole no. 4 Pole no. 2

Motor
Anti condensation heater
Max. rel. humidity = 85% (Std.) Max. rel. humidity = 100%
Approval
PED (97/23/EC) Others ________
Unisab setting values Separator velocity ref. ________ Separator velocity ref. CR ________
Engineering, Service and Maintenance - SAB 151 A-frame

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Vessel data
External surface Design pressure

Type
[m2] [bar]
Condenser
Evaporator
Liquid separator
Oil separator
Safety valve:
Data for calculation of down-
stream line according to EN Oil cooler
13136
Economizer
Other
Pressure loss, if any, from safety valve to customer connection
(based on design pressure, [bar] _____________
Safety valve type:
Back pressure dependent Back pressure independent

Contents
1. Introduction 9
1.1.1 Purpose 9
1.1.2 Main users 9
1.1.3 Manufacturer's information 9
1.1.4 Safety precaution definitions used in this manual 10
2. Signs and warnings 11

2.1.1 Main users 11
2.1.2 Identification of Johnson Control Denmark equipment 11
2.1.3 Unit/pipe system name plate 12
2.1.4 Compressor name plate 14
2.1.5 Vessel name plate 15
2.1.6 Signs 16
3. Safety precautions 17
3.1. Areas of application 18
3.1.1 Application 18
3.1.2 Application of combustion engines 18
3.2. Safety precautions 19
3.2.1 General precautions 19
3.2.2 Work area safety 19
3.2.3 During operation 20
3.2.4 Maintenance safety/safety at servicing 21
3.2.5 Power supply 22
3.2.6 Lubricating oils 22
3.2.7 Refrigerants 23
3.2.8 Purging a refrigeration plant 23
3.2.9 F-gas regulation (fluorinated greenhouse gases) 23
3.2.10 First aid for accidents with ammonia 25
3.2.11 First aid for accidents with HFC/HCFC 26
3.2.12 Protecting the operator as well as the environment 27
4. Technical description 30
4.1.1 Description of the screw compressor 30
4.1.2 Description of main components and systems 32
4.1.3 Control system 32
4.1.4 Compressor 33
4.1.5 Variable speed drive (VSD) 34

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4.1.6 Compressor lubrication system 35
4.1.7 No pump oil system 35
4.1.8 Demand pump oil system 35
4.1.9 Flow security 35
4.1.10 Compressor oil separation system 35
4.1.11 Automatic oil return valve 38
4.1.12 External oil filter 39
4.1.13 Unit with double oil filter 39
4.1.14 Compressor hydraulic system 40
4.1.15 Capacity control 40
4.1.16 Volumizer II Vi control 41
4.1.17 Compressor oil cooling system 42
4.1.18 Single-port liquid injection 42
4.1.19 Dual-port liquid injection 42
4.1.20 Suction check valve bypass 44
4.1.21 Low ambient temperature operation 44
4.1.22 Oil carry-over to plant 45
4.1.23 Oil level glass, pos. 31 46
4.1.24 Selecting lubricating oil for Sabroe screw compressors 46
4.1.25 Oil charge 46
4.1.26 Heating rods element for oil heating, pos 30 46
4.1.27 Oil level switch 47
4.1.28 Cold-start system 48
4.1.29 Compressor protecting system pos. 220 and 221 49
4.1.30 Oil cooling system and general piping layout 50
4.1.31 Liquid injection oil cooling 51
4.1.32 Thermosyphon oil cooling 52
4.1.33 Water-cooled oil cooling 54
4.1.34 Connection to AlfaNova oil cooler 55
4.1.35 Oil pump pos. 63 56
4.1.36 Economizer - high stage (optional) 57
4.1.37 General key to piping diagram 59
4.1.38 General piping diagram 61
4.1.39 Instrumentation 63
5. Physical and connection data 65

5.1. Physical and connection data 65
5.1.1 Physical data 65
5.1.2 Allowable flange loads 66

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5.1.3 Mounting of suction isolation valve 67
5.2. Connection data 68
5.2.1 Connection to compressor unit 68
5.2.2 Electrical connections 72
5.2.3 List of components 73
6. Technical data 75
6.1.1 Technical data 75
6.1.2 Data for SAB 151 75
6.1.3 Other data 76
6.1.4 Selection of vibration dampers 77
6.1.5 Planning the machine room 77
6.1.6 Minimum compressor flow at 3550 rpm 78
6.1.7 Operating limits 80
6.1.8 Selecting electric motor 81
6.1.9 Motor dimension 81
6.1.10 Motor selection and starting torque 81
6.1.11 Motor/compressor torque 83
6.1.12 Direction of rotation 84
6.1.13 Emergency stop 84
6.1.14 Other emergency stop requirements 84
6.1.15 Noise data 85
6.1.16 Noise data for screw compressor 86
6.2. Noise and vibration 87
6.2.1 Noise from compressors and units 87
6.2.2 Sound power and sound pressure 87
6.2.3 Sound power level, Lw 87
6.2.4 Sound pressure level, Lp 88
6.2.5 Frequency 88
6.2.6 Assessing the measured values 88
6.2.7 How to check sound data 90
6.2.8 Reducing acoustic noise in a machine room 90
6.2.9 Reverberation time 91
6.2.10 Vibration data for compressors - all compressor types 92
6.2.11 Test pressure levels for standard compressors and com-
ponents 93
7. Installation instructions 94
7.1.1 Installation 94
7.1.2 Safety precautions 94
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7.1.3 Installation data 94
7.1.4 Installation and first start-up procedure 94
7.1.5 Installation drawings 94
7.1.6 Personnel requirements 94
7.1.7 Preparing the installation 95
7.1.8 Tools and Accessories 95
7.1.9 Safety equipment 95
7.1.10 Local regulations 95
7.1.11 Preparing the mounting site 95
7.1.12 Space requirements 96
7.1.13 Lifting and loading instructions 96
7.1.14 Unpacking and inspection 96
7.1.15 Disposal of materials which are not reusable 96
7.1.16 Moving the equipment to the mounting site 96
7.1.17 Installation instructions 96
7.1.18 Alignment of compressor and unit 97
7.1.19 Alignment of unit against foundation 97
7.1.20 Alignment of compressor and motor 97
7.1.21 Laying of unit foundation 98
7.1.22 Calculation of centre of gravity, support reactions and
kip angle 101
7.1.23 Instruction for mounting of coupling 106
7.1.24 CH coupling installation procedure 106
7.1.25 Piping connections 107
7.1.26 Connecting electricity supply 109
7.1.27 Pressure testing 110
7.1.28 Evacuation of the refrigeration plant 112
7.1.29 Oil charging 112
7.1.30 Final installation check 113
8. Components 114
8.1.1 The purpose of this chapter 114
8.1.2 Unisab III 115
9. Settings 116
9.1.1 Control system 116
10. Operating instructions 117

10.1.1 Operating instructions 117
11. Maintenance instructions 118

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11.1.2 Maintenance of compressor unit 118
11.1.3 Stopping routine 119
11.1.4 Long term storage 119
11.1.5 Visual inspection 121
11.1.6 Measures to be taken 121
11.1.7 General rules for use of lubricating oil in refrigeration
compressors 123
11.1.8 Assessing the oil 123
11.1.9 Visual assessment 123
11.1.10 Analytical evaluation 124
11.1.11 Analyzing the oil 124
11.1.12 Charging compressor with lubricating oil 126
11.1.13 Oil change 128
11.1.14 Motor 129
12. Fault-finding instructions 130

12.1.1 How to carry out faultfinding 130
12.2. Troubleshooting 130
13. Service instructions 135
14. Transport instructions 136

14.1.2 Transport data 137
14.1.3 Personnel requirements 137
14.1.4 Handling of compressor and unit 137
14.1.5 Loading instructions 138
14.1.6 Preparations before lifting 138
14.1.7 Loading 138
14.1.8 Transport instructions 139
14.1.9 Transport regulations 139
14.1.10 Unpacking and inspecting the unit 139
14.1.11 Moving the equipment to the mounting site 140
14.1.12 Storage 140
15. Commissioning instructions 141

15.1.2 Preparations for commissioning 141
15.1.3 Preparations on the mounting site 142
15.1.4 Evacuation and charging of refrigerant 142
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15.1.5 Start-up 142
15.1.6 Commissioning set 143
15.1.7 Checks to be performed after start-up 143
16. Compliance instructions 144

16.1.1 Declaration of conformity 144
17. Certificates 147

17.1.1 Approvals 147
18. Spare parts list 148
19. Spare parts drawings 149
20. Final disposal 150
21. Appendices 151

21.1.1 Appendix 151
Index 152

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Introduction
1. Introduction
The screw compressor and the unit may be fitted with different equipment, depending on
their functions and requirements. Part of this equipment is described in this manual although
it may not be fitted on your particular unit.
1.1.1 Purpose
The purpose of this manual is to provide all the data usually needed in the sales and planning
phases.
• Description of all components parts
• Description of all important technical functions to increase understanding of the prod-
uct functionality
• Refrigerant safety
• Connecting data
• Installation instructions
1.1.2 Main users

This manual is primarily intended for sales, service and contracting purposes.
All compressor intervention within the warranty period must be performed by authorised per-
sonnel only. If not, the warranty no longer applies.
1.1.3 Manufacturer's information

This manual is produced by:
Johnson Controls Denmark ApS
Christian X's Vej 201
8270 Højbjerg, Denmark
Phone +45 87 36 70 00
Fax +45 87 36 70 05
CVR No 19 05 61 71
www.sabroe.com
Copyright © 2011 Johnson Controls Denmark
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 unauthorized pur-
poses. Contravention will be prosecuted.

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Introduction
1.1.4 Safety precaution definitions used in this manual
Danger!
Indicates an imminently hazardous situation which, if not avoided, will result in death or seri-
ous 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 dam-
age to equipment and/or minor injury.
Note: Indicates an operating procedure, practice, etc. or portion thereof which is essential to
highlight.

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Signs and warnings
2. Signs and warnings
This chapter describes:

• how to identify equipment from Johnson Controls Denmark.
• all warning signs used on equipment delivered by Johnson Controls Denmark.
• how information important to safety of personnel and equipment is presented in in-
structions belonging to equipment delivered by Johnson Controls Denmark.
2.1.1 Main users

Information concerning Signs and warnings is intended for all user categories.
The following describes the importance of the individual signs attached to the Johnson Con-
trols Denmark products.
Before a compressor/unit is put into operation, it must be fitted with the warning signs be-
longing to the type of compressor/unit in accordance with the rules and regulations in force.
2.1.2 Identification of Johnson Control Denmark equipment
All Johnson Controls Denmark equipment can be identified by one or several name plates
placed as illustrated in the following drawing:
Fig. 1
1. Compressor name plate

2. Vessel name plate
3. Unit pipe system name plate

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Signs and warnings
2.1.3 Unit/pipe system name plate
2516-342
BY JOHNSON
CONTROLS
Refrigeration unit No Year
Type
Scope
Design code
Approval No
Refrigerant Fluid Group
Supply voltage Control V/Hz
Refrigerant charge kg
Pressure system LP side HP side
Category
Allowable pressure Max. bar g
Test pressure bar g
Allowable temp. Min/Max. °C
The unit name plate is positioned on the frame and contains the following information:
Refrigeration unit No. Identification no. (serial no.)
Year Year of manufacturing.
Type Manufacturer's type designation.
Scope For EC - PED approval: “Unit & Piping” means that the CE mark
covers the complete unit including the piping system.
“Piping “ means that the CE mark covers the piping system only
and it is the sole responsibility of the owner to ensure and de-
clare that the complete unit is in conformity with the provisions
of all relevant directives.
(See the CE Declaration of conformity).
Design code Design code used for the unit and piping system.
Approval no. If the unit/manufacture has been approved by a 3rd party/noti-
fied body.
Refrigerant - Fluid Refrigerant of the unit.
Refrigerant designation (Rxxx) according to ISO 817.
Refrigerant - Group For EC - PED approval:
Fluid group 1 or 2 according to PED directive.
Supply voltage - Control Supply voltage and frequency of the control system.
Refrigerant charge Weight of refrigerant charge of the unit.
Only stated if the unit includes an evaporator and/or a con-
denser.
Pressure system Low pressure side of the unit piping is referred to as LP-side.
High pressure side of the unit piping is referred to as HP-side.

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Signs and warnings
Category For EC - PED approval:

The maximum category of the piping system (CAT 1, 2 or 3.) or
of the assembly unit and piping (CAT 3 or 4).
Allowable pressure, max. The max. pressure (pressure relative to atmospheric pressure)
for which the unit/piping system has been designed in terms of
pressure strength design. Maximum practical operation pres-
sure is lower than “maximum allowable pressure” depending on
operating conditions and the safety equipment settings.
Test pressure The test pressure with which the unit/piping system has been
strength tested.
Allowable temperature, Minimum and maximum temperatures for which the unit/piping
min./max. system has been designed for at the indicated maximum allow-
able pressures.
CE xxxx The CE mark appears on the name plate for EC - PED approval
only. The four digits compose the registration no. of the notified
body/3rd party in charge.
Ex An Ex mark appears on the name plate if the unit has been de-
signed according to the EC – ATEX directive.
Note: Main supply voltage can be found on the motor and/or electrical panel name plate.

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Signs and warnings
2.1.4 Compressor name plate
Fig. 3
Fig. 2
Note: The compressor is fitted with a Frick name plate, Fig. 2, and one of the two refrigerant
name plates illustrated in Fig. 3.
Rotary screw compressor serial numbers are defined by the following information:
EXAMPLE: 10240A90000015Z
Additional
Plant Decade Month Year Global seq. no. remarks
1024 0 A 9 0000015 Z
Month:
A=JAN, B=FEB, C=MAR, D=APR, E=MAY, F=JUN,
G=JUL, H=AUG, K=SEP, L=OCT, M=NOV, N=DEC
Additional remarks: R = Remanufactured; Z = Deviation from standard configuration

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Signs and warnings
2.1.5 Vessel name plate
The pressure vessel name plate is positioned on the shell of the vessel and contains the fol-
lowing information:
Vessel no. Identification no. (serial no.)
Year Year of manufacturing.
Type Manufacturer's type designation.
Design code Design code used for the pressure vessel.
Approval no./CAT The approval no. of the vessel issued by the relevant 3rd party/
notified body.
For EC - PED approval: CAT (Category 1, 2, 3 or 4) according to
PED directives.
Side For heat exchangers only.
Refers to the columns "Shell" side and "Tube" side of the heat
exchanger.
Fluid Designation of the primary refrigerant(s) and the secondary re-
frigerant(s).
For EC - PED approval: Designation of the refrigerant(s) and/or
the highest fluid group (Group 1 or 2) according to PED direc-
tive.
Allowable pressure, PS Min. and max. pressure (pressure relative to atmospheric pres-
sure) for which the vessel or vessel part has been designed.
Allowable temperature, Min. and max. temperatures for which the vessel or vessel part
TS has been designed.
Volume Volume of the vessel or vessel part.
CE xxxx The CE mark appears on the name plate for EC - PED approval.
The four digits compose the registration no. of the notified
body/3rd party in charge.
Note: Depending on the supplier of the pressure vessel/heat exchanger the layout and con-
tent of the name plate may differ from the Sabroe name plate above.

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Signs and warnings
2.1.6 Signs
All signs which may be found on your equipment are shown below. The number of signs, how-
ever, may vary from one product to another.
High surface
High voltage/ The compressor may be
Risk of electrical shock temperature
High pressure top-heavy
(about 70°C)
Dangerous noise level,

Internal overpressure Hazardous substance Cold surfaces
use hearing protectors
The unit IS filled with

Do not step on surface No open flame Flammable gas
refrigerant R290
Internal protection Pacemaker users keep out
Påfyldt be skytte lsesgas N2

Charge d with ine rt gas
Enthält Schutzgas 0, 5 bar
Chargé du gaz prote cteu r 7.3 PSI
Contien e gas protector 1534-169
Compressor blocks and units are The magnetic field on the rotor The VSD contains capacitors capable
usually delivered without refrigerant may affect pacemakers. of storing electrical energy, ie there
and oil. To protect the compressors The motor rotor contains a powerful is a risk of electrical shock within
against internal corrosion, they are magnetic field. This field may affect 15 minutes after the drive has been
delivered evacuated of all atmos- digital devices such as watches, turned off.
pheric air and charged with dry mobile phones etc.
Nitrogen (N2) to an overpressure of Assembly or maintenance of the
0.5 bar [7.3 PSI]. rotor must not be carried out by
In such cases a yellow sign is affixed people with pacemakers or any other
to a visible spot on the compressor. implanted medical electronic device.

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Safety precautions
3. Safety precautions
This chapter provides general safety precautions for the equipment. Additional safety precau-
tions relating to a specific task are given in specific documents.
The safety precautions are intended for all users.

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Safety precautions
3.1. Areas of application
3.1.1 Application
To prevent unintentional application of the compressor which could injure personnel or dam-
age equipment, the following must be observed:
• The compressor must only be used as a refrigeration compressor and within the oper-
ating limits specified in the manuals or in a written agreement with Johnson Controls
Denmark.
• The compressor must only be used with the refrigerant(s) and number of revolutions
per minute, shown on the compressor name plate. Other refrigerants must only be
used in accordance with Johnson Controls Denmark's instructions. All other types of
gas must only be used with a written permission from Johnson Controls Denmark.
• The unit must not be installed in areas where the relative humidity (RH) may exceed
90%.
• Johnson Controls Denmark further accept no liability of any kind for damage to com-
pressor unit and plant parts caused by torsional oscillation or the like which is attrib-
utable to built-in VSD solutions initiated by the customer after delivery.
• The compressors are approved for application in potentially explosive atmospheres,
provided they have been fitted with explosion-proof equipment. This can be seen from
the Ex name plates fixed on each unit.
Please note that specially made tools which do not cause any sparks must be used for all
maintenance work on the compressor.
The compressor must not be used:
• 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.
3.1.2 Application of combustion engines

If combustion engines are installed in rooms containing refrigeration machinery or rooms with
pipes and components containing refrigerant, make sure that in case of leakage, the air in-
take for the engine comes from an area without refrigerant gas.
Failure to do so involves a risk of lubricating oil from the combustion engine mixing with re-
frigerant. At worst this may lead to corrosion and damage the engine.
Warning!
Johnson Controls Denmark is not liable for injuries to personnel or damage to equipment re-
sulting from using the equipment for other purposes than the ones stated above.

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Safety precautions
3.2. Safety precautions
3.2.1 General precautions

These precautions should be used as a supplement to the safety precautions and warnings in-
cluded in:
• all other manuals pertaining to the compressor/unit.
• local, plant and shop safety rules and codes.
• national safety rules and regulations.
Read and understand all safety instructions before setting up, operating or servicing/perform-
ing maintenance on the compressor/unit. Assign only qualified personnel instructed in safety
and all machine functions to operate or service the compressor/unit.
Operators and maintenance personnel must carefully read, understand and fully comply with
all alarm and instruction plates mounted on the compressor/unit.
• Observe the safety warnings.
• Use ear protection when operating the compressor/unit.
• Use safety equipment. Wear appropriate gloves as well as eye and face protection
when working with parts containing refrigerant and/or lubricating oil. Use proper elec-
trical safety protection.
Note: These instructions only provide general information. The owner of the refrigeration
plant is responsible for ensuring that all codes, regulations and industry standards are com-
plied with.
3.2.2 Work area safety

• Always keep your work area clean. Oil, debris or water on the floor may cause some-
one to fall.
• Make sure your work area is free of hazardous obstructions and be aware of protrud-
ing machine parts.
• Always keep your work area tidy so that you can escape if a dangerous situation
should arise.
• Report unsafe working conditions to your supervisor or safety department.

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Safety precautions
3.2.3 During operation
Warning!
All safety features, disengagement and interlocks must be in place and function correctly be-
fore the equipment is put into operation. Never by-pass or wire around any safety device.
Ventilation
Before operating the unit always check, where relevant, the function of the ventilation system
and refrigerant detectors used in the area where the compressor/unit is located (machine
room).
Rotating parts
Warning!
Safety guards, shields, barriers, covers and protective devices must not be removed while the
compressor/unit is operating.
Vibration and noise

During operation, pay attention to the compressor unit process. Excessive vibration, unusual
sounds etc. may indicate problems requiring your immediate attention.
Pressure
Danger!
A compressor/unit comprises a pressurised system. Never loosen threaded joints while the
system is under pressure and never open pressurised system parts.
Note: Whenever a relief valve/safety valve has been activated, we recommend recalibrating
it. This must be carried out by authorised personnel only. See also EN 378 and existing na-
tional legislation.
Cooling water system
Warning!
The recirculation water system may contain chemicals or biological contaminants, including le-
gionella, which can be harmful if inhaled or ingested. Water systems should only be operated
with an effective biological treatment programme.

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Safety precautions
3.2.4 Maintenance safety/safety at servicing

• Personnel must be qualified according to national safety rules and regulations and
perform the maintenance work according to EN 378.
• Read chapter 3. Safety precautions before opening the compressor and other parts of
the refrigeration plant.
• It is recommended to remove all main fuses. Switch off all electric components on the
compressor/unit before starting the dismantling/servicing process and lock the main
switch.
• Make sure that the motor cannot start up inadvertently.
• Make sure that there is no over-pressure and no refrigerant in the part to be disman-
tled. Close all necessary stop valves.
• Use the prescribed tools and check that they are properly maintained and in good
working condition. In explosion-proof areas, use tools suited for this specific purpose.
• Use only Johnson Controls Denmark original spare parts; other parts may impair the
safety of the compressor/unit.
• When performing maintenance, the main switch must be locked.
• Use gloves and protective goggles and make sure to have a gas mask close at hand.
Also use electrical protection equipment and tools suited for electrical operation pur-
poses.

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Safety precautions
3.2.5 Power supply
Danger!
• The voltage used in the drive can cause severe electrical shock and/or burns and may
be lethal. Extreme care must be taken at all times when working with or close to the
drive. Specific warnings are given wherever relevant in this manual.
• The drive line is connected to voltage. Be aware of live circuits.
• Pay close attention to the electrical installation and system maintenance to avoid haz-
ards both during normal operation or in the event of equipment malfunctioning.
• When the cause of the shutdown has been removed, the motor may restart. This can
be dangerous for machines and installations, and it is therefore important that the
user takes adequate precautions against restarting if the motor makes an unsched-
uled stop.
• System maintenance must always be carried out by personnel who have the necessa-
ry training and experience.
3.2.6 Lubricating oils

Compressor oils include the following oil types:
Code design Oil types
M Mineral oil, naphtenic base
A Synthetic oils based on alkylated aromatics (alkyl-benzene)
AP Synthetic oils blended from alkyl-benzene and poly-alfa-olefin base stocks
S Semi synthetic oils (hydro-treated mineral oil on paraffinic base)
PAO Synthetic oils based on poly-alfa-olefin
POE Synthetic oils based on polyol esters
PAG Synthetic oils based on polyalkylene glycols
When charging oil, follow the safety instructions given by the oil supplier (MSDS: Material
Safety Data Sheet). Always avoid direct contact with the oil as this may cause skin allergies.
Always use protective equipment - goggles and gloves - when charging oil.
When changing oil on the compressor or draining oil from the vessel of the refrigeration plant,
always collect the used oil in containers marked “waste oil” and send them to an approved in-
cineration plant. It is not recommended to reuse oil.

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Safety precautions
3.2.7 Refrigerants
Be very careful when dealing with refrigerants. For safe handling please refer to the safety/
data sheets etc. delivered by the refrigerant supplier.
Warning!
Be aware that large amounts of escaping (or released) refrigerant entail a risk of suffocation.
If in direct contact with leaking liquid refrigerant there is a high risk of injuries caused by in-
tense cold.
3.2.8 Purging a refrigeration plant

Purging of air or other non-condensable gases is required in order to keep high system per-
formance and avoid corrosion of the equipment which could endanger the safety of persons
and equipment.
When purging a refrigeration system, make sure to observe the following:
• Refrigerants must not be released into the atmosphere except CO2, which can be re-
leased slowly into the atmosphere.
• When purging an R717 system, use an approved air purger. The purged air must pass
through an open container or water for any remaining R717 to be absorbed. The wa-
ter mixture must be sent to an authorised incineration plant.
• Halocarbon refrigerants (CFC, HCFC and HFC) cannot be absorbed by water. An ap-
proved air purger must be fitted to the system. This must be checked regularly by use
of a leak detector. All precautionary measures practicable must be taken to prevent
and minimise leakage of refrigerant from refrigeration and air conditioning systems to
the atmosphere.
Note: The occurrence of air is usually an indication of poor maintenance or lack of thorough-
ness at installation.
Note: R717 systems should be purged on a regular basis to avoid atmospheric air and other
non-condensable gases.
3.2.9 F-gas regulation (fluorinated greenhouse gases)

Based on the Kyoto protocol regarding reduction of harmful gases in the atmosphere, the Eu-
ropean Parliament (EU) has established guidelines for the regulation of certain greenhouse
gases in a directive named “F-gas regulation”. The following is an extract from the guidelines
which is relevant for end users and operators.
Fluorinated refrigerants are included in the category of greenhouse gases and therefore fall
under the F-gas regulation directive. The table below lists the relevant refrigerants and their
respective GWP (Global Warming Potential) according to the F-gas regulation.
Refrigerant GWP (Global Warming Potential)
R134a 1300
R407C 1650
R404A 3785
R507 3850
R410A 1975
Requirements of the F-gas regulation include:
• Labelling
• Leakage test

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Safety precautions
• Recovery of refrigerant
• Certification of personnel
• Log book.
Labelling: The unit must be fitted with a label (name plate). Refrigerant type and charge in
kg must be stated on the plate.
Leakage test: It is the operator’s responsibility to ensure that the unit is checked for leak-
ages by a certified person. For units charged with fluorinated greenhouse gases, the following
conditions apply depending on type of plant and amount of charge:
• Applications containing 3 kg or more of fluorinated greenhouse gases must be
checked for leakage at least once every 12 months.
The applications must be checked for leakage within one month after a leak has been repaired
to ensure that the repair has been effective.
For units containing 300 kg or more of fluorinated greenhouse gases leakage detecting sys-
tems must be checked at least once every 12 months.
Recovery of refrigerant: Operators must be responsible for putting in place arrangements
for the proper recovery of fluorinated greenhouse gases by certified personnel to ensure their
recycling, reclamation or destruction.
Certification of personnel: Since July 2008 it has been mandatory for the member states to
establish certification and training programs for personnel involved in leakage inspections and
the recovery, recycling, reclamation and destruction of fluorinated gases.
Logbook: For all units containing more than 3 kg fluorinated greenhouse gases a logbook
must be kept indicating the quantity and type of product, quantities added for recharges and
the quantity recovered during servicing, maintenance and final disposal. Other relevant infor-
mation is also requested, such as identification of the servicing company or technician as well
as dates and results of the checks.
For further information please see the F-gas regulation in full.

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Safety precautions
3.2.10 First aid for accidents with ammonia

(Chemical formula: NH3 - refrigerant no.: R717)
General
Ammonia is not a cumulative poison. It has a distinctive, pungent odour that even at very
low, harmless concentrations is detectable by most persons.
Since ammonia is self-alarming, it serves as its own warning agent so that no person remains
voluntarily in hazardous concentrations. Since ammonia is lighter than air, adequate ventila-
tion is the best means of preventing an accumulation.
Experience has shown that ammonia is extremely hard to ignite and under normal conditions
a very stable compound. At extremely high, though limited concentrations, ammonia can form
ignitable mixtures with air and oxygen and should be treated with respect.
Basic rules for first aid

Always call a doctor immediately
Be prepared: Keep an irrigation bottle available containing a sterile isotonic (0.9%) NaCl-sol-
ution (salt water). A shower or a water tank should be available near all bulk installations with
ammonia.
When applying first aid, the persons assisting must be duly protected to avoid further injuries.
First aid measures

Inhalation: Immediately, move affected personnel into fresh air and loosen clothing restrict-
ing breathing.
Call a doctor/ambulance with oxygen equipment.
Keep the patient still and warmly wrapped in blankets.
Do not in any way attempt to provoke vomiting or to give an unconscious person anything to
drink.
Oxygen may be given to the patient, if needed, but only when authorised by a doctor. If the
patient stops breathing, apply artificial respiration.
Consumption: Not relevant.
Eyes: In case of injuries from liquid splashes or concentrated vapour, immediately rinse with
water (preferably using an eye rinser) and consult a doctor. Continue rinsing until otherwise
notified by a doctor.
If the affected person wears contact lenses these must be removed before the rinsing.
Skin: In case of burns from liquid splashes or concentrated vapour, immediately wash with
large quantities of water until the pain stops.
Consult a doctor about actual burns.
After washing, apply wet compresses - wetted with a sterile isotonic (0.9%) NaCl-solution
(salt water) - to affected areas until medical advice is available.

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Safety precautions
3.2.11 First aid for accidents with HFC/HCFC

General
HFC/HCFC form colourless and invisible gases which are heavier than air and smell faintly of
chloroform at high concentrations.
Characteristics:
• non-toxic
• non-inflammable
• non-explosive
• non-corrosive
When heated to above approx. 300°C, they break down into toxic, acid gas components,
which are strongly irritating and aggressive to nose, eyes and skin and are generally corro-
sive.
Besides the obvious risk of unnoticeable, heavy gases displacing the atmospheric oxygen, in-
halation of large concentrations may have an accumulating, anaesthetic effect which may not
be immediately apparent. 24 hours of medical observation is therefore recommended.
Basic rules for first aid

When affected persons are moved from low-lying or poorly ventilated rooms where high gas
concentrations are suspected, the rescuer must wear a lifeline and be under constant obser-
vation from an assistant outside the room.
Do not use adrenaline or similar heart stimuli.
Inhalation: Immediately move affected persons into fresh air. Keep them still and warm and
loosen clothing restricting breathing.
If the patient is unconscious, call a doctor/ambulance with oxygen equipment immediately.
Apply artificial respiration until a doctor authorises other treatment.
Eyes: Immediately rinse with water (preferably using an eye rinser) and consult a doctor.
Continue rinsing until otherwise notified by a doctor.
If the affected person wears contact lenses these must be removed before the rinsing.
Skin: In case of frost-bite, immediately rinse with luke-warm water (max. 37°C) and remove
all clothes impeding blood circulation.
Consult a doctor.
Avoid direct contact with contaminated oil/refrigerant mixtures from electrically burnt-out
hermetic compressors.

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Safety precautions
3.2.12 Protecting the operator as well as the environment

Industrialisation affects our environment and it is therefore essential that we do what we can
to minimise the harmful effect on nature.
Many countries have passed legislation in an effort to reduce pollution and preserve the envi-
ronment. This legislation applies to all fields of industry, including refrigeration, and must be
complied with.
Pay extra attention to the following substances:
• Refrigerants
• Cooling media (brine etc.)
• Lubricating oils
Refrigerants usually have a natural boiling point considerably below 0°C. This means that
liquid refrigerants can be extremely harmful in contact with skin or eyes. High concentrations
of refrigerant vapours can be suffocating when they displace air. If high concentrations of re-
frigerant vapours are inhaled, they will attack the human nervous system.
When halogenated gases come into contact with open flame or hot surfaces (over approxi-
mately 300°C), they will decompose to produce poisonous chemicals. These have a very pun-
gent odour and will therefore warn personnel of their presence.
At high concentrations R717 causes respiratory problems. When the amount of ammonia va-
pour in air is between 15 and 28 vol. % the combination is explosive and can be ignited by an
electric spark or open flame.
Oil vapour in the ammonia vapour increases this risk significantly as the point of ignition falls
below that of the mixture ratio stated.
Usually the strong smell of ammonia will warn personnel before the concentration
becomes dangerous.
The following table shows the values for the max. permissible refrigerant content in air meas-
ured in volume %. Certain countries may, however, have official limits different from the ones
stated.
Halogenated refrigerants
HFC HCFC Ammonia CO2
R134a R404A R407C R410A R507 R22 R717 R744
TWA Unit
Time weighted
0.1 0.005 0.5
average during a vol. % 0.1 0.1 0.1 0.1 0.1
week
Warning smell vol. % 0.2 0.002

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Safety precautions
Furthermore, it can be said about refrigerants:

HFC/HCFC
If released into the atmosphere, halogenated refrigerants of the types CFC and HCFC (e.g.
R22) will contribute to the depletion of the ozone layer in the stratosphere. The ozone layer
protects the earth from the ultraviolet rays of the sun. Refrigerants of the types CFC, HFC and
HCFC are greenhouse gases which contribute to an intensification of the greenhouse effect.
They must, therefore, never be released into the atmosphere. Use a separate compressor to
draw the refrigerant into the plant condenser/receiver or into separate refrigerant cylinders.
Ammonia
• Ammonia is easily absorbed by water: At 15°C 1 litre of water can absorb approx. 0.5
kg liquid ammonia (or approx. 700 litres ammonia vapour).
• Even small amounts of ammonia in water (2-5 mg per litre) are enough to wreak hav-
oc with marine life if allowed to pollute waterways and lakes.
• As ammonia is alkaline, it will damage plant life if released into the atmosphere in
large quantities.
Hydro carbons (HC)
• HC gases are a group of B1 refrigerants characterised as very flammable.
• Hydro carbons are odourless and non-toxic gases. Specific mixtures of air and gas
create danger of explosion. As the gases are heavier than air, they will be concentra-
ted at the lowest possible level in case of leaks.
Carbon dioxide (CO2)
• Carbon dioxide (CO2) is a greenhouse gas with a GWP (Global Warming Potential) fac-
tor of 1. It is found in the atmosphere in a concentration of 0.036 vol. % (360 parts
per million, ppm). As CO2 is extracted from atmospheric air, it can safely be released
into the atmosphere and does not contribute to enhancing the greenhouse effect.
• At atmospheric pressure, solid CO2 (dry ice) at the temperature -78.5°C will not melt
like ordinary water ice. Instead it will evaporate and turn into gaseous state CO2,
(substances transitioning directly from the solid to the gaseous state are said to sub-
lime).
• CO2 is an odourless, non-toxic non-inflammable gas. The limit value for CO2 is 5000
ppm. The gas is heavier than air and will thus be concentrated at the lowest level of
the room in case of a leak. In closed rooms the gas can displace oxygen and cause
suffocation.
Refrigerant evacuated from a refrigeration plant must be charged into refrigerant cylinders in-
tended for this specific refrigerant. This does not apply to CO2, however.
CO2 must under no circumstances be collected in bottles as there is a risk of overfill. At worst,
this may cause the bottles to explode because of the rise in pressure.
If the refrigerant is not to be reused, return it to the supplier or to an authorised incineration
plant.
Halogenated refrigerants must never be mixed. Nor must R717 ever be mixed with halogen-
ated refrigerants.
Cooling media
Salt solutions (brines) of calcium chloride (CaCl2) or sodium chloride (NaCl) are often used.

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Safety precautions
In recent years alcohol, glycol and halogenated compounds have been used in the production
of brine.
In general, all brines must be considered harmful to nature and they must be used with cau-
tion. Be very careful when charging or purging a refrigeration plant.
Never empty brines down a sewer or into the environment.
The brine must be collected in suitable containers clearly marked with the contents and sent
to an approved incineration plant.
Note: These instructions only provide general information. The owner of the refrigeration
plant is responsible for ensuring that all codes, regulations and industry standards are com-
plied with.

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Technical description
4. Technical description
4.1.1 Description of the screw compressor
The screw compressor unit is intended for high pressure operation and booster operation.
Since it is designed and constructed as a ready-to-operate unit, all that is required is connec-
tion to the plant system.
CS M
OS
Fig. 4: SAB 151, front Fig. 5: SAB 151, back
Design/Construction
A description of the components which form part of the unit is given below. More detailed de-
scriptions are included in separate documents for the individual components.
The compressor (CS), the electric motor (M) and the oil separator (OS) are mounted on a
base frame. The base frame also serves as a foundation for the other components of the unit.
The torque from the electric motor is transmitted to the compressor via a flexible disc cou-
pling.
When describing the individual components in the following sections, the position
numbers stated in the piping diagram, instrumentation figures and/or general key
to piping diagram later in this section will be used.

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Compressor description
Fig. 6: Screw compressor
The screw compressor unit type SAB 120-151, includes the XJF compressor series, types XJF
120 and 151.
The drawing below illustrates and explains the compressor name:
MODEL AND SERIAL NUMBER EXPLANATION
XJF 151 M 0123 M

MODEL NUMBER
ROTOR DIA. (MM)
2.13/1 GEAR R ATIO – S

1.31/1 GEAR R ATIO – M
1.62/1 GEAR R ATIO – L
1.93/1 GEAR R ATIO – N
SERIAL NUMBER
A - 151A
M- 151M
L - 151L
N - 151N
Fig. 7: Model and serial number explanation
Chapter 6. Technical data includes a list of tables of the screw compressors indicating weight,
dimensions, geometric sweept volume etc.
Compressor type is stated on the name plate shown in Fig. 8. All compressors are equipped
with a name plate. See details in chapter 2
The serial number of each compressor is stamped into the compressor block.
Fig. 8: Compressor name plate
Always state the compressor serial number when contacting Johnson Controls Denmark.

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4.1.2 Description of main components and systems

The screw compressor unit is an integrated system consisting of the following major subsys-
tems:
• Control system
• Compressor
• Compressor lubrication system
• Compressor oil separation system
• Compressor hydraulic system
• Compressor oil cooling system
• Compressor easy-start system
For instructions to properly start up and operate the screw compressor unit, see the operating
manual.
4.1.3 Control system
Unisab III reading, safety and capacity regulating system

Unisab III is a control and monitoring system which is developed to fit all Johnson Controls
Denmark's Sabroe reciprocating and screw compressors, i.e. the same Unisab unit is used for
both compressor types. Once compressor type, refrigerant and a few other functions have
been selected, Unisab III is ready for operation. Unisab III is based on Johnson Controls Den-
mark's extensive experience with design and operation of compressor control systems.
Fig. 9: Unisab III
Unisab III is designed for safe control, monitoring and optimization of compressor operation
and a minimum of unintended operation stops. In addition to efficient control and monitoring
of single compressors Unisab III is also designed for advanced control and monitoring of any
combination of up to 14 compressors. It is thus possible to centrally control and monitor up to
14 compressors by using Profibus DP protocol, Modbus TCP protocol or a Comsab II module.

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Multilingual system
Unisab III is available in 19 different languages and you can switch to the English version at
any time.
Easy to operate
Unisab III has a systematic and easily accessible user interface which does not require any
special knowledge or education.
Operational data and status appear from the distinct display which features four lines with
twenty characters each. The user interface has arrow keys for menu selection, set key for pa-
rameter changing and keys for selection of start/stop and resetting. Manual/automatic opera-
tion and manual capacity regulation is performed with function keys.
Safety monitoring and control

Unisab III provides safe monitoring by means of shutdown and alarm values/settings for all
measuring points. If a set value is exceeded, a red diode will flash slowly in alarm situations
without stopping the compressor and quickly in shutdown situations. A display text will show
the cause of the alarm or shutdown. In both alarm and shutdown situations separate relays
are activated for connection of a remote lamp, bell or alarm panel.
It is easy to find all the set values and their alarm and shutdown values through the straight-
forward menu system.
Besides monitoring the compressor pressures and temperatures, Unisab III also calculates the
suction pressure vapour overheating, monitors the capacity slide position and oil flow and cal-
culates the oil filter differential pressure on screw compressors and SMC reciprocating com-
pressors.
For correct fault diagnosis in case of compressor shutdown, Unisab III immediately stores all
shutdown situations in its memory which can be displayed and analyzed on the display at any
time.
Instrumentation
Depending on compressor type Unisab III is equipped with a number of pressure and temper-
ature transducers as well as position transmitters on the compressor.
Screw compressors are fitted with four pressure transducers and three temperature transduc-
ers as well as one or two slide position transmitters.
Furthermore, a thermistor input is available for motor protection.
Factory test
Every Unisab III is tested during the production process and when it is mounted on the com-
pressor. A computer test is performed before the compressor leaves the factory.
For further information see separate Unisab III manual.
4.1.4 Compressor
The compressor is equipped with an integral suction strainer placed in the transversely suc-
tion side “cylinder like cavity” with access from the side on top of the compressor block. The
filter prevents impurities in the gas from entering and demaging the compressor.
The suction stop valve, 101, is bolted to the suction side flange with a non-return valve, 129,
in between. The non-return valve prevents the compressor from rotating backwards during a
standstill period or shutdown.

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The discharge gas is sent via the discharge line to the oil separator (193). Gas on the dis-
charge side of the compressor is mixed with a relatively large amount of oil injected into the
compressor for lubrication, cooling and tightening. The oil and the gas must be separated be-
fore the discharge gas proceeds into the refrigeration plant.
The rotary screw compressor utilizes mating asymmetrical profile helical rotors to provide a
continuous flow of refrigerant vapour and is designed for both high-pressure and low-pressure
applications. The compressor incorporates the following features:
• Heavy-duty roller bearings to carry radial loads at both inlet and outlet ends of the
compressor.
• Heavy-duty angular contact ball bearings to carry axial loads are mounted at the dis-
charge end of compressor.
• Moveable slide valve to provide infinite step capacity control from 100% to 25% of full
load capacity.
• VOLUMIZER® II adjusts to the most efficient of three volume ratios (2.2, 3.5 or 5.0)
depending on system requirements.
• Hydraulic cylinders to operate the volumizer slide stop and slide valve.
• Compressor housing suitable for 28 bar [400 PSI] pressure.
• Most bearing and control oil is vented to closed threads in the compressor instead of
suction port to avoid performance penalties from superheating suction gas.
• The shaft seal is designed to maintain operating pressure on the seal well below dis-
charge pressure for increased seal life.
• Oil is injected into the rotors to maintain good volumetric and adiabatic efficiency,
even at very high compression ratios.
COMPRESSOR
Fig. 10: Shaft rotation
Compressor rotation is clockwise when facing the end of the compressor drive shaft.
The compressor should never be operated in reverse rotation as bearing damage
will result.
4.1.5 Variable speed drive (VSD)

The compressor can be VSD driven as long as the rpm limits are not exceeded. For standard
and total unloading compressors, Unisab III controls the VSD combined with the mechanical
capacity control in the most efficient way considering both energy consumption and wear.
It should be noted that compressors running variable speed (VSD) are at higher risk of facing
vibrational problems than similar fixed speed applications. Johnson Controls Denmark and
Sabroe Factory have gained comprehensive experience in VSD and we are integrating this
knowledge into both the mechanical design and control systems of our products. For this rea-
son, we cannot accept liability for any damage related to vibrations or variable speed drive on
non-factory built equipment. This includes both mechanical and electrical equipment, meaning
that VSD equipment must be purchased as complete factory built and tested packages to en-
sure optimum reliability, and to attain full factory warranty coverage. It should be noted that

34/157 008983 - en 2014.03
vibrations may appear as structural vibrations in frames, piping, instrumentation, etc., or as

torsional vibrations in rotating equipment (compressor shaft, coupling and motor rotor).
4.1.6 Compressor lubrication system

The compressor is designed specifically for operation without oil pump for high stage service.
Boosters and some low-differential pressure applications require the demand pump option.
The lubrication system on the screw compressor unit performs several functions:
• Lubricates the rotor contact area, allowing the male rotor to drive the female rotor on
a cushioning film of oil.
• Provides lubrication of the bearings and shaft seal.
• Serves to remove the heat of compression from the gas, keeping discharge tempera-
tures low and minimizing refrigerant or oil break down.
• Fills gas leakage paths between or around the rotors with oil, thus greatly reducing
gas leakage and maintaining good compressor performance even at high compression
ratios.
• Provides oil pressure for development of balance load on the balance pistons to re-
duce bearing loading and increase bearing life.
4.1.7 No pump oil system

The screw compressor unit is designed to be self-lubricating. Oil supplied to the compressor
from the oil separator is at system head pressure. In the compressor, oil from all lubricating
points is returned to a point in the compressor body where the pressure is lower than the
compressor discharge pressure. During normal compressor operation, the compressor unit es-
sentially operates as its own oil pump. All oil entering the compressor is moved by the com-
pressor rotors out the compressor outlet and back to the oil separator.
For normal high-stage operation an oil pump is not required.
4.1.8 Demand pump oil system

This system is designed to provide adequate compressor lubrication for some high stage ap-
plications that operate with low differential pressure across the compressor suction and dis-
charge sides and all booster applications.
During the period from start-up to normal operation the oil pressure alarm and oil pressure
cutout setpoints will vary according to formulas built into the microprocessor control program.
4.1.9 Flow security

To ensure compressor lubrication before start-up, an oil level transmitter (LIT) is placed in the
oil separator reservoir. The transmitter registers the oil level and is connected electrically to a
temperature sensor which will only let the compressor start when both limits are fulfilled.
4.1.10 Compressor oil separation system

The compressor is an oil flooded screw compressor. The oil charged to the compressor for lu-
brication, sealing and cooling of the compressor block is mixed with the refrigerant gas and
led to the oil separator collectively.
Oil and gas are separated in the oil separator and the gas, which is almost free of oil, leaves
the compressor unit through the discharge connection. The system is described in detail be-
low.

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Note: Automatic oil return: Open service valves completely to keep coalescer end of separa-
tor free of oil.
Fig. 11: Oil separator
External heat surface (m2)

OHU 04123/2719 5.4 m2
Design and operating mode

As illustrated in Fig. 11 the oil separator system consists of two containers, an oil separator at
the top and an oil reservoir at the bottom. In the oil separator the oil is separated from the
discharge gas and taken to the oil reservoir. Both vessels are firmly connected to pipes which
cannot be separated.
Oil separator
As illustrated in Fig. 12 the discharge gas and the oil from the compressor first pass the de-
misters where the main part of the oil is separated from the discharge gas and drained into
the oil vessel.
Demister A
53
52
Vessel
T245754_0
Fine separator element pos. 55
Fig. 12
However, the discharge gas still contains a certain amount of fine oil drops which is separated
as the discharge gas passes the fine oil separator elements (the fine filters). This oil is
returned to the compressor in separate piping systems as described later in this section.
Normally, the fine oil separator elements do not need to be inspected but if it is considered
necessary - e.g. if observing increased oil consumption in the unit - they can be removed
through the ends of the oil separator.

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Oil return system for fine filter element

The oil separator is fitted with an automatic oil return valve, see 4.1.11..
Oil vessel
As already mentioned, the lubricating oil is collected in the oil vessel. The oil level in the ves-
sel must always be visible in the sight glasses pos. 31. The correct amount of oil in the unit is
stated in Table 29 and Table 30 in section 11.1.13. Oil change.
The oil vessel contains a heating elements, pos. 30, which must always be switched on
when the unit is not operating and switched off when the compressor is started. Re-
member to switch off the heating elements when oil is drained off the oil vessel before an oil
renewal.
After a long period of standstill where the heating elements have been switched off they must
be connected for at least 8 hours before the unit is put into operation.

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4.1.11 Automatic oil return valve
2
5
6 1
55 3
1
4
1: Inlet G1/4” 4: Stop valve, outlet side

2: Filter 5: Outlet G1/4”
3: Stop valve, inlet side 6: Sight glass
Fig. 13
Note: Valve inlet and outlet are marked on the valve housing with "in" and “out”.
Function
The function of the automatic oil return valve EVRB is to return the separated oil in the fine
separator to the compressor.
Oil and gas from the fine separator flow into the oil return valve at pos. 1, through the filter,
pos. 2, and via the nozzles, pos. 7 and 8, and back to the compressor through the outlet, pos.
5, see Fig. 14.
The gas and oil flow through the nozzles, pos. 7 and 8, is adapted to the spring force of pos. 9
as well as the viscosity difference between oil and gas. Consequently, the pressure loss of the
gas flow through the nozzle, pos. 7, is unable to move the piston, pos. 7.
However, the pressure loss of the oil flow through the nozzle, pos. 7, is able to move the pis-
ton, pos. 7.
Thus the spring force, pos. 9, is equalised and a transverse bore, pos. 10, with a considerably
larger bore than pos. 7 will open.
Because the bore is larger, oil collections at the oil return valve inlet can quickly be removed.
When the oil has been removed, the gas flow will rise and the piston, pos. 7, will close the
transverse bore. The gas flow will be lowered to a minimum.
Through the sight glass, pos. 6, it is possible to watch the oil return. As a small amount of gas
will always pass through the nozzle, pos. 7, gas bubbles will be visible.
The valve can be serviced by closing the stop valves, pos. 3 and 4.

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6 8 10
2
1
5
Out In
9 7
4 3
Fig. 14
Note: The sectional view shows the valve structure. Not all internal oil channels are visible.
4.1.12 External oil filter

The compressor unit is equipped with an external oil filter, pos. 195/196, which is mounted in
the oil pipe between the oil separator or oil cooler (if present) and the compressor.
The external oil filter may be constructed with either one or two parallel filters.
Fig. 15: External oil filter
The filter is a horizontal filter through which the oil must pass the filter cartridge from the out-
side in. The filter is protected against bursting because Unisab III will stop the compressor if
the pressure drop across the filter exceeds 1 bar.
Stopping the compressor at a too high differential pressure will happen with a 600 second de-
lay as the pressure difference may momentarily exceed 1.7 bar if the compressor is started
up with cold oil.
4.1.13 Unit with double oil filter

If the unit is equipped with two parallel oil filters, only one filter at a time must be in opera-
tion. The filter not in use can be cleaned when the compressor is in operation.

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When cleaning the oil filter during operation, please note that the pressure is higher when the
vent valve/plug is opened, see Fig. 33 in subsection 4.1.38. General piping diagram. Especial-
ly in connection with HFC/HCFC plants there may be a lot of oil foam.
Note: During operation at least one or both discharge valve(s) must be open to avoid hy-
draulic pressure in the filter housing.
4.1.14 Compressor hydraulic system

The hydraulic system of the compressor utilizes oil pressure from internally drilled passages in
the compressor casing to selectively load and unload the compressor by applying this pres-
sure to the actuating hydraulic piston of the movable slide valve (MSV). It also uses oil pres-
sure to actuate a hydraulic piston that moves the movable slide stop, Volumizer ® II. This al-
lows adjustment of the compressor volume ratio, (Vi) while the compressor is running.
4.1.15 Capacity control

Compressor loading: The compressor loads when MSV solenoid coil YY2 is energized and oil
flows from the solenoid valve through the regulating valve 182 to compressor port 2 where it
enters the load side of the slide valve piston. This equalizes the force on the slide valve piston
and discharge pressure on the slide valve area loads the compressor.
Compressor unloading: The compressor unloads when MSV solenoid YY1 is energized and
oil is allowed to flow from compressor port 2 through the regulating valve 181 to the MSV sol-
enoid. This allows discharge pressure on the slide valve piston to unload the slide valve as the
piston moves outward.
182 181
CONTROL VALVE PORT LABELS
ENERGIZE “b” COIL (YY2) TO LOAD

ENERGIZE “a” COIL (YY1) TO UNLOAD
Fig. 16: Control valve
Adjustment (capacity control): Capacity slide valve movement for SAB 120 and 151 with-
out adjustment, driven by the pressure difference between suction and discharge sides of the
compressor, will cause the capacity slide to move fast towards higher capacity (up) and slow
towards lower capacity (down). To avoid this two one way regulating valves, 181 and 182,
are built in as shown in Fig. 16. The regulating valves separate the up and down slide speed.
The regulation valves are provided to adjust slide valve travel time, preventing excessive slide
valve “hunting”. The two valves should be adjusted to restrict oil flow to the compressor port
so that slide valve travel time from full load to full unload, or vice versa, is minimum 30 sec-
onds.
See also the Engineering manual for Unisab for adjustment of the slide speed.
Note: A change in operating conditions, such as winter-to-summer operation, may require re-
adjustment of the slide valve travel time.

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4.1.16 Volumizer II Vi control

The compressor is equipped with a special internal control that automatically adjusts the com-
pressor volume ratio to the most efficient of three available steps, (2.2, 3.5, or 5.0 volume
ratio). This gives the compressor the ability to operate at varying operating conditions while
minimizing power consumption by avoiding over or undercompression.
Solenoid valves 3 and 4 control the Volumizer® II volume ratio control. Oil is internally ported
to apply hydraulic pressure to two stepping pistons in order to move the moveable slide stop
to the optimum position. The following chart shows the logic of solenoid operation to adjust
the volume ratio.
Vi YY3 YY4
2.2 Energized Energized
3.5 Deenergized Energized
5.0 Deenergized Deenergized

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4.1.17 Compressor oil cooling system

The unit can be equipped with one of two systems for controlling the compressor oil tempera-
ture. They are thermosyphon or water-cooled oil coolers. Each system is automatically con-
trolled, independent of compressor loading or unloading.
Oil cooling systems maintain oil temperature within the following ranges for R717 and HCFC/
HFC:
Liquid injection oil cooling:
55 - 65°C [130 - 150°F]
External* oil cooling:
49 - 60°C [120 - 140°F]
* ThermoSyphon Oil Cooling (TSOC)
or Water-Cooled Oil Cooling (WCOC).
4.1.18 Single-port liquid injection

The single-port liquid injection system is designed to permit liquid refrigerant injection into
one port on the compressor at any given moment and operates as outlined.
The liquid injection solenoid valve is energized by the microprocessor when the temperature
sensor, installed in the compressor discharge, exceeds the set point. High-pressure liquid re-
frigerant is then supplied to the temperature control valve ( TCV).
Refer to P&I diagrams section for piping and instrumentation drawings.
4.1.19 Dual-port liquid injection

The dual-port liquid injection system is designed to obtain the most efficient compressor per-
formance at high and low compression ratios by permitting injection of liquid refrigerant into
one of two ports optimally located on the compressor. This minimizes the performance penal-
ty incurred with liquid injection oil cooling.
The dual-port system contains all the components of the single-port system with the addition
of a double-acting solenoid valve and operates as outlined.
The liquid injection solenoid valve is energized by the microprocessor when the temperature
sensor, installed in the oil manifold, exceeds the set point. Liquid refrigerant is then passed
through the temperature control valve (TCV) to the double-acting solenoid valve. Depending
on the compressor’s operating volume ratio (Vi), the microprocessor will select the flow of the
liquid refrigerant to the optimum compressor port.
Liquid injection adjustment. For discharge temperature set point and PID regulator param-
eters, refer to the operating manual for the control system. The discharge temperature set
point is set to the required oil temperature.

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COMPRESSOR LOW VI
ECONOMISER OR
CLOSED THREAD
TUBING LINE
5
SOLENOID VALVE MOTORISED
STRAINER EXPANSION
LIQUID REFRIGERANT VALVE
FROM RECEIVER
165 170
LIQUID LINE SIGHT
GLASS
Fig. 17: P & I diagram - liquid injection, single port
Fig. 18: P & I diagram - liquid injection, dual port

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4.1.20 Suction check valve bypass

A 1/4" angle valve is installed between the compressor and suction flange. It can be used as a
suction valve bypass. This feature has several uses including reducing starting torque, im-
proving oil quality, and relieving the refrigerant to low side for servicing.
In most cases, the valve should be left open approximately 1 to 2 turns at all times. If the
compressor back-spins or too much oil foaming is experienced while venting, partially close
valve to slow speed of equalization. If system is on AUTO CYCLE and short cycling occurs, the
valve must be closed.
To relieve refrigerant to low side, close separator discharge service valve. Slowly open bypass
valve (if closed) and wait for pressure to equalize. Close bypass and suction service valves
before evacuating the unit.
4.1.21 Low ambient temperature operation

It is recommended that oil separators are insulated as a minimum requirement to preserve
the heat generated by the oil heaters. It is important that the coalescer end of the separator
is insulated to prevent refrigerant condensation.
On systems located outdoors or in unheated buildings where the ambient temperature may
drop below 5°C [+41°F], insulating and/or heat tracing of the compressor lubricating oil sys-
tems is highly recommended.
When low ambient temperatures (below -7°C [+20°F]) may occur, it is recommended to heat
trace and insulate lubricating oil lines, oil filters, oil pumps and oil coolers.
Freeze-up protection must also be provided for all water-cooled equipment.
Suction check valve power assistance is not necessary on check valves with linear ball bear-
ings.

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4.1.22 Oil carry-over to plant
Total oil carry-over estimate

Formula: 0.36 x total ppm value x total mass flow (kg/s) (COMP1) = > (100 kg/100 h)
The COMP1 calculation program provides the discharge temperature and the circulated mass
flow of refrigerant through evaporator, economizer and side load. In the formula, the total
mass flow (all single flow of refrigerant to be added provides condenser mass flow or total
mass flow) must be used.
The COMP1 calculation program also provides the oil separator load (%).
Total oil carry-over calculation

Oil vapour pressure calculation based on an empiric formula with good conformity to practice
experience:
1 1
( 12* Fp + 1270 )* ( - ) [torr]
P oil = 10 1 .1* Fp + 220 t Disch + 273
Fp = Flash point (Oil data) [°C]
tdisch = Discharge temperature [°C]
Alternatively, use steam pressure from oil company.

Dalton’s law for partial pressure of two substances in vapour form gives good conformity with
practice experience.
Poil * M oil
Vapour, ppmoil = * 1,000,.000 * 0.00133 [ppm]
(Theoretical) PDisch * M Ref
Poil = Oil vapour pressure [torr]
PDisch = Discharge pressure saturated [bar, a]
Moil and MRef = Molecular weight for oil

and refrigerant [kmol/kg]
1
Vapour , ppmoil = * Vapour, ppm oil
1 + Oil separator load (%)
(Practical) (Theoretical)
100
Liquid oil aerosol carry-over depends on oil separator, oil separator challenge flow, refriger-
ant, oil type, solubility, pressures and temperatures.
R717: Oil separator load (%) * 14

100
HC/HCFC/HFC: Oil separator load (%) * 25

100
Total oil carry-over (ppm) = Vapour (ppm) + liquid (ppm)

(Practical)

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4.1.23 Oil level glass, pos. 31

The oil level must always be visible in one of the oil level glasses. If oil is recharged, the oil
level will rise approx. 10 mm if the indicated amount of oil is charged.
10 mm
4.1.24 Selecting lubricating oil for Sabroe screw compressors

To ensure the compressor unit a long service life with safe and reliable operation, it is impor-
tant to use an oil type recommended by Johnson Controls Denmark. Please refer to Sabroe oil
recommendation where various oil types are listed in a table including oil brand, oil code and
part numbers.
Only use oil recommended by Johnson Controls Denmark when first charging the plant and
when recharging. Mixing different oil types can cause irreversible damage.
4.1.25 Oil charge

See section 11. Maintenance instructions.
4.1.26 Heating rods element for oil heating, pos 30

In order to keep the lubricating oil in the compressor warm during a standstill period, the oil
receiver has one or two built-in heating rods. Before start-up, the heating rods must have
been activated for six to eight hours to ensure that there is only a minimum of refrigerant in
the oil. When containing a lot of refrigerant, the oil will lose its lubricating property and tend
to foam which can cause shutdown by the level switch.
As illustrated in Fig. 19, the direct heating rod consists of an electric heating element incorpo-
rated in a pipe with a diameter of 30 mm. The entire heating cartridge is screwed on tightly at
the G 1 1/4" thread.
It is available in ATEX execution.
Note: The heating rod must not be energized if the oil level in the receiver is below the mini-
mum mark in the sight glass and it should generally be switched off during compressor opera-
tion.

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Marking: Prod. no.

Watt
NV50 Volt
G1¼ Manu. date
30
50
L1
80 L2
Fig. 19: Heating rod - type A
Heating rods
Power Voltage L1 L2 Used for:
Watt V mm mm
460 250
460 230 158 175 SAB 120/151/193/233/283/355
460 115
4.1.27 Oil level switch
Four red LED

77 mm
Plast housing
PROCAP -LS20
M4 fixing screw
NW27
1/2 “ BSP
Tube AISI304
DIA. 15 mm
105 mm
Fig. 20: Oil level switch
Two oil level switches may be mounted on the oil separator.

During normal operation the lower switch must always be activated. If the oil level drops be-
low minimum the switch will deactivate and this will be registered on the Unisab III control
system.
The upper switch (optional) gives signal to an oil equalizing system which equalizes the oil re-
turn from the plant between several units.

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4.1.28 Cold-start system

The unit is equipped with a special "cold-start" discharge check valve on the gas outlet con-
nection of the oil separator. Due to this valve, the oil separator develops oil pressure rapidly
on initial start in order to lubricate the compressor. Oil pump is not required even in cold am-
bient temperatures with all pressures equalized.
For high-stage units, the cold-start valve is equipped with a large spring that creates a 2.0
bar [30 psi] pressure in the oil separator (above suction pressure), for lubrication of the com-
pressor.
Caution!
Do not attempt to service the cold-start valve. Please contact Johnson Controls Den-
mark.
Once the compressor is running it will begin to force gas to the condenser at connection P2.
As the condenser heats up it will begin to rise in pressure as the compressor suction pulls
down in pressure. As soon as differential pressure is developed between the condenser and
suction side, these pressures act across a piston inside the cold-start valve to partially over-
come the spring force. When the differential pressure reaches and exceeds 2.0 bar [30 psi],
the piston fully overcomes the spring force and powers the valve fully open for very low oper-
ating pressure drop.
For booster applications, the valve is equipped with a lighter spring which produces 0.5 bar [7
psi] oil pressure above suction pressure before it fully powers open.
The unit is also equipped with a suction check valve bypass. The oil separator will slowly bleed
down to system suction pressure when the unit is stopped. This allows the compressor drive
motor to have an easier start, and the discharge check valve will seat more tightly. See sec-
tion 4.1.20. Suction check valve bypass for operation.
P3 - TO SUCTION P3
CLOSED OPEN
P2 - TO
CONDENSER P2
P1 - FROM P1
OIL SEPARATOR
Fig. 21: Cold-start valve

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4.1.29 Compressor protecting system pos. 220 and 221

Pilot valve BSV8
(Pos. 221)
Main valve POV

(Pos. 220)
To oil separator Condensing Evaporating From evaporator

condenser pressure pressure
Fig. 22: System with closed valve
In order to protect the compressor against an inadmissible high pressure (if the electric sys-
tem has not already stopped the compressor), the compressor is fitted with a protecting sys-
tem with one or two main valves, pos. 220 and corresponding pilot valve(s), pos. 221, see
Fig. 22
Functional description
The pilot valve, pos. 221, is actuated by the compressor discharge pressure P1 and is kept
closed by a built-in spring whose closing force is adjusted to the pressure shown on the valve
plate. The reference pressure of the pilot valve is the atmospheric pressure Po, and the valve
is dimensioned in such a way that the pressure P2" does not affect the opening pressure of
the valve.
If the pressure P1 rises above the set opening value on the valve plate, the pilot valve, pos.
221, will modulate open and raise the pressure P2" below the piston, pos. 5, in the main
valve.
In the chamber above the piston, pos. 5, there is the same pressure P1 as under the valve
cone, pos. 2, since the piston rod, pos. 3, is pierced. When the main valve is closed, the pres-
sure P2" in the chamber, pos. 6, below the piston will be the same as the compressor dis-
charge pressure P2 since the pressure P2" is equalized through the nozzle, pos. 7.
If the pilot valve, pos. 221, opens due to too a high pressure P1, gas will flow from the pilot
valve to the main valve through the P2" line. If there is more gas that can flow through the
nozzle, pos. 7, the pressure will rise in the chamber, pos. 6, and modulate open the main
valve.
Thus the way is open for a gas flow through the main valve from the compressor discharge
side to the suction side.
When the pressure P1 falls below the set pressure of the pilot valve again, the pilot valve will
close. The pressure P2" in the chamber, pos. 6, is equalized to the P2 pressure through the
nozzle, pos. 7, and the main valve closes in less than 50 seconds. The activation of the com-
pressor protecting system will usually not result in valve leaks or in the need for regulation.

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Fig. 23: System with open valve
4.1.30 Oil cooling system and general piping layout

General:
Min. oil temperature before start-up: 4°C (+40°F)
Min. oil temperature in running condition: 20°C (+68°F)
Liquid injection oil cooling: The compressor oil is cooled by direct contact with the refriger-
ant injected through an optimized port location prior to the compressor discharge. Liquid feed
arrangements include isolation valves, strainer, solenoid valve, sight glass, a thermal expan-
sion temperature control valve and a pressure differential control valve. The temperature con-
trol valve will maintain the temperature of the oil returning to the compressor between
54.4°C [130°F] and 66°C [150°F].
Water-cooled oil cooling: The optional water-cooled oil cooler is either a plate and shell de-
sign (Vahterus) with oil on the plate side or a plate type oil cooler (AlfaNova). The coolers are
designed for design pressure 28 bar on both sides. The oil temperature is maintained between
50°C [120°F] and 60°C [140°F] for ammonia and halocarbons with a thermally controlled
valve. The oil cooler is mounted on the unit with the oil piping connected. Water connections
and controls are field installed.
Thermosyphon oil cooling: The optional thermosyphon cooler is a plate and shell design
(Vahterus) or a plate type oil cooler (AlfaNova). It is designed for design pressure 28 bar on
the shell side and 28 bar on the plate side. The oil coolers are mounted on the unit with the
oil piping connected. Refrigerant connections and controls are field installed. The oil tempera-
ture is maintained between 50°C [120°F] and 60°C [140°F].

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4.1.31 Liquid injection oil cooling

The liquid injection system provided on the unit is self-contained but requires the connection
of the liquid line sized as shown in the table.
* Liquid line sizes an additional receiver volume (quantity of refrigerant required for 5 mi-
nutes of liquid injection oil cooling) are giving in the following table:
Liquid line size * Flow Flow Liquid Liquid

Refrige-
Unit Pipe SCH Tubing rate (lb) rate volume volume
rant
80 OD 5 min kg/5 min Cu. Ft. Liter
SAB 120 S 1/2 - 20 9,1 0.6 17,0
SAB 120 M 1/2 - 25 11,3 0.7 19,8
SAB 120 L 1/2 - 30 13,6 0.8 22,7
R-717 SAB 120 E 3/4 - 40 18,1 1.1 31,1
High stage SAB 151 S 3/4 - 47 21,3 1.3 36,8
SAB 151 M 3/4 - 55 24,9 1.6 45,3
SAB 151 L 3/4 - 70 31,8 2.0 56,6
SAB 151 E 3/4 - 80 36,3 2.3 65,1
SAB 120 S 3/4 7/8 31 14,1 0.5 14,2
SAB 120 M 3/4 7/8 36 16,3 0.6 17,0
SAB 120 L 3/4 7/8 42 19,1 0.7 19,8
R-507 SAB 120 E 1 1⅜ 56 25,4 0.9 25,5
High stage SAB 151 S 1¼ 1⅜ 68 30,8 1.1 31,1
SAB 151 M 1¼ 1⅜ 78 35,4 1.2 34,0
SAB 151 L 1¼ 1⅜ 97 44,0 1.5 42,5
SAB 151 E 1¼ 1⅜ 120 54,4 1.9 53,8
SAB 120 S 1/2 - 4.5 2,0 0.1 2,8
SAB 120 M 1/2 - 5.5 2,5 0.2 5,7
SAB 120 L 1/2 - 6.5 2,9 0.2 5,7
R-717 SAB 120 E 1/2 - 8.5 3,9 0.3 8,5
Booster SAB 151 S 1/2 - 10 4,5 0.3 8,5
SAB 151 M 1/2 - 12 5,4 0.3 8,5
SAB 151 L 1/2 - 15 6,8 0.4 11,3
SAB 151 E 1/2 - 18 8,2 0.5 14,2
SAB 120 S 3/8 1/2 10 4,5 0.2 5,7
SAB 120 M 3/8 1/2 11 5,0 0.2 5,7
SAB 120 L 3/8 1/2 13 5,9 0.2 5,7
R-507 SAB 120 E 3/4 7/8 17 7,7 0.3 8,5
Booster SAB 151 S 3/4 7/8 23 10,4 0.4 11,3
SAB 151 M 3/4 7/8 26.5 12,0 0.4 11,3
SAB 151 L 3/4 7/8 33 15,0 0.5 14,2
SAB 151 E 3/4 7/8 40.5 18,4 0.6 17,0
* 100 ft./30 m liquid line. For longer runs, increase line size accordingly.
High-stage compressor units may be supplied with single-port (low Vi, side, or closed thread)
or dual-port (low Vi and high Vi), liquid injection oil cooling. Single port will be furnished for
low compression ratio operation and dual port for high compression ratio operation. Booster
compressor units use single-port (High Vi), liquid injection oil cooling due to the typically low-
er compression ratios.
The control system on high-stage units with dual-port, liquid injection oil cooling switches the
liquid refrigerant supply to the high port when the compressor is operating at higher compres-
sion ratios (3.5 Vi and above) for best efficiency.

008983 - en 2014.03 51/157
Caution!
It is imperative that an uninterrupted high-pres sure liquid refrigerant be provided to the in-
jection system at all times. Two items of EXTREME IMPORTANCE are the design of the re-
ceiver/liquid injection supply and the size of the liquid line. It is recommended that the receiv-
er be oversized sufficiently to retain a 5-minute supply of refrigerant for oil cooling. The evap-
orator supply must be secondary to this consideration. Failure to follow these requirements
causes wire draw which can result in damage to the expansion valve, loss of oil cooling, and
intermittant oil cooling. One method of accomplishing this is described below.
Dual dip tube method

The dual dip tube method uses two dip tubes in the receiver. The liquid injection tube is below
the evaporator tube to assure continued oil cooling when the receiver level is low. See Fig. 24.
TO EVAPORATOR
TO COMPRESSOR
FROM CONDENSER OIL COOLING
SYSTEM
RECEIVER
LOCATE TO PROVIDE
5 MIN. LIQUID SUPPLY
Fig. 24
4.1.32 Thermosyphon oil cooling

Thermosyphon oil coolers, like water (or glycol)-cooled oil coolers, eliminate the capacity and
power penalties associated with liquid injection oil cooling. Thermosyphon oil coolers have the
further advantages of eliminating water (or glycol) pump power consumption and mainte-
nance, fouling and potential system contamination.
The principle of operation is as follows, see Fig. 25. A supply of high pressure liquid is main-
tained in a receiver at a predetermined minimum head above the oil cooler and below the
condenser. Gravity causes the liquid refrigerant to flow to the oil cooler where a portion of the
liquid is boiled off, thereby cooling the hot oil. New liquid from the receiver displaces the light-
er refrigerant liquid/vapour mixture which rises to the receiver, dropping out the remaining
liquid before allowing the vapour to return to the condenser, completing the cycle.
Piping arrangement for thermosyphon oil cooling systems
Equipment
The basic equipment required for a thermosyphon system consists of:
1. A source of liquid refrigerant at condensing pressure and temperature located in close
proximity to the unit to minimize piping pressure drop. The liquid level in the refriger-
ant source must be 6 to 8 feet above the center of the oil cooler.

52/157 008983 - en 2014.03
2. A shell and tube or plate-type oil cooler with a minimum 300 psi design working pres-
sure on both the oil and refrigerant sides.
Due to the many variations in refrigeration system design and physical layout, several
systems for assuring the above two criteria are possible.
SYSTEM
CONDENSER
VAPOR
STATIC HEAD
TO OVERCOME
SAFETY 2
VALVE
CONDENSER THERMOSYPHON
PRESSURE DROP RECEIVER
LIQUID OVERFLOW
OIL TEMP DRAIN TO RECEIVER
CONTROL VALVE
LIQUID
6 Ft
Min. HOT COOL LEVEL
COOL OIL
OUT TO SYSTEM
3 EVAPORATOR
REFRIGERANT OUT
HOT OIL IN REFRIGERANT IN

SYSTEM
1 PLATE
COOLER RECEIVER
TSOC (Mounted below Thermosyphon
receiver level)
Fig. 25
Installation
The plate-type thermosyphon oil cooler with oil side piping and a thermostatically controlled
mixing valve are factory mounted and piped. See Fig. 25.
1. Thermosyphon oil cooler is supplied with oil side piped to the compressor unit and
socket weld ends supplied on the refrigerant side.
2. A refrigerant-side safety valve is required when refrigerant isolation valves are instal-
led between the cooler and thermosyphon receiver. If no valves are used between the
cooler and thermosyphon receiver, the safety valve on the thermosyphon receiver
must be sized to handle the volume of both vessels. Then, the safety valve on the
cooler vent (liquid refrigerant side) can be eliminated.
3. System receiver must be mounted below thermosyphon receiver level in this arrange-
ment.
4. The refrigerant source, thermosyphon or system receiver, should be in close proximity
to the unit to minimize piping pressure drop.
5. The liquid level in the refrigerant source must not be less than 6 feet above the center
of the oil cooler.
6. Frick recommends the installation of an angle valve in the piping before the thermosy-
phon oil cooler to balance the thermosyphon system. Frick also recommends the in-
stallation of sight glasses at the TSOC inlet and outlet to aid in troubleshooting. The
factory-mounted plate-type thermosyphon oil cooler requires a refrigerant-side drain
valve to be provided and installed by the customer.
The component and piping arrangement shown in Fig. 25 is intended only to illustrate
the operating principles of thermosyphon oil cooling. Other component layouts may be

008983 - en 2014.03 53/157
better suited to a specific installation. Refer to publication E70-900E for additional in-
formation on Thermosyphon Oil Cooling.
4.1.33 Water-cooled oil cooling

The plate and shell or plate-type water-cooled oil cooler is mounted on the unit complete with
all oil piping. The customer must supply adequate water to the oil cooler.
Johnson Controls Denmark recommends a closed-loop system for the waterside of the oil
cooler. Careful attention to water treatment is essential to ensure adequate life of the cooler if
cooling tower water is used. It is imperative that the condition of cooling water and
closed-loop fluids be analyzed regularly and as necessary and maintained at a pH of
7.4, but not less than 6.0 for proper heat exchanger life.
After initial start-up of the compressor package, the strainer at the inlet of the oil cooler
should be cleaned several times in the first 24 hours of operation.
In some applications, the plate-type oil cooler may be subjected to severe water conditions,
including high temperature and/or hard water conditions. This causes accelerated scaling
rates which will penalize the performance of the heat exchanger. A chemical cleaning process
will extend the life of the heat exchanger. It is important to establish regular cleaning sched-
ules.
Cleaning: A 3% solution of Phosphoric or Oxalic Acid is recommended. Other cleaning solu-
tions can be obtained from your local distributor, but they must be suitable for stainless steel.
The oil cooler may be cleaned in place by back flushing with recommended solution for ap-
proximately 30 minutes. After back flushing, rinse the heat exchanger with fresh water to re-
move any remaining cleaning solution.

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4.1.34 Connection to AlfaNova oil cooler

The maximum permitted connection forces and moments during mounting and operation for
AlfaNova heat exchangersare listed in the following tables. Keep these values in mind when
designing your system. It is also recommended to minimize connection loads when designing
piping systems. See Fig. 26
Fig. 26: AlfaNova oil cooler
Reduction of max
Fx = Fy = Fz = F Mx = My = Mz = M
approved design
(N) (Nm)
pressure (bar)
AlfaNova HP-52 120 25 10
Table 1: Maximum recommended load components during operation
Connection
Fx (N) Fy (N) Fz (N) Mx (Nm) My (Nm) M(Nm)
Treaded
1 1/4" 700 700 700 300 20 20
Table 2: Maximum recommended load components during mounting

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4.1.35 Oil pump pos. 63
1 2 3
Fig. 27: The pump principle
Description
The oil pump is an internally toothed gear pump with slide ring shaft sealing. The pump is
positioned vertically with horizontal suction and discharge connections. The pump is fitted on
an intermediate piece which again is mounted on the electric motor. The electric motor is se-
cured to the oil separator by means of a small frame.
Standard lubrication system limits - high stage

The standard system for compressor operation without a lubricating oil pump may be used on
high stage applications shown in the clear area of Fig. 28. The optional demand oil pump is
required only on low differential pressure applications shown in the shaded area Fig. 28.
Where condensing temperatures fluctuate into the shaded area only on an occasional basis in
the winter, the demand pump avoids unnecessary consumption of pump horsepower.
°C °F
37.8
32.2
Condensing temperature
26.7 Pressure differential is acceptable for

use of standard system when operated
21.1 in clear area - demand oil pump option
required for shaded area
15.6
10
4.4
°F
-40 -34.4 -28.9 -23.3 -17.8 -12.2 -6.7 -1.1 4.4 °C
Saturated suction temperature
Fig. 28: Standard lubrication system limits - high stage
Start-up
The pump must only run without an oil flow for brief periods because of bearings and shaft
seal.
Service
The oil pump is designed as one unit and should therefore not be disassembled.

56/157 008983 - en 2014.03
Checking the rotating direction of the motor

Before the initial start-up of the oil pump, remember to check that it has the correct rotating
direction. Do this by looking through the fan shield mounted at the end of the motor away
from the oil pump. Seen through this shield the motor must rotate counter-clockwise.
4.1.36 Economizer - high stage (optional)

The economizer option provides an increase in system capacity and efficiency by subcooling
liquid from the condenser through a heat exchanger or flash tank before it goes to the evapo-
rator. The subcooling is provided by flashing liquid in the economizer cooler to an intermedi-
ate pressure level. The intermediate pressure is provided by a port located part way down the
compression process on the screw compressor. As the screw compressor unloads, the econo-
mizer port will drop in pressure level, eventually being fully open to suction. Because of this,
an output from the microprocessor is generally used to turn off the supply of flashing liquid on
a shell and coil or DX economizer when the capacity falls below approximately 45%-60% ca-
pacity (85%-90% slide valve position). This is done because the compressor will be more effi-
cient operating at a higher slide valve position with the economizer turned off, than it will at a
low slide valve position with the economizer turned on. Please note however that shell and
coil and DX economizers can be used at low compressor capacities in cases where efficiency is
not as important as assuring that the liquid supply is subcooled. In such cases, the econo-
mizer liquid solenoid can be left open whenever the compressor is running.
Due to the tendency of the port pressure to fall with decreasing compressor capacity, a back-
pressure regulator valve (BPR) is generally required on a flash economizer system (Fig. 31) in
order to maintain some preset pressure difference between the subcooled liquid in the flash
vessel and the evaporators. If the back-pressure regulator valve is not used on a flash econo-
mizer, it is possible that no pressure difference will exist to drive liquid from the flash vessel
to the evaporators, since the flash vessel pressure will approach suction pressure at a de-
creased slide valve position. In cases where wide swings in pressure are anticipated in the
flash economizer vessel, it may be necessary to add an outlet pressure regulator to the flash
vessel outlet to avoid overpressure of the economizer port, which could result in motor over-
load. Example: A system feeding liquid to the flash vessel in batches.
The recommended economizer systems are shown below. Notice that in all systems there
should be a strainer (STR) and a check valve (VCK) between the economizer vessel and the
economizer port on the compressor. The strainer prevents dirt from passing into the compres-
sor and the check valve prevents oil from flowing from the compressor unit to the economizer
vessel during shutdown.
Caution!
In addition to the isolation valve which is needed for strainer cleaning, it is essential that the
strainer is the last device in the economizer line before the compressor. Also, piston-type
check valves are recommended for installation in the economizer line, as opposed to disc-type
check valves. The latter are more prone to gas pulsation-induced failure. The isolation and
check valves and strainer should be located as closely as possible to the compressor, prefera-
bly within 1 metre.
For refrigeration plants employing multiple compressors on a common economizing vessel, re-
gardless of economizer type, each compressor must have a back-pressure regulating valve in
order to balance the economizer load, or gas flow, between compressors. The problem of bal-
ancing load becomes most important when one or more compressors run at partial load, ex-
posing the economizer port to suction pressure. In the case of a flash vessel, there is no need
for the redundancy of a back-pressure regulating valve on the vessel and each of the multiple
compressors. Omit the BPR valve on the flash economizer vessel and use one on each com-

008983 - en 2014.03 57/157
pressor, as shown in Fig. 32. It is also recommended that the back-pressure regulating
valves, used on economizer lines, should be specified with electric shutoff option. The electric
shutoff feature is necessary to prevent flow from the common economizer vessel to the suc-
tion side of a stopped compressor, through the suction check valve bypass line, if the other
compressors and the common economizer vessel are still operating and the HV2 valve on the
suction bypass is open.
For refrigeration plants using a Packaged Refrigerant Recirculation (PRR) unit and a direct ex-
pansion (DX) economizer system it is necessary to operate the liquid feed solenoid on the PRR
unit and the liquid feed solenoid on the DX vessel off of a common signal to avoid liquid over-
feed on the DX economizer system.
If multiple compressors are operated with a common economizer vessel, it is necessary to in-
stall a back-pressure regulator valve with an electric shutoff option in the vapour line piped to
the compressor's economizer port. If an electric shut-off is not installed in the economizer va-
por line, valve HV-2 must remain closed to avoid a gas bypass from the economizer line
through the suction check valve bypass, back to the suction line on a compressor that is shut
down.
Suction Suction Intermediate pressure High

Intermediate pressure gas to compressor pressure
gas to compressor
Economizer liquid
cooler
STR VCK High STR VCK
pressure
Sub-cooled Wiring
Sub-cooled liquid
high pressure
high pressure
liquid to
liquid to
evaporator
evaporator
Economizer
cooler
Fig. 29: Shell and coil economizer system
Fig. 30: Direct expansion economizer system
Suction Intermediate pressure

Suction
Intermediate pressure gas to compressor
gas to compressor Economizer
vessel
Economizer
vessel STR VCK BPR
STR VCK BPR High
pressure
liquid
Controlled pressure
saturated liquid to evaporator Controlled pressure
saturated liquid to evaporator
Fig. 31: Flash economizer system Fig. 32: Multiple compressor economizer system

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4.1.37 General key to piping diagram
Pos. no. Designation In-operation position

101 Suction stop valve Open
102 Stop valve after oil separator Open
Open to safety valve,
103 Change over valve
no. 1 or no. 2
104/PSV1 Safety relief valve (Closed) Fixed set point
105/PSV1 Safety relief valve (Closed) Fixed set point
106 Service valve for oil drainage Closed
107 Purge valve Closed
108 Service valve “Pump out”/Closed
114 Stop valve, suction check valve by-pass Open
115 Check valve
116 Oil level indicators
117 Oil level indicators
119 Stop valve after oil separator Open
120 Oil temperature regulating valve Fixed set point
121 Service valve, oil filter Closed
123 Stop valve after oil filter Open
Open (partly)
124 Regulating valve (oil flow)
Adjusted according to manual
126 Cold-start discharge valve Opens automatically
(Closed)
127 Compressor protection valve
Controlled by pilot valve
128 Pilot valve for pos. 127 (Closed) Fixed set point
129 Suction check valve
130 Change over valve
131 Safety valve oil cooler
135 Stop valve before oil filter, Oil filter 1 Open when filter is in use
136 Stop valve before oil filter, Oil filter 2 Open when filter is in use
123 Stop valve after oil filter, Oil filter 1 Open when filter is in use
138 Stop valve after oil filter, Oil filter 2 Open when filter is in use
137 Service valve - oil filter (Closed)
139 Non-return valve (check valve)

140 Check valve
Economizer kit (optional)
141 Stop valve
142 Strainer
143 Check valve
144 Strainer before oil pump

145 Service valve Closed
146 Oil pump overflow valve Closed. Fixed set point
151 Suction gas temperature

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Pos. no. Designation In-operation position

152 Discharge gas temperature
153 Lubricating oil temperature
154 Separator oil temperature
155 Oil pressure after filter
156
157 Discharge pressure
158 Suction pressure

159 Pressure switch control
160 Low level shutdown
161 Heater
163 High level indicator
Liquid injection - optional

165 Liquid stop valve Open
170 Stop valve Open
172 Stop valve Open
173 Stop valve Open
175 Stop valve Closed
181 Slide valve - unload

182 Slide valve - load
183 Moveable slide stop
184 Moveable slide stop
191 Compressor
192 Electric motor
193 Oil separator
194 Oil cooler
195 Oil filter
196 Oil filter
200 Stop valves - oil return Open

200 Automatic oil return
Note: On units delivered without valves the bracketed figures near the branches refer to the
component numbers in this list. These components must be fitted by the customer.

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4.1.38 General piping diagram

158
115
SUCTION GAS
TO COMPR
101 SUCTION VALVE
114 SHIPPED LOOSE
129
128
151
182 181
127
192 191
143 142 141

DISCHARGE GAS
FROM UNIT
104 105
DISCHARGE
152
STOP/CHECK
VALVE
159
ECONOMIZER KIT
ASSEMBLY
PURGE VALVE
103
102 107 108 157
1 1/2 HAND 126
EXPANSION VALVE
193
155
140
OPTIONAL 116
124
153 OILCHARGE 117
163
156 144
195 161 160 145
135
121 119
200 106 154
139
146
123 120 SEE TABLE FOR REF OUT
196 SAFETY VALVE WATER IN
137 136
138 194 TSOC / WCOC

CUSTOMER IS RESPONSIBLE FOR PROVIDING AND INSTALLING
RELIEF PROTECTION IF COOLER IS ISOLATED
SAFETY VALVE
REF IN 131 132 133

WATER OUT
130
Fig. 33

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Legend (Covers all P&I diagrams in this manual)

C Compressor TSH Temperature switch high alarm
CV Check valve TW Thermowell
DP Discharge pressure VI Vi control
FG Flow glass SB-2 Inlet bearing and balance piston
HV Hand valve SB-3 Discharge bearings and seal
HTR Heater SC-1 Slide valve - unload
LG Level glass SC-2 Slide valve - load
LSLL Separator low oil level shutdown SC-3 Moveable slide stop
M Motor SC-4 Moveable slide stop
1MC Motor control centre SC-5 Inlet pressure
2MC Motor control centre SC-6 Discharge pressure
NOS No oil switch SC-7 Seal weepage
OF Oil filter SC-8 Oil drain connection
OP Oil pressure SC-9 Inlet housing oil drain
P Demand pump SC-13 Oil drain cylinder
PAH High discharge pressure alarm SE-1 Electrical connection
PAHH High discharge pressure shutdown SE-2 Electrical connection
PAL Low pressure alarm SL-1 Liquid injection low Vi
PALL Low pressure shutdown SL-2 Liquid injection high Vi
PDAH High pressure differential alarm SM-1 Main oil injection
PDI Pressure differential indicator SV-1 Vapour injection tongue and groove
PDSLL Compressor low diff. pressure cut-out SD-1 Coalescer bleed str trh O-ring port
TW-1 Thermowell
PE Pressure transducer Pressure transducers indicate:
PI Pressure indicator PE-1 Oil pressure (manifold)
PIC Pressure indicator controller PE-2 Oil pressure before filter
PM Pump motor PE-3 Discharge pressure
PS Pressure switch control PE-4 Suction pressure
PSV High pressure safety valve Temperature probes indicate:
SP Suction pressure TE-1 Suction gas temperature
STR Strainer TE-2 Discharge gas temperature
TAH High temperature alarm TE-3 Lubricating oil temperature
TAHH High temperature shutdown TE-4 Separator oil temperature
TAL Low oil temperature alarm Solenoid valve function:
TALL Low oil temperature shutdown YY-1 Energize unload slide valve
TC Temperature controller YY-2 Energize increase volume rate
TCV Thermal control valve YY-3 Energize increase volume ratio
TE Temperature element YY-4 Energize decrease volume ratio
TI Temperature indicator YY-5 Solenoid valve
TS Temperature switch YY-9 Dual-port liquid injection solenoid

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4.1.39 Instrumentation
The screw compressor unit can be controlled by Unisab III control system which is mounted
on the unit and connected to a number of temperature and pressure sensors on the unit.
The Unisab III control system is described in a separate manual.
Fig. 34 and Fig. 35 show the positions of sensors, valves, etc.
See also the general piping diagram in this section, Fig. 33
The numbers refer to 4.1.37. General key to piping diagram.
Not shown
114
EC 151 158 101 192 107
102
200
126
108 163 116 161 103 105

154 106 117 104
Fig. 34: Position of valves and components SAB 151

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155 192 124 157 127 128 YY2 YY1
159
136
PM-1
196 193
140
138
144
145
146
195 123 135 160 153 119
Fig. 35: Position of valves and components SAB 151

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Physical and connection data
5. Physical and connection data

5.1. Physical and connection data
The purpose of this chapter is:
• to describe the physical data of the equipment
• to provide complete information about the requirements of the surrounding system
The safety precautions are intended for all user categories.
Safety precautions
In addition to the safety precautions mentioned in chapter 3. the following applies to the con-
nection of the unit:
- The pipe dimensions on the connections made for the unit must fit the dimensions of
the connection place. Further, the type and dimension of pipes must be approved for
the maximum pressure of the plant.
- When planning the pipe layout, make sure that it complies with prevailing standards
regarding pipe bend, flange design, etc.
- Electrical connection must be carried out so that it complies with current legislation
within the area in question.
- Electric cables must be dimensioned on the basis of the maximum power consumption
of the plant. The short-circuit levels in the installation point shall be in compliance
with figures for the exact electrical equipment on the unit. Furthermore, the overcur-
rent protection in front of the electrical panel shall be in compliance with the electrical
equipment on the unit. Make sure that the cables do not touch any moving parts. It is
recommended to place the cables in cable trays. The electrical installation must al-
ways be carried out in accordance with the prevailing rules of the installation site and
the regulations of the particular area. If in doubt, contact the local authorities.
5.1.1 Physical data

Dimension sketches and tables, see 6. Technical data.
• Data for SAB 151 compressor unit
• Data for compressor
• Block weight and centre height
• Weight of electric motor

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5.1.2 Allowable flange loads

In any screw compressor installation, suction and discharge lines should be supported in pipe
hangers (preferably within 2 ft. of vertical pipe run) so that the lines will not move if discon-
nected from the compressor, see Table 3 and Table 4.
Moments (ft-lbf) Moments {Mn]

Noz. size
Axial Vert. Lat. Axial Vert. Lat.
Nps
MR MC ML P VC VL
1 25 25 25 34 34 34
1.25 25 25 25 34 34 34
1.5 50 40 40 68 54 54
2 100 70 70 136 95 95
3 250 175 175 339 237 237
4 400 200 200 542 271 271
5 425 400 400 576 542 542
6 1000 750 750 1356 1017 1017
8 1500 1000 1000 2034 1356 1356
10 1500 1200 1200 2034 1627 1627
Table 3: Allowable flange loads
Load (lbf) Load [N]

Noz. size
Axial Vert. Lat. Axial Vert. Lat.
Nps
P VC VL P VC VL
1 50 50 50 222 222 222
1.25 50 50 50 222 222 222
1.5 100 75 75 445 334 334
2 150 125 125 667 556 556
3 225 250 250 1001 1112 1112
4 300 400 400 1334 1779 1779
5 400 450 450 1779 2002 2002
6 650 650 650 2891 2891 2891
8 1500 900 900 6672 4003 4003
10 1500 1200 1200 6672 5338 5338
Table 4: Allowable flange loads

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5.1.3 Mounting of suction isolation valve

The suction isolation valve is shipped loose from the factory so it can be installed at various
positions within the suction line piping to the compressor. Do not install the valve at the
compressor suction with flow against the cone/button, see Fig. 36.
When the isolation valve is installed in this position, uneven flow is generated across the suc-
tion check valve which is mounted at the inlet to the compressor. This uneven flow causes the
disks in the check valve to strike against the stop pin and eventually damage the internal of
the check valve.
If the isolation valve is mounted at the compressor suction, install it with flow across the
cone/button, see Fig. 36. Please design your system piping accordingly.
Incorrect
Correct
Fig. 36: Suction isolation valve mounting

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5.2. Connection data
5.2.1 Connection to compressor unit

See unit dimension sketches
Screw compressor dimension
END VIEW
TOP VIEW
Fig. 37
Note:
• A SAB 120 is shown for illustrative purposes only. Configurations of other compressor
sizes vary slightly.
• The suction connection may be moved to the other side.
• The SAB 151 has 3 pads instead of 4 feet for mounting.

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95 mm 120 mm 151 mm
Dim. Description
in mm in mm in mm
A Compressor length (shaft end to bolt) 25.63 651 30.02 763 43.63 1108
Compressor width 22.94 583 23.37 594 29.23 743
B
(stub out to bolt with or without sealing disk)
C Suction CL to shaft end 10.87 276 11.77 299 19.56 497
D Discharge CL (side) to shaft end 18.57 472 21.27 540 N/A N/A
E Discharge CL (bottom) to shaft end 18.44 468 21.90 556 31.10 790
F Shaft end to rear mounting holes 9.31 237 10.15 258 13.19 335
G Mounting holes length between centers 4.06 103 5.62 143 12.56 319
H Mounting holes width between centers, drive end 10.62 270 11.24 286 7.50 190
H Mounting holes width between centers, non-drive end 10.62 270 11.24 286 2.25 57
I Suction CL to shaft CL 6.93 176 8.47 215 10.70 272
J Discharge CL (side) to shaft CL 1.38 35 0.97 25 N/A N/A
K Discharge CL (bottom) to shaft CL 4.34 110 1.83 47 6.09 155
L Suction diameter, S 2.50 64 3.00 76 5.00 127
L Suction diameter, M 2.50 64 4.00 102 5.00 127
L Suction diameter, L 3.00 76 4.00 102 5.00 127
M Discharge diameter 2.50 64 3.00 76 4.00 102
N Shaft CL to base 4.72 120 5.34 136 5.80 147
O Shaft diameter 1.38 35 1.58 40 2.00 51
P Shaft length available for coupling, XJS 2.02 51 2.42 62 N/A N/A
P Shaft length available for coupling, XJF 2.02 51 2.24 57 3.86 98
Q Keyway width 0.39 10 0.47 12 0.50 13
R Motor adapter length from shaft end 6.87 175 7.48 190 8.13 207
Table 5: Dimensional outline
Refrigeration suction side

On the compressor suction side the pipe connection is made to the stop valve pos. 101 -
see piping diagrams. The pipe connection is welded on the valve connecting branch.
Note: Be careful not to damage the valve and other parts of the unit when welding.
See chapter 7, Installation instructions.
Refrigerant discharge side

On the unit discharge side the pipe connection is made to stop valve pos. 102 on the oil sepa-
rator - see Piping Diagrams. The pipe connection is welded on the connecting branch of the
valve.
Note: Be careful not to damage the valve and other parts of the unit when welding.
See chapter 7, Installation instructions.

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Compressor port locations
PORT CONNECTION SIZE

1 1 - 11½ NPTF
2 1/4 - 18 NPTF
3 3/8 - 18 NPTF
4 3/8 - 18 NPTF
5 1 - 11½ NPTF
6 1/2 - 14 NPTF
7 1/4 - 18 NPTF
8 1/4 - 18 NPTF
10 1/4 - 18 NPTF
11 1/4 - 18 NPTF
12 1/4 - 18 NPTF
15 3/8 - 18 NPTF
16 3/4 - 14 NPTF
18 1/8 - 27 NPTF
19 1/4 - 18 NPTF
20 1/8 - 27 NPTF
21 3/8 - 18 NPTF
Fig. 38: Compressor port location - SAB120 / XJF120

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PORT CONNECTION SIZE

1 1¹⁄₁₁ - 12UN-2B
2 7/16 - 20UNF-2B
3 1¹⁄₁₁ - 12UN-2B
4 1¹⁄₁₁ - 12UN-2B
5 1⁷⁄₈ - 12UN-2B
6 5/8 - 18UNF-2B
7 1¹⁄₁₁ - 12UN-2B
8 7/16 - 20UNF-2B
9 5/8 - 18UNF-2B
10 5/8 - 18UNF-2B
11 3/4 - 14 NPTF
12 1¹⁄₁₁ - 12UN-2B
13 1/4 - 18 NPTF
14 1/8 - 27 NPTF
15 1/2 - 14 NPTF
16 5/8 - 18UNF-2B
17 1¹⁄₁₁ - 12UN-2B
Fig. 39: Compressor port location - SAB151 / XJF151

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5.2.2 Electrical connections

The screw compressor unit can be controlled by a Unisab III regulation and control system,
which is mounted on the unit and connected to a number of temperature and pressure sen-
sors on the unit.
114
EC 151 158 192
163 160 116 161
Fig. 40
155 192 157 YY2 YY1
159
PM-1
154 153
Fig. 41

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5.2.3 List of components
151 TE1 Suction gas temperature

152 TE2 Discharge gas temperature
153 TE3 Oil temperature
154 TE4 Separator oil temperature
155 PE1 Oil pressure
156 PE2 Oil pressure filter before compressor
157 PE3 Discharge gas pressure
158 PE4 Suction pressure
159 PS Pressure switch control
160 LSLL Low level shutdown
161 HTR 1 Heater
163 High level transmitter
ZI2 Capacity linear transmitter, slide valve
ZI3 Volumizer transmitter - slide stop
YY-1 Solenoid valve. Energize unload slide valve
YY-2 Solenoid valve. Energize increase volume rate
YY-3 Solenoid valve. Energize increase volume ratio
YY-4 Solenoid valve. Energize decrease volume ratio
EC Unisab III electronic computer control
PM-1 Pump motor
192 Electric motor
Motor, pos. M
Connection data for supply voltage: VAC

Permissible variation: +10%/-15%
Frequency: 45-65 Hz
Power: kW
Supply voltage and motor power appear from the order sheet.

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Control of unit, computer control, Pos. EC

Unisab III:
Supply voltage: 85-250 VAC

Frequency: 47-63 Hz
Power: 32 VA
The connecting terminals supplying the heating elements may be supplied separately with
115 or 230 VAC, see Engineering Manual for Unisab III.
With Unisab III

As standard units are delivered with Johnson Controls Denmark control system Unisab III.
Unisab III is described in a separate manual which also includes a description of Unisab III's
general controls and how these are connected to Unisab III.
With a control system not delivered by Johnson Controls Denmark

See document no. 006204 Guidelines for mounting of control systems not supplied by John-
son Controls Denmark which is available for download on www.sabroe.com.

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Technical data
6. Technical data
6.1.1 Technical data
The purpose of this chapter is to provide the technical data of the equipment. In this chapter
technical data is defined as:
• Data for unit
• Data for compressor
• Working range
• Handling the compressor
• Noise level data
• Vibration data
• Test pressure for compressors
This chapter is primarily intended for designers, service engineers, sales personnel and pro-
spective customers.
6.1.2 Data for SAB 151

Height
Lenght
Width
Fig. 42: Data for SAB 151
See also complete dimensioned sketches of the individual compressor types and units.
External heat surface (m2)

OHU 04123/2719 5.4 m2
Max. net.
Width Length Height
Compressor type weight
mm mm mm
kg.*
SAB 151 OHU 04123 1475 3250 1900 2050
Table 6: Unit dimension data
* Excluding motor oil and water

For more exact data, see 7.1.22. Calculation of centre of gravity, support reactions and kip
angle or get the data from COMP1.

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Technical data
6.1.3 Other data
Motor type
Shorch Leroy Somer
Sizes IP 23 IP 54 PLS LS FLS
kg lb kg lb kg lb kg lb kg lb
IEC 160L 102 225 80 176 78 172 120 265
IEC 180M 190 419 173 381 98 216 100 220 135 298
IEC 180L 210 462 188 414 128 282 110 243 184 406
IEC 200M 240 529 165 364
IEC 200L 265 584 235 518 190 419 170 375 260 573
IEC 225S 309 681 205 452 290 639
IEC 225M 355 783 340 750 240 529 235 518 388 855
IEC 250S 455 1003 335 739
IEC 250M 480 1058 445 981 360 794 340 750 395 871
IEC 280S 625 1378 570 1257 460 1014 445 981 475 1047
IEC 280M 680 1499 630 1389 515 1135 490 1080 565 1246
IEC 315S 875 1929 900 1984 720 1587 850 1874
IEC 315M 945 2083 940 2072 730 1609 785 1731 1000 2205
IEC 315L 1050 2315 1200 2646 830 1830 1050 2315
IEC 355S 1500 3307
IEC 355M 1790 3946 1600 3527 855 1885
IEC 355L 2095 4619 1750 3858 1510 3329
IEC 355L (LA) (LA) 1550 3417
1900 1900
(LB) (LB)
2150 2150
IEC 400
IEC 450
See data from actual motor
IEC 500
IEC 560
Table 7: Electric motor weight
Geometrical
swept
volume
Rotor Max. drive shaft CFM M3/H
Compr. dia. Rotor Speed end 3550 2950
model mm L/D rpm Ft3/Rev. M3/Rev. rpm rpm
XJS/XJF 120M 120 1.4 5,772 0.05065 0.001433 180 254
XJS/XJF 120L 120 1.4 4,661 0.06272 0.001775 223 314
XJS/XJF 120S 120 1.4 3,600 0.08234 0.002330 292 412
XJF 151A 151 1.6 6,297 0.09623 0.002723 342 482
XJF 151M 151 1.6 5,332 0.11366 0.003217 403 569
XJF 151L 151 1.6 4,306 0.14075 0.003983 500 705
XJF 151N 151 1.6 3,600 0.16833 0.004764 598 843
Table 8: Geometrical swept volume

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Technical data
6.1.4 Selection of vibration dampers

See 7. Installation instructions for selection of vibration dampers.
6.1.5 Planning the machine room

When planning the machine room, make sure that is enough space around the plant to make
easy access for repair and maintenance tasks.
See also complete dimensioned sketches of the individual compressor types and units.
Fig. 43: Planning the machine room

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Technical data
6.1.6 Minimum compressor flow at 3550 rpm

The minimum flow capacity for each compressor varies depending upon its geometry and its
operating conditions. Typical minimum flow for each of our compressor models is listed below.
Table 9 represents minimum suction flow with the slide valve fully unloaded.
XJF 120S XJF 120M XJF 120L XJF 151A XJF 151M XJF 151L XJF 151N
Approx comp.
840 (380) 1195 (542)
Wt, lb (kg)
Minimum Driver-
600 (1)(2) 600 (1)(2)
Speed(1)(2) RPM
Maximum Driv-
3550 5772 4661 6297 5332 4306 3600
erSpeed RPM
Max. Input Pow-
208 400
erto Rotor
(155) (298)
ShaftBHP (KW)
Min. Breakaway
4 5
Torque ft-lb
(5.4) (6.8)
(Nm)
Mass Momentof
2.2 0.88 1.3 2.7 3.6 5.4 7.6
Inertia (3) ft2-
(0.093) (3) (0.037)(3) (0.055)(3) (0.114)(3) (0.154)(3) (0.228)(3) (0.319)(3)
lbm (m2-kg)
Suction Flange 4 5
in. (mm) (102) (4) (127)
Discharge Flange
XJS=Side XJF=Side or Bot. 3 (76) (5) XJS=N/A XJF=Bottom 4 (102) (5)
(5) in. (mm)
Theoretical Dis-
0.082343 0.050648 0.062718 0.09623 0.11366 0.14075 0.16833
placement ft3/
(0.002332) (0.001434) (.001776) (0.002725) (0.003219) (0.003986) (0.004767)
rev. (m3/rev.)
Displ. at 3550
rpm Driver 292 180 223 342 404 500 598
Speed ft3/min (497) (306) (378) (580) (686) (849) (1015)
(m3/hr)
Displ. at 2950
rpm Driver 243 149 185 284 335 415 497
Speed ft3/min (413) (234) (314) (482) (570) (706) (844)
(m3/hr)
Displ. at 1750
rpm Driver 144 89 110( 168 199 246 295
Speed ft3/min (245) (151) 187) (286) (338) (419) (501)
(m3/hr)
Displ. at 1450
rpm Driver 119 73 91 140 165 204 244
Speed ft3/min (203) (125) (155) (237) (280) (347) (415)
(m3/hr)
Capacity Control Infinitely adjustable from 100% to 25% by piston- or hand wheel- (except 95) actuated
slide valve
Volume Ratio. Variable in 3 steps: 2.2, 3.5, 5.0
1. Contingent upon compression ratio, bearing L10 limitations, oil viscosity, and other operating conditions.
2. Compressor suction flow may be zero at full unload slide valve position below 1800 RPM.
3. Does not include coupling. Resolved to drive shaft.
4. A 3 in. suction flange is installed on 120S compressors if operating at 1750 or 1450 rpm.

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Technical data
XJF 120S XJF 120M XJF 120L XJF 151A XJF 151M XJF 151L XJF 151N
5. XJS and XJF discharge casings are interchangeable within a model size to allow selection of discharge flange
orientation.
6. At compressor suction flange. Minimum evaporator temperature can be lower.
7. Standard ASTM A48 class 40 gray cast iron housing. Some models capable of higher pressures. Consult fac-
tory.
8. ASTM A395 grade 60-40-18 ductile iron housings.
Table 9

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Technical data
6.1.7 Operating limits

Fig. 44 shows an example of a permissible working range for a compressor. The operating
limits depend on the specific compressor, compressor cooling method, economizer or not, the
refrigerant used, etc. You will get the relevant diagram from the COMP 1 calculation program.
TC
5C
60
Con densing temperature (deg. C)
40
20
Oil pump required

-20
-40
-60
5C
-8 0 -7 0 -6 0 -5 0 -4 0 -3 0 -2 0 -10 0 10 20 30
TE
Evapo rating temperature (deg. C)
Fig. 44: Operating limits, example only

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Technical data
6.1.8 Selecting electric motor

The IEC electric motors type IP23 or IP54 (55) are the motors which are normally used to
drive the compressors.
Fig. 45: IP23 Drip-proof motor
When selecting an electric motor, the following factors should be taken into consideration:
6.1.9 Motor dimension

The motor size is determined on the basis of power demands of the compressor during the
current operating conditions calculated by the Sabroe COMP1 program. Always choose a mo-
tor a little bigger, however, because:
a. To ensure that the motor has sufficient driving power both during start-up, at minor
deviations from the calculated operating conditions and with regard to mechanical
transmission loss, the calculated power demand should be increased by one of the fol-
lowing factors:
1) Air conditioning plant: Factor 1.10
2) Other refrigeration plants: Factor 1.15
b. Consider which type of plant the compressor is going to work on. The motor must be
dimensioned in accordance with the following rules:
• For plants where a high ET may be expected, consequently also a higher CT in
the start-up phase, the motor must be dimensioned to meet the high operat-
ing temperatures. Usually, there is no need to incorporate factors 1 and 2.
For booster compressors special consideration should also be given to the
choice of motors.
• Alternatively, the motor can be connected to a system for ampere limitation,
which reduces the compressor capacity until the planned operating tempera-
tures have been reached. This element is found in Unisab III, which must be
linked to the Amp. signal. Also in this case, disregard factors 1 and 2.
Note: Please note that for class F insulation motors (105K) for operating conditions like for
class B (90K), approximately 10% continual overloading of the motor is acceptable in relation
to the marking effect.
6.1.10 Motor selection and starting torque

Motors must be sized adequately for all expected operating conditions as start-up, pull down
and load variations quite often require significantly more horsepower than nominal design.
Motor starting torque capacity must also be considered, especially when across-the-line start
is not used. Motor starting and pull-up torque must be at least 20% greater than compressor
requirements at maximum expected start-up conditions. See the torque data.
Note: Motor starting torque varies considerably with various manufacturers - therefore, ob-
tain specific torque data for the motor being used.

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(2)(3)
Mass (2)(3)
Mass
Starting Breakaway Breakaway
moment of moment of
SAB model torque (1) torque torque
inertia inertia
multiplier (ft-lb) (Nm)
(lb-ft2) (kgm2)
SAB 120 S 2.65 4 5 2.20 52.1
SAB 120 M 1.63 4 5 0.88 20.9
SAB 120 L 2.02 4 5 1.30 30.8
SAB 120 E 2.65 4 5 2.20 52.1
SAB 151 S 3.05 5 7 2.70 64.0
SAB 151 M 3.58 5 7 3.64 86.3
SAB 151 L 4.47 5 7 5.42 128.5
SAB 151 E 3.32 5 7 7.56 179.2
Table 10
1. High stage or booster application.

2. Including standard compressor coupling half.
3. Inertia resolved to drive shaft.
Nm / ft-lb
68 / 5 0 Psig / Bar
275 / 19
250 / 17
54 / 4 0
225 / 16
High stage
Discharge pressure - Psig / Bar
Starting torque Nm / ft-lb
200 / 14
41 / 3 0 175 / 12
150 / 10
125 / 9
27 / 2 0
Psig / Bar
55 / 3,8
Booster
45 / 3,1
35 / 2,4
14 / 1 0 25 / 1,7
15 / 1,0
10 / 0,7
0
0 50 100
Fig. 46

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Fig. 47: Motor/compressor torque
Motor “A”: Adequate to start the compressor.

Motor “B”: Will not start the compressor.
Note: Starting torque of both motors (1) is above compressor torque. However, the pull-up
torque (2) of motor “B” is below the compressor torque curve and motor “B” will not acceler-
ate the compressor to 100% speed.
Starting torque for specific compressor

Multiply the starting torque value from high stage or booster curves at 100% of normal run
speed by starting torque multiplier for appropriate compressor size.
6.1.11 Motor/compressor torque

Ensure that the motor starting and minimum pull-up torque capabilities will exceed the com-
pressor requirements at the anticipated condition that will be experienced during normal
starting.
Note: Star-delta and auto transformer (reduced voltage) motor starting methods drastically
effect the starting torque available from motors as indicated:
Across-the-line 100% torque

Auto transformer 25-64% torque
Star-delta 33% torque

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Technical data
6.1.12 Direction of rotation

The direction of rotation of the compressor is clockwise when looking at the coupling flange
and the compressor as illustrated in Fig. 48.
Fig. 48: Direction of rotation
6.1.13 Emergency stop

The compressor control system must be equipped with an emergency stop.
If the compressor is delivered with a Unisab control system, this emergency stop will be an
integrated part of the system as shown in Fig. 49.
Emergency stop
Fig. 49: Emergency stop on the unit
The emergency device must be adjusted in such a way that after a stop instruction it stays in
its stop position until it is deliberately reset.
It must not be possible to block the emergency stop without a stop instruction being released.
It should only be possible to reset the emergency stop by a deliberate act. Resetting the
emergency stop must not cause the compressor to start operating, but only make it possible
to restart the compressor.
6.1.14 Other emergency stop requirements

• It must be possible to operate the emergency stop by means of an easily recognizable
and visible manual handle to which there is free access.
• The emergency stop must be able to stop any dangerous situation as quickly as possi-
ble without this leading to any further danger.

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6.1.15 Noise data

Noise data is stated in:
- A-weighted sound power level, Lw
- A-weighted sound pressure level, Lp
• The average sound pressure is calculated from the formula 8.3 in ISO 3744.
• Normally, the immediate sound pressure on site lies between the Lw and Lp values
and can be calculated if the acoustic data of the machine room is known (reverbera-
tion time).
• In a typical machine room without any noise absorbing materials, the sound pressure
will be 2-6 dB below the stated sound power.
• Check measurement of the sound pressure should therefore always be accompanied
by a measurement of the reverberation time or similar of the room.
The values are stated for a complete unit including noise cabinet and when the compressor is
in 100% capacity.
Fictional frame
Dimensional plane
1 metre Reflecting plane

1 metre
Fig. 50: Noise cabinet

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Technical data
6.1.16 Noise data for screw compressor
Noise data for screw compressors
Evaporating temperature TE -15°C

Condensing temperature TC +35°C
Refrigerant R717/HCFC/HFC
Speed 2950 rpm
Lw Lp
Type of unit
(dBA) (dBA)
SAB 120 S 100 83
SAB 120 M 101 84
SAB 120 L 103 86
SAB 120 E 104 87
SAB 151 S 106 88
SAB 151 M 107 89
SAB 151 L 107 89
SAB 151 E 108 90
Table 11: Noise data
Sound pressure values higher than the stated average value may be found locally, e.g. close
to the air inlet or outlet grid for the drive motor or air discharge on top of the noise cabinet.
Higher noise levels may appear if the noise is not mounted correctly.
See also section 6.1.15. Noise data6.1.16. Noise data for screw compressor.

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6.2. Noise and vibration
6.2.1 Noise from compressors and units

Noise is inevitable when a compressor or unit is working. But by taking this into consideration
in the project phase, the noise pollution of the environment can be reduced considerably.
As Johnson Controls Denmark has been aware of this problem for years, our compressors and
units are designed to meet market demands concerning maximum noise levels.
Naturally, modern compressor units must be expected to make noise and this only makes it
more important to evaluate the sound data of the compressor or unit correctly.
This will be discussed in the following. In this connection Johnson Controls Denmark would
like to point out that the machine room can be made a pleasant place to work at a reasonable
cost. Using noise absorbing materials could be one solution to the problem.
6.2.2 Sound power and sound pressure

As shown in subsection 6.1.15.6.1.16. in Table 11, sound data is indicated as
• sound power level, Lw
• sound pressure level, Lp
It is essential to distinguish between these two values as they are stated in dB (decibel) and
should be read as explained in the following.
6.2.3 Sound power level, Lw

According to ISO 9614-2, Lw is measured directly at the unit by installing a measuring grid as
close to the unit as possible, see Fig. 51.
Fig. 51: Unit covered with a measuring grid
The measuring grid is divided into fields of max. 1 sq. m each. Measuring is carried out
by moving the sound level meter in a back and forth movement, as illustrated in Fig. 51. The
sound level meter now calculates the total sound power level, Lw, for the entire unit. As the
sound power level depends on the surroundings of the noise source, it must be considered a
somewhat theoretical value. This is where the sound pressure level, Lp, becomes interest-
ing.

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6.2.4 Sound pressure level, Lp

It is in fact the sound pressure level, Lp, that is measured by the sound meter. The sound
pressure level, Lp, is automatically converted to the sound power level, Lw, in the sound meter
by means of its built-in calculation programs.
The sound pressure measuring, however, depends on the room where the measuring is car-
ried out. Consequently, this may present different results from one room to another.
The way the room is arranged and the choice of building materials considerably influence the
measuring results.
This is why the measured values of manufacturers for sound pressures are based on standard
measuring according to ISO 3989 which refers sound pressure level, Lp, to a free field
above a reflecting plane at a distance of 1 metre from the measuring grid as described in
subsection 6.1.3. Sound power level, Lw.
The above facts should be taken into consideration during a check measuring of the plant as
mentioned in subsection 6.1.6. Assessing the measured values.
6.2.5 Frequency
Sound is fundamentally a pressure wave in the air at a given wave length (frequency).
Sound waves are emitted at many different frequencies from a compressor unit because of
the different moving parts.
The human ear can normally perceive frequencies in areas from 20 Hz to 20 k Hz but we do
not perceive all frequencies equally well. Consequently, a sound meter must measure the
sound pressure at various frequencies and then filter the measuring corresponding to the per-
ceptual capacity of the ear (the A-weighting).
Add to this the purely subjective perception of sound, as most people feel considerable un-
ease when hearing the so-called "pure" notes. If a frequency is followed by a sound pressure
of 3-6 dB above the other frequencies, it feels annoying. For screw compressors it is a fact
that 300 and 600 Hz is normally felt to be annoying whereas reciprocating compressors issue
a more low-frequency (pleasant) sound.
6.2.6 Assessing the measured values

Because of the difference between the actual measured sound and the sound perceived by the
human ear, the measured values are weighted in the sound meter. Usually, the sound meter
is set for A-weighted values called dB (A), based on a logarithmic scale. This is why it is so
important to apply the same unit of measure when comparing values from several different
machines.
Further, we would like to point out that the sound pressure level, Lp, measured in the machine
room as described in subsection 6.1.4. Sound pressure level, Lp will always be higher than the
one indicated in Table 11. The measured value will normally be somewhere between the sta-
ted Lp and Lw values.
In machine rooms with several compressors the total sound pressure level can be calculated
by adding ∆ L (see the curve in Fig. 52) to the sound pressure value for the unit with the
highest sound pressure.

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3,0
2,5
2,0
∆ L 1,5
dB
1,0
0,5
0 5,0 10,0 15,0
Difference (L2-L1) dB
Fig. 52: Curve for adding logarithmic levels
Example 1:
Two compressors in the same room
Compressor 1, LP1 = 81 dB (A)
Compressor 2, LP2 = 86 dB (A)
Difference 5 dB (A)
Total sound pressure level:
LP = 86 + 1.2 = 87.2 =/~ 87 dB (A)
Example 2:
If two compressors have the same sound pressure level, e.g. 86 dB (A), the difference
will be 0.
Total sound pressure level:
LP = 86 + 3 = 89 dB (A)
Example 3:
With several compressors in the same room, the sound pressure level is calculated by
means of the curve, Fig. 53, as follows:
3 compressors
56 52 61 dB
57.5
62.6 63 dB
6 compressors
48 54 61 62 62 58 dB
55.0
62.0
65.0
66.7
67.2 67 dB
Fig. 53
In case of check measuring, it is important to make more than one sound pressure meas-
urement, e.g. by measuring in fields as shown in Fig. 51. A few local measurements may re-
sult in incorrectly high values.
Likewise, be aware that the stated measured values for a certain unit should comprise a com-
plete unit including compressor, motor, oil separator etc. which have all been covered by the
measuring grid. When assessing the measuring results it is therefore important to know the
extent of the measured surface area in the surrounding measuring grid.

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If the compressor is working at part load, the measured values will generally be higher than
the ones indicated in the tables.
6.2.7 How to check sound data

The only proper method to check the sound data is to measure the sound power level, LW, on
the actual site. This requires setting up a measuring grid and the use of sound intensive
equipment.
If only using sound pressure Lp meters, an additional measurement of the reverberation peri-
od of the room will be required. It will then be possible to determine a theoretical value of the
emitted sound power provided that the background noise is too low to be of any sig-
nificance.
6.2.8 Reducing acoustic noise in a machine room

The acoustic environment should be considered when planning or rebuilding a machine room.
A minor investment can change an acoustically hard room into a noise reduced room which is
pleasant to work in.
This is achievable by fitting sensible noise absorbing materials on walls and ceilings or making
it part of the building construction.
It is recommended to consult a firm with noise reduction experience in order to find the best
possible solution for your particular needs.
Computer calculated frequency analyses for this purpose are available from Johnson Controls
Denmark for your particular compressor unit.
Another and very effective solution is to noise insulate the compressor unit itself. Johnson
Controls Denmark offers to deliver pre-fabricated and tested noise baffle boards.
Fig. 54
In general
The following includes a description of the different factors that influence the acoustic quality
of a machine room.

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6.2.9 Reverberation time

By correct application of noise absorbing materials, the reverberation time of a machine
room can be changed. The reverberation time is defined as the time it takes for the sound
pressure level, Lp, to drop 60 dB once the noise source stops.
The duration of the reverberation time depends on the volume of the room and of the average
absorption coefficient for the noise absorbing materials fitted in the room as they should be.
Absorption coefficient
Usually the absorption coefficient, a, for noise absorbing materials is 0.5 to 0.8. See Fig. 55.
Incident Noise reducing

sound power material
Absorbed
sound power
Transmitted
sound power
Reflected sound power

X=
Incident sound power
Fig. 55
Subjective perception of noise reduction

With reference to Table 12, which indicates how the human ear perceives the effect of noise
insulation in a machine room, note the following:
• Investing in sensible noise insulation of the machine room ceiling usually reduces the
reverberation time by half. This has a great subjective effect.
• Using a pre-fabricated noise baffle board from Johnson Controls Denmark typically re-
duces the sound pressure in the machine room by 20 dB. This is naturally considered
a great improvement, subjectively perceived.
Reduction of sound Subjective perception

pressure by noise Reduction of the average sound of the improved
insulation of pressure level by noise insulation acoustic quality of the
compressor unit room
Relative
dB dB reverberation
time
0 0 1 -
1 0.5 0.9 Insignificant
3 1 0.8 Perceivable
6 2 0.6 Distinct
10 3 0.5 Considerable
25 6 0.25 Very considerable
Table 12
Johnson Controls Denmark prefabricated Version 2.0 noise baffle board for compressor units.

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6.2.10 Vibration data for compressors - all compressor types

Vibration data for Johnson Controls Denmark's Sabroe reciprocating compressors comply
with: the ISO 10816, standard, Part 6, Annex A, group 4, AB, which fixes max. permissi-
ble operating vibrations at 17.8 mm/s.
Vibration data for Johnson Controls Denmark's Sabroe screw compressors comply with: ISO
10816 standard, part 1, Annex B, Class III, C, which fixes max. permissible operating vi-
brations at 11.2 mm/s.
The measurements are made as illustrated in the figure below (points A-D).
Fig. 56: Vibration data
Pay attention to the following, however:

• Motors comply with EN 60034-14 (CEI/IEC 34-14) Class N.
• When placing the unit on the vibration dampers supplied by Johnson Controls Den-
mark (additional), the vibrations against the foundation are reduced by:
- 85-95% for screw compressor units
- 80% for reciprocating compressor units
• However, higher vibration level may occur if
- motor and compressor have not been aligned in accordance with requirements
- the compressor runs at an incorrect Vi ratio. This applies to screw compres-
sors
- the piping connections have been executed in a way that makes them force
pull or push powers on the compressor unit or transfer vibrations to the unit
caused by natural vibrations or connected machinery
- the vibration dampers have not been fitted or loaded correctly as indicated in
the foundation drawing accompanying the order

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6.2.11 Test pressure levels for standard compressors and components

All components for refrigeration plants which are under the influence of gas pressure must be
pressure tested to prove their strength and tightness.
The approving authorities determine the test pressure levels on the basis of various criteria.
However, the test pressure requirements can be summarized into a number of standard pres-
sure levels which in practice meet the requirements set up, and which can therefore be ap-
proved by all authorities involved.
Table 13 shows the standard pressure levels used by Johnson Controls Denmark. In case of
specific applications, the authorities may, however, demand a higher test pressure level.
Within certain limits such requirements can be met for Sabroe compressors - against an addi-
tional price. Please, contact Johnson Controls Denmark for further information.
When pressure testing compressors and vessels, components must first prove their strength
by resisting the test pressure of the strength test. This test is carried out with air.
Afterwards, the leak test is carried out, also with air, at the prescribed pressure for 30 mi-
nutes.
Units consist of components which have been pressure tested as described in the following
table. This means that it is only necessary to leak test the unit. Dwelling time is 20 minutes.
Leak testing is carried out with pressurized air at the pressure stated in the table. All weldings
and connections are covered with a frothing liquid which will start foaming in case of a
leak.
Standard test pressure levels

Strength Leak testing with
Compressor
Compressor side Testing pressurized air
type
bar [psi] bar [psi]
SAB 120
SAB 151 The entire compressor block 40.3 [566] 28 [377]
SABflex
Compressor All types
40.3 [566] 28 [377]
unit The entire unit
Table 13: Test pressure levels

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Installation instructions
7. Installation instructions
7.1.1 Installation
The purpose of this chapter is to describe:
• The dangers which may occur from failure to follow instructions and safety precau-
tions pertaining to the installation phase
• How to install the equipment safely and effectively
This chapter is primarily intended for installation supervisors, installation technicians and elec-
tricians. It can also be used in sales activities to inform future customers of installation re-
quirements for a compressor unit.
7.1.2 Safety precautions

Read chapter 3. Safety precautions carefully before installation. In case of doubt please con-
tact Johnson Controls Denmark.
The safety precautions and instructions belonging to the individual sections of this manual
must also be read and followed.
7.1.3 Installation data

The physical data of the compressor is included in chapter 5. Physical and connection data.
See also section 6.1.15. Noise data6.1.16. Noise data for screw compressor.
7.1.4 Installation and first start-up procedure

Installation in terms of mechanical work (refrigeration system and piping), electrical work and
installation of safety equipment must be performed in accordance with local codes/rules
and/or according to EN 378-3 and EN 378-4 as a minimum requirement.
The pressure loss in the downstream line from the safety valve must meet the values stated
in EN 13136 to which EN 378 is referring. The data necessary to dimension the line in accord-
ance with this standard is stated in the data sheet for the specific unit on the first page of this
manual.
Make sure that all necessary documents are available including declarations, certificates,
identification plates, manuals, machine card, log books etc. and/or other documentation re-
quired according to local rules and/or EN 378.
7.1.5 Installation drawings

Before commencing the installation, make sure to have drawings showing how to connect the
unit available.
7.1.6 Personnel requirements

The personnel carrying out the installation must be well-trained within the area of refrigera-
tion technique, possess knowledge of refrigeration systems and have experience with piping
as well as wiring installations. Where authorisation is required, the electrician must possess
an approved authorisation.
The compressors must only be connected by an authorised refrigeration company.

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7.1.7 Preparing the installation

The following describes the preparations to be carried out before commencing installation.
7.1.8 Tools and Accessories

The list below shows the tools, accessories and materials which are necessary in order to car-
ry out the installation correctly.
Ordinary Hand Tools
Tools for installing pipes
including welding tool
The following can be ordered:
Tools for alignment of coupling
Tools for shaft seal removal
Accessories
Lifting eye
Shackles
Oil charging pump, see description in section 11.1.12. Charging compressor with lu-
bricating oil.
7.1.9 Safety equipment

During installation, use the following safety equipment, which must be in good condition:
• Safety shoes
• Gloves
• Eye protectors
• Fire-fighting appliances
• Salt water solution for rinsing eyes
• Oxygen equipment
7.1.10 Local regulations

The installation must be carried out in accordance with the prevailing rules of the installation
site and the regulations of the particular area. If in doubt, contact the local authorities.
7.1.11 Preparing the mounting site

Before installing the unit, carry out the following:
1. Check that the foundation is level and has the necessary strength.
2. Check that all access roads are wide enough for the unit to pass, see the dimension
sketches.
3. Block the mounting site. The site must be blocked to prevent unauthorised personnel
from being injured or causing damage.
4. Clear the mounting site.

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7.1.12 Space requirements

When installing the unit, make sure that the plant can be serviced without problems, i.e. al-
ways make sure that there is enough space around the plant. See section 6.1.5. Planning the
machine room.
7.1.13 Lifting and loading instructions

See chapter 14. Transport instructions.
7.1.14 Unpacking and inspection

7.1.15 Disposal of materials which are not reusable

Materials from the unit packing which cannot be reused must be disposed of according to local
regulations.
7.1.16 Moving the equipment to the mounting site
after unloading and unpacking

7.1.17 Installation instructions
Danger!
Risk of injury to personnel and damage to equipment! Always read the safety precautions be-
longing to this equipment before start. Failure to comply with safety precautions may cause
death or injury to personnel. It may also cause damage to or destruction of the equipment.

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7.1.18 Alignment of compressor and unit

The following describes the installation process of the compressor unit.
• Alignment of unit against the foundation, see 7.1.19.
• Alignment of compressor/motor against the base frame, see 7.1.20.
• Mounting of coupling between compressor and motor, see 7.1.23.
• Piping connections, see 7.1.25.
To ensure that the compressor and motor have a long service life and vibrationless operation,
the compressor/motor and unit must be aligned with care. Misalignment of the compressor
unit may produce stress and vibrations which can be transmitted to the compressor or motor
and cause a breakdown.
Normally the arrangement of motor and compressor is pre-aligned and mounted stress free
on the unit to ensure stress free operation. If the motor has not been mounted from factory
or if the motor or compressor has been replaced, the arrangement must be aligned properly
by weighing and adjustment.
Vibrations may be caused by the following:
1. Distortion between compressor unit and foundation.
2. Distortion between compressor and base frame.
3. Distortion between motor and base frame.
4. Strains from piping connections between compressor and plant.
5. Untruth in compressor or motor shafts.
6. Untruth in coupling.
7. Imperfect balancing of coupling.
8. Imbalance in compressor and motor.
The fitter who sets up the unit is responsible for points 1 to 4. The other points 5 to 8 must be
checked by the compressor or motor manufacturer prior to delivery.
The following sections will deal with the points which the fitter is responsible for.
7.1.19 Alignment of unit against foundation

When installing the unit on the foundation or the machine floor, it must stand free of stress
and rest evenly on all supports.
The unit can be installed in the following ways:
• directly on the foundation with foundation bolts,
see section 7.1.21. a. Mounting directly in foundation.
• on vibration dampers, see section 7.1.21. c. Mounting on vibration dampers.
In both cases the unit must be aligned before fitting the connecting pipes to the installation.
7.1.20 Alignment of compressor and motor

Under preparation.

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7.1.21 Laying of unit foundation

Foundation for standard units for stationary purposes is made in one of the following ways:
a. Mounting directly in foundation
When installing a unit directly on a concrete foundation, the foundation should be cast in ac-
cordance with the foundation drawings. In principle the foundation is designed as shown in
Fig. 57.
Fig. 57: Foundation sketch
When the foundation has been cast with the holes set out (see foundation drawing) and has
hardened, the unit is positioned on wooden beams in a flush position. Adjust the height of the
beams so that the foundation plate is slightly recessed into the foundation, see Fig. 57.
To make sure that the foundation plates are kept close to the base frame during the casting
process, secure the foundation plates to the base frame by means of steel wire.
The concrete which is used for the foundation bolts must be dry, i.e. it must have a low water
content. Stamp down the concrete around the bolts and the foundation plate.
It is important that the concrete has a low water content as this prevents the hardening con-
crete from shrinking.
10-14 days should pass before tightening the foundation bolts. Remove the steel wire and
the wooden beams beforehand and check that there is no air space between the foot plate of
the base frame and the foundation plate. Otherwise, shims must be inserted between the
plates before tightening them.
As shown in Fig. 57 the foundation has been cast as part of the machine floor and as indicated
it is 100 mm above the floor surface.
With this type of foundation, vibrations can be transferred from the unit to the building.
However, the vibrations can be reduced by isolating the concrete foundation from the building
as described in section b or by placing the unit on vibration dampers as described in section
c.
b. Isolating unit foundation from building
To avoid vibrations from the unit being transferred to the building, the compressor unit can be
mounted directly on a foundation block which is isolated from the building.
The foundation block is cast as an independent unit as shown in Fig. 58.

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Fig. 58: Foundation block
This foundation block is cast directly on a firm and supporting bedding and is isolated from
the machine floor by means of approx. 20 mm thick plates made of e.g. high density
polystyrene.
If the bedding is part of the cast building construction, the foundation block can be cast on a
vibration mat with a suitable bearing capacity. This should be taken into account by the sup-
plier.
The dead weight of the foundation block must be in accordance with the weight of the unit.
Consequently, the block is cast with an outer length and width as indicated in the foundation
drawing accompanying the order.
The height H of the block must be 450 mm for all units provided that concrete with a density
of approx. 2.2 tonnes per m3 is used.
When mounting the compressor unit on top of the block, follow the description in section a.
The general values for vibrations emitted from the unit are stated in section 6.1.15. Noise da-
ta6.1.16. Noise data for screw compressor.
c. Mounting on vibration dampers
In view of reducing the transmission of vibrations from the compressor unit to the building,
the unit is often positioned on vibration dampers. This way reductions can be obtained as
indicated in section 6.1.15. Noise data6.1.16. Noise data for screw compressor.
On delivery of a unit from Johnson Controls Denmark, the vibration dampers have not been
mounted. They are included in the delivery and marked with a code.
Similar codes are written in the drawing indicating the position of the vibration
dampers. This drawing will be forwarded for each specific order and must be used
for that particular order only.
It is very important that the vibration dampers are fitted correctly as shown in the drawing as
the load on the foot plates varies. Fig. 59 illustrates the different types of vibration dampers
for stationary and marine units.
The vibration dampers for stationary units are made with a rubber surface underneath so that
they can be positioned directly on the concrete foundation without having to be fixed. This
means that pockets in the foundation are not required.
Further, vibration dampers for stationary use can be adjusted in height and thus equalize mi-
nor deviations that may occur in the foundation level. Vibration dampers for marine use, how-
ever, cannot be adjusted, which makes a level foundation even more important. Read more
about this in the following.

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Fig. 59: Stationary plant
Stationary plant
The machine room floor or foundation where the unit should be positioned must have the nec-
essary bearing strength. It must be plane within a maximum of 5 mm from the horizontal
level so that the difference in height between the foundation plates does not exceed the scope
of adjustment on the vibration dampers.
The vibration dampers are installed on the unit in their unloaded state while the unit is sus-
pended from a crane; the unit is then placed in its final position and aligned with the aid of
wedges positioned close to the vibration dampers.
When the unit is horizontal, both longitudinally and laterally, the screws in the vibration
dampers are tightened exactly enough to release the wedges.
The vibration dampers have been selected to compress between 1.0 and 2.0 mm below the
expected load calculated at the point of support.
To check that the vibration dampers are adjusted for the correct load, make a note of meas-
urement “A” in the unloaded state for each individual damper. After loading of the vibration
dampers, “A” should be reduced by 1 to 2 mm. When the adjustment is correct, tighten the
lock nut. The alignment of the unit against the foundation is now completed. See also section
7.1.19. Alignment of unit against foundation.
Marine plant
As mentioned earlier the vibration dampers for marine use cannot be adjusted in height. This
means that the foundation must be plane and horizontal within a maximum deviation of 2
mm.
As the loads on the supporting surfaces of the unit vary, different vibration dampers may be
used on the same unit. Consequently, it is important to position them in the right places in
compliance with the drawing forwarded for the unit in question.
To check the deflection of the vibration dampers while loaded, measure "A", Fig. 59: Station-
ary plant, while the unit is still suspended in the crane. After the unit has been installed,
measure "A" once more. The difference (deflection) must be between 3 and 5 mm for all vi-
bration dampers.
If this is not the case, liner plates must be inserted under the vibration dampers until the
above deflection has been obtained.
As the vibration dampers for marine use also have to dampen the vibrations coming from the
foundation caused by the main and auxiliary engine, vibration dampers are selected on the
basis of the information table and the mentioned descriptions, etc. This table including ap-
pendices is sent to the person in charge at Johnson Controls Denmark, who will then select
the appropriate dampers.

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7.1.22 Calculation of centre of gravity, support reactions and kip angle

Calculation example: SAB 193L, IEC 280, single oil filter, oil cooler type AlfaNova ,
no oil pump.
1. Calculate compressor centre of gravity
(only necessary when calculating of kip angle is desired)
Calculate:
z (Table 16 Column 9) = h + zi + J.
zg motor (Table 16 Column 3) = h + shaft height ∆z + J.
Then edit the table with the calculated value. (the present values is based on J = 140 mm)
2. Fill in/edit Table 20 with the values from the tables above corresponding to the unit in
question.
3. Calculate M*X, M*Y, M*Z and ∑M*X……..
4. Calculate center of gravity.
5. Calculate support reactions.
6. Calculate kip angle
Selection of vibration dampers.
When You have calculated the support reactions You are able to select the right vibration
dampers from the table xx.
Note: Only calculations with separator OHU 04123 can be done with the data below
Some basic informations:
Weight kg
Support reaction kg
Unit
Kip angle degrees
Dist. mm
Table 14
Dimensions oil separator OHU 04123

(l, b measured between "feets", h to the upper side of the horizon profiles).
Length x Width y Height z

l b h
2268 906 890
Table 15

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Motor displacement Compressor

Centre of gravity on unit
Column Column Column Column Column Column
Column Column Column
1 2 3 4 5 6
7 8 9
Shaft
x Yg zg ∑M
height zi X Y z
flange motor motor comp
∆z
1288
SAB 120 1031 500 1222 137 203 488 1562 414
(IEC250)
1305
SAB 151 794 607 1242 157 220 658 1522 481
(IEC250)
SAB 193 S 1217 377 1323 290 310 1081 2053 463 1343
SAB 193 L 1217 377 1323 290 325 1206 2080 457 1358
SABflex 927 421 1284 394 413 660 1630 427 1303
Fixed values
Calculated and/or edited values
Table 16
∑M comp = comp + tunnel+ support + POV + stop valve

zi: centre of gravity of compressor in relation to dist. flange
zg motor = h + Shaft height ∆z + J
z = h + zi + J
Shaft height ∆z: dist. discharge flanges (∆z) to drive shaft
j: height of discharge flange (from dimension sketch)
SABflex j: 0
zi from Table 16, Column 5
h from Table 15
Example: SAB 193 L, J = 143 gives
zg motor = 890 + 290 + 143
z = 890 + 325 + 143
Oil filter, Oil cooler, Oil pump
Type M x y z
AlfaNova ANHP52-1 63 1720 -172 422
3HH 34 134,4 1659 -147 385
Oil cooler
Wahterus 3HH 66 159,6 1659 -147 385
3 HH 116 207,6 1659 -147 385
Oil pump 960A0082 65 2440 133 450
Oil filter 1,
SAB 193 535E0013EU 126 256 -147 210
lower
Oil filter 2,
SAB 193 126 256 -147 605
upper
Oil filter 1, SAB 151/
535C0513 39,6 500 -147 330
lower SABflex
Oil filter 2, SAB 151/
39,6 500 -147 660
upper SABflex
Fixed values
Table 17

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The parts is added weight for estimated related tubing and oil etc.
Electric motor
Motor Column 10 Column 11

Motor weight from motor data sheet + 40 kg for
IEC ∆x motor M
motor support
See column 1 in Table 16
180 241,5
and column 10 in Table 18
200 266,5 x =x flange - ∆x motor
225 304,5 See column 2 in Table 16
250 323,5 y =Yg motor
280 374 See column 3 in Table 16
315 419 z =zg motor
Fixed values
Table 18
Electrical cabinet
X
x from dimension
Only SABflex M Y Z
sketch or
compressor
use default
kg mm mm mm
VLT 125 -430 -45 1250
Electrical cabinet 50 -462 490 1320
Table 19

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M X Y Z M*X M*Y M*Z

kg mm mm mm kg*mm kg*mm kg*mm
Separator 900 1075 466 520 967500 419400 468000
Diverse 49 733 1000 914 35917 49000 44786
Oil 120 934 702 320 112080 84240 38400
See
Compressor 1206 2080 457 1358 2508480 551142 1637748
Table 16
See
Motor 1140 800 377 1323 912000 429780 1508220
Table 18
See Oil filter 1
126 256 -147 210 32256 -18522 26460
Table 17 lower
See Oil filter 2
0 256 -147 605 0 0 0
Table 17 upper
See
Oil cooler 63 1720 -172 422 108360 -10836 26586
Table 17
See
Oil pump 0 2440 140 450 0 0 0
Table 17
See
SABflex VLT 0 -630 -45 1250 0 0 0
Table 19
See SABflex
Table 19 electrical 0 -662 490 1320 0 0 0
cabinet
3604 4676593 1504204 3750200
Fixed values
Table 20
Calculated center of gravity
Mt XG YG ZG
kg mm mm mm
3604 1298 417 1041
XG=M*X/∑M
Table 21
Calculated Support reactions
F1 710 kg F1=Mt*YG/b*l-XG/l
F2 832 kg F2=Mt*b-YG/b*l-XG/l
F3 950 kg F3=Mt*YG/b*XG/l
F4 1112 kg F4=Mt*b-YG/b*XG/l
3604
Table 22

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Reactions: Unit to bee seen from top
F1 710 F3 950
x = 0, x = 2268 = L,
Y = 906 = b y = 906
Motor Compressor
F2 832 F4 1112
x = 0, x = 2268 =l,
y=0 y=0
Filter Oil cooler
Table 23
Calculation of kip angle:
Kip angle = atan YK/ZG

where
YK = YG if YG < b/2
or YK = (b - YG) if YG > b/2
Calculated kip angle
YK = YG = 417
21,9 degrees
Fig. 60
Dimensions in mm Overall Max.

Thread Weight
Type bolt load
D H min. H max. G (kg)
length (Kg)
TF 3000 151 35 1) 120 M 20 2.2 3000
TF 4000 170 39 1) 120 M 20 2.9 4000
TF 6000 205 44 1) 150 M 24 4.8 6000
1) Levelling of the bolt up to its total length.
Table 24: List of vibration dampers
Compression Max. load

Type
1 1.5 2 2.5 [kg]
TF3000-80 400 900 1450 2150 3000
TF4000-80 440 1530 2450 4700 4000
TF6000-80 1000 2000 3000 4000 6000
Table 25: Loading range

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7.1.23 Instruction for mounting of coupling

The arrangement of motor and compressor is mounted stress free on the unit to ensure sound
operation. The arrangement is pre-aligned from factory. If the motor has not been mounted
from factory or, if for some other reason, either the motor or the compressor has been moun-
ted on site the arrangement must be aligned properly by weighing and adjusting.
Checking motor/compressor rotation
Warning!
Make sure coupling hubs are tightened to the shaft before rotating the motor to prevent them
from flying off and possibly causing serious injury or death.
Warning!
Injury may occur if loose clothing, etc. becomes entangled on the spinning motor shaft.
Compressor rotation is clockwise when
facing the end of the compressor shaft.
COMPRESSOR
Under no conditions should the motor rota-
tion be checked with the coupling centre in-
stalled as damage to the compressor may re-
sult. Bump the motor to check for correct
compressor rotation. After verification, install
disc drive spacer, as applicable.
Compressor/motor coupling installation

The SAB unit has compressor to motor alignment through the use of a machined cast iron
tunnel. This tunnel is factory set through machining tolerances ensuring motor compressor
alignment. No alignment is required in the field.
7.1.24 CH coupling installation procedure

The T.B. Woods Elastomeric type CH coupling is used in most applications. This coupling con-
sists of two drive hubs and a gear-type Hytrel or EDPM and neoprene drive spacer. The split
hub is clamped to the shaft by tightening the clamp screws. Torque is transmitted from the
motor through the elastomeric gear which floats freely between the hubs. Because of the use
of the motor/compressor adapter housing on the RWF II, no field alignment is necessary.
Fig. 61
1. Inspect the shaft of the motor and compressor to ensure that no nicks, grease, or for-
eign matter is present.
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2. Inspect the bores in the coupling hubs to make sure that they are free of burrs, dirt
and grit.
3. Check that the keys fit the hubs and shafts properly.
4. Slide one hub into each shaft as far as possible. It may be necessary to use a screw
driver as a wedge in the slot to open the bore before the hubs will slide on the shafts.
5. Hold the elastomeric gear between the hubs and slide both hubs onto the gear to fully
engage the mating teeth. Center the gear and hub assembly so there is equal en-
gagement on both shafts. Adjust the space between hubs as specified in Table 26: CH
coupling data table.
6. Torque the clamping bolts in both hubs to the torque value given in Table 26: CH cou-
pling data table. Do not use any lubricants on these bolts.
Coupling hub
CH Between shaft spacing Shaft engagement Clamp bolt Keyway set-

Face spacing Size
Series Min. Max. Min. Max. Torque (dry) screw torque
Size UNC
Size In. mm In. mm In. mm In. mm In. mm Ft-lb Nm ft-lb Nm
6 2 50.8 23/4 69.9 1 25.4 115/16 49.2 7/

8 22.2 15 20.3 1/
4-20 UNC 13 17.6 5/
16 - 18
7 25/16 58.7 37/16 87.3 1 25.4 23/16 55.6 11/16 27.0 30 40.7 5/
16-24 UNF 13 17.6 5/
16 - 18
8 29/16 65.1 4 101.6 11/ 16 27.0 21/ 2 63.5 11/ 8 28.6 55 74.6 3/
8-24 UNF 13 17.6 5/
16 - 18
9 31/16 77.8 45/8 117.5 17/16 36.5 3 76.2 17/16 36.5 55 74.6 3/
8-24 UNF 13 17.6 5/
16 - 18
10 39/16 90.5 51/4 133.4 111/ 16 42.9 31/ 2 88.9 111/ 16 42.9 130 176.3 1/
2-20 UNF 13 17.6 5/
16 - 18
11 41/8 104.8 57/8 149.2 17/8 47.6 4 101.6 17/8 47.6 130 176.3 1/ -20
2 UNF 13 17.6 5/
16 - 18
Table 26: CH coupling data table
7.1.25 Piping connections

To avoid transmitting stress from piping connections between unit and plant, pipes must be
laid so as not to generate compressive stresses or tensile strains in the event of expansions or
contractions due to temperature changes. Steel pipes expand approx. 1 mm per metre per
100°C.
Johnson Controls Denmark recommends the pipe layout shown in example 2 of the sketch,
Fig. 62. Example 1 illustrates a pipe layout which is too rigid.
> 1.5 m
1 2
Fig. 62: Pipe layout

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Compressor flange to Suction

EU Reference
Compressor separator flange (2) flange (2)
designa- model
model Bolt size Torque Torque Bolt size Torque Torque
tion RXF
(ft-lb) (Nm) (ft-lb) (Nm)
SAB 120 24, 30, 39, 50 XJF 120S, M, L, S M20 x 2.5 150 203 M22 x 2.5 288 390
SAB 151 58, 68, 85, 101 XJF 151 A, M, L, N M22 x 2.5 167 226 M24 x 3.0 405 550
Motor flange to
EU Reference
Compressor compressor tunnel (1)
designa- model
model Bolt size Torque Torque
tion RXF
(in.) (ft-lb) (Nm)
SAB 120 24, 30, 39, 50 XJF 120S, M, L, S 1/2 or 5/8 58 78
SAB 151 58, 68, 85, 101 XJF 151 A, M, L, N 5/8 or 3/4 144 195
Table 27: Torque requirements
Note: Based on:

(1) Metal to metal contact
(2) Gaskets-Garlock(R) Blue-Gard(R) 3300 and KLINGERSIL C-4430 (suction flange),
Bolts-class 8.8 hex head bolts and stud bolts (suction flange), lightly oiled and clean
Chapter 5. Physical and connection data includes dimension data and piping connections de-
scriptions.
Refrigerant connection to compressor and unit

The connecting pipe must be welded onto a connecting branch on a stop valve. In order to
protect the stop valve when welding, remove the insides of the valve. Do not put the insides
back into the valve until the weld has cooled off - see the instructions from the valve supplier
in chapter 21. Appendices.
The welding must be carried out according to the specifications and standards applying to the
plant in question.
Refrigerant connection to oil cooler

Connection dimensions as well as location of connecting branches are included in section
5.2.1. Connection to compressor unit.
Connection to safety valve

Piping connections to external safety valves are made according to current legislation in the
country in question.
Connection to economizer
Piping connection to the economizer is made according to the piping diagram applying to the
plant.

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7.1.26 Connecting electricity supply

Data of the electrical components on the unit and their supply is included in chapter 5. Physi-
cal and connection data.
Danger!
Before connecting, make sure that:

- there is no power on the cables you are about to connect
- the power cannot be connected accidentally. Lock the switches or place a sign indicat-
ing that connection is not allowed. All electrical connections must be checked by an
electrician.
Connecting the motor

Installation and connection instructions for the chosen motor type is order specific and deliv-
ered together with the unit by Johnson Controls Denmark. These data sheets include descrip-
tions on how to connect the motor. Motor data appears from the motor name plate.
Always follow the connecting instructions from the manufacturer.
Remember! Check that the direction of rotation is correct - see section 6.1.12. Direc-
tion of rotation.
Shutdown output
The Unisab III shutdown output is made in such a way that under normal conditions there is a
connection between terminals whereas in a shutdown situation there is no connection be-
tween terminals. The alarm output is supplied by applying max. 230 V to terminal.
Connections to oil pump

Follow instructions in Unisab III manual.
Connections to economizer
Follow instructions in Unisab III manual.
Control without Unisab III.

If the unit is going to be controlled by a system not delivered by Johnson Controls Denmark,
the connection must be made as described in the schematic control diagrams of the actual
control system.
Chapter 21. Appendices includes data sheets for the individual control components including
detailed descriptions on how to connect.

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7.1.27 Pressure testing

After installation, the unit must be pressure tested and pumped down.
Pressure testing of refrigeration plant

Before charging refrigerant to the plant, it must be pressure tested and pumped down.
Pressure test the plant with one of the following:
• dry air - pressurized cylinders containing dry atmospheric air but never oxygen cylin-
ders
• air compressor for high pressure
• nitrogen
See also section 15.1.4. Evacuation and charging of refrigerant.
Danger!
The plant compressors must not be used to pressurize the plant.
Warning!
Water and other fluids must not be used for pressure testing.
Danger!
If using nitrogen, it is important to place a reducing valve with a pressure gauge between the
nitrogen cylinder and the plant.
During pressure testing, it is important to make sure that pressure transducers and other con-
trol equipment are not exposed to the test pressure. The compressor stop valves must also be
closed during pressure testing.
Plant safety valves must normally be blanked off during pressure testing as their opening
pressure is lower than the test pressure.
Danger!
During pressure testing, no persons are allowed in rooms with plant parts or in the vicinity of
the plant.
• The entire plant must be pressure tested according to local pressure testing rules.
• The test pressure must never exceed the pressure the unit was designed for.
• If required that the compressor is pressure tested with the unit, the test pressure
must not exceed 28 bar.
• As an initial tightness test, reduce pressure to 10 bar for a period of 24 hours. A
tightly sealed plant will maintain this pressure throughout that period.
• Please make sure that manometers, pressure controls, pressure transducers and oth-
er control equipment are not exposed to the test pressure.
During leak testing it is permitted to enter the rooms and approach the plant.
• As a second tightness test, examine all welds, flange joints etc. for leaks by applying
soapy water while maintaining the 10 bar pressure.

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When pressure testing, make a pressure test report containing the following points:
• date of pressure testing
• name of person performing the test
• test pressure
• comments

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7.1.28 Evacuation of the refrigeration plant

After pressure testing, the refrigeration plant must be evacuated to remove atmospheric air
and moisture. Evacuation must be carried out on all types of plants, regardless of the refriger-
ant type to be charged to the plant.
Note that HCFC and HFC refrigerants mix only minimally with water. Consequently, it is im-
portant to carry out evacuation of such plants with particular care.
The boiling point of a liquid is defined as the temperature where the steam pressure equals
atmospheric pressure. The boiling point of water is 100°C. If the pressure is reduced, the boil-
ing point will also be reduced.
The following table shows the boiling points of water at very low pressure levels.
Boiling point At pressure

of water °C mm Hg bar
5 6.63 0.0088
10 9.14 0.0122
15 12.73 0.0170
20 17.80 0.0237
For evacuation, use a vacuum pump to empty the plant of both air and water steam. The vac-
uum pump must be able to reduce the pressure to approx. 0.1 mm Hg (mercury column), and
it must be fitted with a gas ballast valve. Use this valve to the greatest extent possible to pre-
vent condensation of water vapour in the vacuum pump.
Important!
Never use the refrigeration compressor to evacuate the plant.
To perform an evacuation satisfactorily, the final pressure must be lower than 5 mm Hg.
Please note that water left in the refrigeration plant may freeze if ambient temperatures are
lower than 105°C. In such cases it is necessary to supply heat to the component surroundings
as ice evaporates with difficulty.
It is recommended to carry out evacuation as follows:
• Evacuate to a pressure lower than 5 mm Hg.
• Blow dry air or nitrogen into the system to a pressure corresponding to atmospheric
pressure.
Never use OXYGEN cylinders
• Repeat evacuation to reduce pressure to less than 5 mm Hg.
• Shut off the vacuum pump from the refrigeration plant and check that the pressure
does not rise within the next couple of hours. If the system still contains water, this
will evaporate and cause the pressure to rise thereby indicating unsatisfactory evacu-
ation. In such cases, repeat the above procedure.
7.1.29 Oil charging

The compressor unit is usually delivered without oil and must therefore be charged with oil
before start-up. The oil is chosen according to the Sabroe Oil recommendation. Oil charging is
carried out by means of a special oil pump. Section 11.1.12. Charging compressor with lubri-
cating oil describes the oil charging procedure and the amount of oil to be charged.

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7.1.30 Final installation check

After completing installation you must go through the following check list.
Danger!
It is of vital importance that all security systems and their functions are checked before start-
up. Failure to comply with safety precautions may cause death, personal injury or damage to
the equipment.
Check list for installation OK

1 Level foundation Check whether the foundation is level
2 Position of vibration dampers Measure flexion
Position of motor on Check that the motor rests on all four supporting
3
foundation surfaces
Position of compressor Check that the compressor rests on all four
4
on foundation supporting surfaces
Pressure testing: After putting the unit under
Tightness of piping
5 pressure, paint with soapy water around welds,
connection
thread connections and union nuts
Check that the alignment is in order - must be
Coupling between motor
6 checked again after 5 hours of operation while the
and compressor
compressor is warm
Check that all bolts are tightened to the torque
7 Torque
indicated
8 Electrical connection Check all electrical connections
Check that the oil goes up to the middle of the
9 Oil charging
sight glass

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Components
8. Components
8.1.1 The purpose of this chapter
The purpose of this chapter is to describe the product components and the different accesso-
ries which can be mounted.
This chapter is primarily intended for constructing engineers, service technicians, future cus-
tomers, sales personnel and personnel in the process of training.
General
The screw compressor unit is supplied as a complete plant mounted on a base frame. All com-
ponents are connected internally.
Sub-components
Base frame
Welded steel sections, treated and painted.
Motor
The standard SAB 120 and 151 units are available with motors in different sizes, with differ-
ent enclosures, power and supply voltage.
• Makes: Schorch and Leroy-Somer
• Supply voltage: 3 x 400V 50 Hz or 3 x 440V 60 Hz
• Protection class: IP 22/23 or IP 54/55
• Size: IEC 160 - 315
The necessary motor power depends on the unit operating conditions. The motor size can be
determined on the basis of the calculations in the calculation program COMP1. See also sec-
tion 6.1.8. Selecting electric motor.
Transmission system
The power transmission between motor and compressor takes place by means of a coupling.
The coupling types are described in detail in chapter 7. Installation instructions.
Oil separator
The oil separator is described in detail in section 4.1.10. Compressor oil separation system. All
internal piping connections to the oil separator have been carried out on the unit. The stop
valve, pos. 204, is welded on the discharge gas line.
Oil coolers
The oil coolers are described in detail in chapter 4. Technical description. The size of the oil
coolers is calculated in COMP1 on the basis of the plant operating conditions.
Economizer
SAB 120 and 151 is available with economizer system. The economizer systems are described
in section 4.1.36. Economizer - high stage (optional).
Oil pump
The oil pump and the pumping principle are described in detail in chapter 4.1.35. Oil pump
pos. 63.
Note: Remember to check the direction of rotation before start-up.

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Components
8.1.2 Unisab III

Unisab III control receives its impulses from pressure transducers and temperature sensors.
Pressure transducers, marked PE1 , PE2 , PE3 and PE4
See chapter 5. Physical and connection data and data sheet in chapter 21. Appendices.
Temperature sensors, marked TE5 , TE6 and TE7
See chapter 5. Physical and connection data and data sheet in chapter 21. Appendices.
Heating element
The function of the heating element is to boil out refrigerant from the oil, see section
4.1.26. Heating rods element for oil heating, pos 30 and chapter 5. Physical and connection
data, which include dimensions and effect.
Oil level switch
See description in section 4.1.9. Flow security and chapter 5. Physical and connection data.
Accessories
If the compressor is going to be installed in rooms where explosive gasses may occur, special
explosion-proof components can be supplied.

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Settings
9. Settings
9.1.1 Control system
Compressors are delivered with the Unisab III reading, safety and capacity regulating system
only.
Note: Changes in factory settings must only be carried out by an authorised refrigeration
company.
The control system is described in the Unisab III Operating manual.
A Unisab III Engineering manual is also available. This manual describes the control system in
more detail.
Consequently, set point setting etc. is not described in this chapter.

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Operating instructions
10. Operating instructions

10.1.1 Operating instructions
This chapter is included in the separate Operating manual. Please consult this manual if you
need information on how to operate the compressor.

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Maintenance instructions
11. Maintenance instructions

This chapter describes:
• Dangers resulting from failure to comply with safety precautions when performing
maintenance tasks.
• Scheduled maintenance tasks for this equipment, and how to carry them out safely.
• When these scheduled maintenance tasks should be performed.
This chapter is primarily intended for operators and service engineers.

Read chapter 3. Safety precautions carefully before servicing the compressor.
11.1.2 Maintenance of compressor unit

Read chapter 3. Safety precautions carefully before performing any maintenance on the com-
pressor unit.
To ensure that the compressor unit operates without problems throughout a long service life,
the system of maintenance presented in the following instructions must be followed.
Daily maintenance is normally performed by operating personnel. Other maintenance and
service tasks which require the refrigeration system to be opened must be performed by au-
thorized personnel.
Maintenance can be divided into 3 groups:
1. Daily maintenance
(minimum twice a week)
Daily maintenance consists of visual inspections.
• Inspect the compressor unit and check that both noise and vibrations are nor-
mal.
• To observe trends it is recommended to enter the observed operating data in-
to the operations log, see example in Operating manual, Operating instruc-
tions. Check that all operating values are within the permissible ranges. Com-
pare them with previous values to detect trends.
• Check the oil level in the oil separator.
• Check the refrigerant charge.
• Observe for leaks of refrigerant (smell of R717), oil or water.
• Check mechanical seal oil draining bottle.
• Check the control system for alarms/shutdowns.
2. Periodic maintenance
Motor lubrication and other routine maintenance tasks are usually based on running
time. Please refer to Table 28: Maintenance intervals.
3. Major overhaul
For major maintenance tasks such as compressor overhauls, contact Johnson Controls
Denmark.

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11.1.3 Stopping routine

Comprehensive maintenance often requires the compressor to be stopped for a certain period
of time.
Brief stop
Stopping and starting up compressor during a short period of standstill

Before stopping the compressor, capacity must be reduced to the lowest capacity stage for a
few minutes.
During short periods of standstill, it is not necessary to shut off the suction stop valve and the
discharge stop valve. The heating rod must be energised.
If the compressor is cooled with cooling water, the water flow must always be stopped during
standstill periods. This is normally done by means of a solenoid valve in the water inlet line to
the compressor.
Connect the solenoid valve to the start/stop relay of the compressor motor.
Always start up the compressor at the lowest capacity stage. After start-up, capacity should
be increased stepwise at suitable intervals to avoid that a sudden excessive pressure reduc-
tion in the evaporation system causes liquid hammering in the compressor and oil foaming in
the crankcase.
Shutting down for a long standstill period (2-3 months or more)

If the plant is stopped for a long period of time, follow this procedure:
1. Close the main shut-off valve after the receiver.
2. Pump down evaporators. It might be necessary to adjust low pressure cut-out to a
lower suction pressure during pump down. Continue pump down until the suction
pressure has been reduced to a little above atmospheric pressure.
3. Close the suction and discharge stop valves and the stop valve in the oil return line.
4. Follow the plant instructions which indicate how to stop and close down the plant cor-
rectly.
5. Shut off main and control power supply.
6. Remember to write down all actions in the log book.
11.1.4 Long term storage

Long term storage (6 months to 5 years) provisions are required regardless of storage envi-
ronment if start-up and/or useful operation does not take place within six (6) months of
equipment shipment. Special provisions may be required for storage of less than six (6)
months, if the storage area is subject to unusual environment such as high humidity, large
changes in temperature, dusty atmosphere, etc.
Long term storage of equipment may lead to the deterioration of components over the period
of time. Synthetic components in the compressor may deteriorate over time even if they are
kept flooded with oil. A warm and dry environment is essential to minimise environmental and
corrosive damage.
For further information contact Johnson Controls Denmark.

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Maintenance intervals
Hours operation (maximum)
Maintenance schedule
200
1000
5000
8000
10000
15000
20000
25000
30000
35000
40000
45000
50000
55000
60000
65000
70000
75000
80000
85000
90000
95000
Change oil As directed by oil analysis

Oil analysis x Every 6 months
Change filters x x x x x x x x x x x
Clean oil strainers x x x x x x x x x x x
Table 28: Maintenance intervals

Clean liquid strainers x x x x x x x x x x x
Change coalescers (d) x x x x x x
Check and clean suction screen x x x x x x x x x x x x
Check alignment (e) x x x x x x x x x x x
Check coupling (a) x Annually regardless of operating hours
Check electrical connections (b) x x x x x x x x x x x x x x x x x x x x
Check sensor calibration (c) x x x x x x x x x x x x x x x x x x x x x
Vibration analysis (f) x Every 6 months, more frequently if levels increase
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Replace shaft seal When leak rate exceeds 7 - 8 drops per minute
(a) Check bolts, shim packs, centre inserts, keys and all bolt torque.
(b) Check and torque all terminals in the processor and starter panel per the specification posted in the enclosure.
(c) Check calibration of slide valve, slide stop and pressure.
(d) Booster: 20,000 h. High stage/air conditioning: 10,000 h. One stage: 30,000 h.
(e) Not for flange motors.
(f) Vibration measurement must be carried out continuously to obtain optimum preventive control on bearings. If not continuously controlled then
every 6 months, more frequently if levels increase. Alternatively, major overhaul after maximum 30000 h.
(g) Verify tightness of bolts on suction and discharge flanges on a daily basis. See Table 27 for torque requirements.
Leak test: According to national rules or as a minimum according to EN 378-2 (Minimum annually if leak rate < 1% year)
Safety equipment: Check of safety equipment (Safety switch devices, pressure relief valve) according to national rules. Minimum requirement ac-
cording to EN 378, annual check of safety switch devices and every 5 years for pressure relief valve.
008983 - en 2014.03
11.1.5 Visual inspection
Oil pressure
Check that the oil pressure complies with the recommended cut-out pressure.
Oil level
Check the oil level in the compressor. It is of vital importance for the service life of the com-
pressor that an optimal lubrication is maintained. The oil level must always be visible in the oil
level glass. If the oil level is below the lowest part of the oil level glass, oil must be recharged.
Recharging of oil (“topping up”) can be carried out during operation either by means of a
hand-operated oil pump or as described in section 11.1.12. Charging compressor with lubri-
cating oil. Use the recommended oil only.
Remember to write down drained or recharged amount of oil.
11.1.6 Measures to be taken

The following describes the measures which must be taken, including information about mate-
rials, preparation and implementation.
Noise and vibration

No special requirements are imposed regarding equipment and materials. Inspect the unit,
and check that there is no abnormal noise and vibration. Listen for any knocking or other ab-
normal noise caused by poorly clamped pipes or faulty valves.
Evaporating pressure and condensing pressure

No special requirements are imposed regarding equipment and materials. Check on the oper-
ator's panel or manometers that the pressures comply with the specifications issued for the
reciprocating compressor unit in question and that they are within the permissible operating
ranges.
Evaporating pressure
The terms “evaporating pressure” and “suction pressure” refer to the pressure on the suction
side of the compressor.
Usually the pressure is the same at the evaporator outlet as at the compressor inlet. The only
difference is the pressure drop in the line. Because of this pressure drop, the pressure at the
evaporator outlet is a little higher than on the compressor. The non-return valve in the suc-
tion line will also contribute to the pressure drop.
Normal evaporating pressure

According to fundamental refrigeration engineering principles, the refrigerant absorbs heat
from the medium that is being cooled.
In order for heat to be transferred to the refrigerant, it must boil at a lower temperature than
the temperature of the medium being cooled in the evaporator. A basic rule is that the evapo-
rating temperature is lower than the temperature of the medium that is being cooled in the
evaporator. This rule sets a maximum value for the suction pressure.

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Condensing pressure
The terms “condensing pressure” or "high pressure", as used here, refer to the pressure at
the compressor outlet side. Usually the pressure is the same at the condenser inlet as at the
compressor outlet. The only difference is the pressure drop in the line.
Because of this pressure drop in the line, the pressure is a little higher at the compressor than
at the inlet to the condenser. The oil separator and stop valve mounted in the discharge line
will also contribute to the pressure drop.
Normal condensing pressure

In the condenser the absorbed heat energy in the refrigerant is released to the surroundings.
The heat energy in the refrigerant is the sum of the heat energy absorbed in the evaporator
and the energy supplied to the compressor via the electric motor taking the oil cooling system
into account.
During the condensing process, the refrigerant vapours are transformed into liquid again. To
give off the energy (heat) from the condenser, the temperature of the medium (air, water), to
which the heat is going to be transferred, must be lower than the condensing temperature.
Since there is a connection between the temperature and the pressure in the condenser, there
is a minimum value for how much the condensing temperature must fall. If the condensing
pressure level becomes too low, it will result in operational failures.

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11.1.7 General rules for use of lubricating oil in refrigeration compres-

sors
• Charge only fresh, clean refrigeration machine oil. Oil tapped from the evaporator sys-
tem in an ammonia plant must not be reused in the compressor.
• Use the grade of oil originally prescribed for the compressor.
• To the extent possible, avoid mixing different types of oil. Mixed oil is generally inferi-
or to the two original oils. Mixing various types of oil may give rise to formation of
sludge, which will lodge in valves and filters.
• If it is necessary to switch to another brand of oil, please contact the supplier of the
new oil for instructions. Note that some of the old oil may be left in the piping system.
• The refrigeration oil must be moisture free as moisture may cause operating malfunc-
tions and corrosion attacks.
The oil should therefore be bought in containers containing enough oil for one or, at the most,
two top-ups. The oil containers must be kept carefully sealed. If all the oil in a container is not
used at once, the container should be tightly sealed and stored in a warm place to prevent
moisture absorption.
Note: It is inadvisable to reuse oil which has been drawn from a compressor or plant. Such oil
has absorbed moisture from the air and may cause operating problems. Always switch off the
power to the heating rod before drawing off oil.
Caution!
Never add oil until the cause of the oil level drop has been found and corrected.
Warning!
Corrosive oil is a hazardous substance. It can cause irritation and other injuries.
11.1.8 Assessing the oil

Oil in refrigeration plants is a vital part of the compressor. In addition to lubricating and cool-
ing the movable parts of the compressor, it also prevents abrasive particles from entering the
bearings.
An oil analysis provides important information on how the compressor runs. Johnson Controls
Denmark therefore recommend that the oil analyses are carried out at regular intervals as
described.
In order to obtain a representative oil sample it must be drawn off while the compressor is in
operation. Before taking the sample, clean the drain valve and tap off a little oil to prevent
any impurities which may have accumulated in the valve or piping system from mixing with
the sample.
11.1.9 Visual assessment

When pouring the sample into a clean transparent glass bottle or test-tube and holding it up
against a clear light source, it is easy to assess the quality. The oil can also be compared to a
fresh oil sample of the same make and grade.
Oil approved by visual assessment must:
• be clear and shiny

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• not contain any visible particles

• feel viscous, smooth and greasy when rubbing a drop between two fingers.
If the oil cannot be approved by visual assessment, charge with new oil or send a sample to a
laboratory for analysis.
Warning!
If the oil sample is poured into a glass bottle, this must not be hermetically sealed until all the
refrigerant in the oil sample has evaporated. Refrigerant in the oil may produce excess pres-
sure in the bottle with subsequent risk of explosion. Never fill up a bottle completely. Do not
send glass bottles by mail - use purpose-made plastic bottles. Please see below.
11.1.10 Analytical evaluation

Naturally, the oil sample can be analysed by the oil supplying company. As a special offer to
our customers, Johnson Controls Denmark has developed an analytical concept, so that we
are able to analyse all oil makes. This will mean a uniform reporting of the results.
The analysis will determine the following:
• Whether or not the oil can still be used, if necessary after filtering.
• Whether solid particles present in the oil originate from bearings or other components
exposed to wear and tear; in which case the compressor must be inspected.
Each report will include the corresponding measuring results from the previous three oil
analyses. This way, it is possible to follow up on the state of both the oil and the compressor
from one analysis to the next.
Procedure
• A form set with a plastic sample bottle and a dispatching envelope can be requested
from your local Johnson Controls Denmark representative.
• The oil sample must be drained from the cleaned oil drain valve into the sample bot-
tle. Screw the lid on loosely and let the bottle stand for a few hours to make refriger-
ant contained in the oil sample evaporate before sending the sample to the laborato-
ry.
Do not fill up the bottle completely.
• Please follow the Sampling and shipping instructions enclosed with the form set in
which the address of the laboratory in Holland is also stated.
11.1.11 Analyzing the oil

The following table lists a number of average values which can be applied in practice. Howev-
er, one should be on the alert whenever the results of the analyses approach these values. In
some cases the water content of 100 ppm in HCFC plants may be too much and thus lead to
Cu-plating in the shaft seal.

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Sabroe Oil PAO 68 Sabroe Oil AP 68 Sabroe Oil A 100

Tar- Tar- Tar-
Parameter Unit Method
get Max. Min. get Max. Min. get Max. Min.
spec. spec. spec.
Viscosity @40°C cSt ASTM D 445 66 76 53 64 74 51 100 115 80
TAN*1) mg KOH/g ASTM D 664 0.03 0.2 - 0.01 0.02 - 0.05 0.02 -
SAN*2) mg KOH/g ASTM D 665 - 0 - - 0 - - 0 -
Water ppm Karl Fisher - 100 - - 100 - - 100 -
Apperarance - - re- re- re-
port port port
Colour - ASTM D re- re- re-
1500 port port port
Pentane Insolubles W% MM 490 - 0.05 - 0.05 - - 0.05 -
(Sum)
Oxidation abs/cm IR, - 5 - - 5 - - 5 -
1700-1720/
cm
Nitration abs/cm IR, - 5 - - 5 - - 5 -
1627-1637/
cm
Nitro Compounds abs/cm IR, - 0.5 - - 0.5 - - 0.5 -
1547-1557/
cm
Maximum values for metal content in the oil)
Lead ppm ICP - 10 - - 10 - - 10 -
Copper ppm ICP - 10 - - 10 - - 10 -
Silicium ppm ICP - 25 - - 25 - - 25 -
Iron ppm ICP - 100 - - 100 - - 100 -
Chromium ppm ICP - 5 - - 5 - - 5 -
Aluminium ppm ICP - 10 - - 10 - - 10 -
Tin ppm ICP - 10 - - 10 - - 10 -
1) TAN (Total Acid Number) is only non-ammonia applications

2) SAN (Strong Acid Number) is only reported for non-ammonia applications
A report is compiled for every sample received. This report will describe:
• Whether the oil can still be used - without taking any further action.
• Whether the oil can be used after it has been filtered through a very fine filter. If this
is necessary, the oil must be pumped directly from the compressor unit through a 3
micron filter and back to the unit. The system must be completely closed to prevent
the oil from being affected by moisture in the air.
• Whether the oil can no longer be used.
The report will always be sent to the address stated on the sample label included in the form
set. A copy will be sent to Johnson Controls Denmark so that we are in a position to advise
you, if required.

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11.1.12 Charging compressor with lubricating oil

Oil charging is carried out by means of a portable oil charging pump, see Fig. 63. Proceed as
follows:
1. Connect the high-pressure hose, pos. 7, to the service valve, pos. 106, on the unit via
non-return valve, pos. 12. Use correct reduction nipple. See Fig. 64.
2. Place the free end of the suction hose from the pump, pos. 1, together with the by-
pass hose, pos. 2, in the barrel.
3. Open ball valve, pos. 9, and service valve, pos. 106, and start the pump, pos. 5.
4. Circulate the oil until the system is free from air bubbles. Close the ball valve, pos. 9.
The oil will now be charged to the unit.
5. When the desired amount of oil has been charged to the unit, stop the pump and
close the service valve, pos. 106.
6. Open the ball valve, pos. 9, carefully to equalize the pressure. The hoses can now be
dismantled.
7. Loosen the non-return valve carefully to equalize the remaining pressure. Remember
to mount the cap nut on the charge valve and to seal the oil barrel if there is any oil
left.
1/4”RG
20
5 3/8”RG
1/2”RG
7/8”RG
2
RG= Pipethread
Length: 460 mm
9 Height: 350 mm
Width: 340 mm
7
Weight: 22 kg
Part number: 4541.001
12
Fig. 63: Oil charging

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106
20
12
7 5
Fig. 64: Piping diagram for oil charging

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11.1.13 Oil change

The oil in the unit must be changed after a specific number of operating hours or when an oil
analysis shows that the oil needs to be changed.
We advise you to let Johnson Controls Denmark’s service organization change the oil as it is
recommended to replace all filters in the unit at the same time.
Oil charge: Oil level approximately at the middle of upper sight glass during operation.
The oil level difference between mid-upper and mid-lower sight glass is approximately 25 li-
tres.
The necessary oil charge is depending on the composition on the specific unit in question.
You may calculate the oil charge using the tables below.
Oil separator Oil cooler
SAB 151 & 193 SAB 151 & 193 SAB 151 & 193
OHU 04123 Vahterus 3HH AlfaNova HP52
Litres Plates Litres Plates Litres

34 2,7 30 1,3
66 5,1 50 2,3
90
116 9 80 3,7
100 4,7
Table 29
Tubesystem Oil filter
SAB 151 SAB 193

SAB 151&193
SAB SAB 553C0513EU 553E0013EU
151 193
Oil pump* Single Double* Single Double*
Litres Litres Litres Litres Litres Litres Litres

7 10 7 11 23 40 80
Table 30
* Optionally
Note: Be sure always to have approx. 25% extra oil available to refill at first start-up.

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11.1.14 Motor
Motor lubrication
In connection with electric motors, it is absolutely essential to lubricate the bearings correctly
and use the appropriate type of grease.
Please refer to the motor manual and/or the motor name plate.
Replacing motor bearings

Please contact Johnson Controls Denmark’s service organisation.

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Fault-finding instructions
12. Fault-finding instructions

In this chapter you find:
• A list of common problems
• Suggested causes and recommended actions to solve the problem
This chapter is primarily intended for service engineers.
Qualification requirements
Faultfinding requires highly skilled and qualified personnel with extensive knowledge of the
system. The formal requirements include knowledge of refrigeration engineering and familiari-
ty with the actual system.
12.1.1 How to carry out faultfinding

Faultfinding is necessary in three general situations:
• When acute problems arise
To find out what caused the reciprocating compressor unit to malfunction.
• Maintenance
During scheduled maintenance to detect operational deficiencies that may lead to fu-
ture disturbance or uneconomical operation.
• Start-up after repairs
E.g. after replacement of a damaged component to find external reasons why the
component failed.
Systematic faultfinding
Faultfinding should be carried out systematically. Experienced personnel with a thorough
knowledge of the unit often knows what the problem is and will find the error immediately.
If you do not have a thorough knowledge of the unit consider the situation carefully. Do not
change any settings immediately, instead spend some time working out a systematic ap-
proach.
Operating condition
Pressure and temperature variations in a refrigeration system can provide information about
the operating conditions of the refrigeration plant.
Particularly, the suction and condensing pressure as well as the temperatures of suction and
discharge gases may provide important information about the operating conditions of the
plant.
Considerable changes in the operating conditions can often be produced by even very small
changes in the variable pressure and temperatures.
The following troubleshooting chart shows the cause and remedy for any operating disturb-
ance.
12.2. Troubleshooting
The tables below cover the most common problems. For detailed troubleshooting of the refrig-
eration plant, please refer to the manual of the plant or common refrigeration literature.

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Refrigeration plant - general

Symptom Probable cause Correction
Refrigeration load lower than com-
Reduce compressor capacity.
pressor capacity.
High suction line loss. Check valves, strainers etc.
Suction pressure
Check evaporator (fouling, accu-
- excessively low
mulated oil etc.), liquid expansion
Malfunction of evaporator.
valve system, filter in liquid line,
refrigerant charge (insufficient).
Check the setting of alarms and
Safety cut-out set too low. warnings (control system) and the
separate safety pressure cut-out.
High discharge line loss. Check valves, check valve etc.
Discharge pressure Check condenser, liquid drain from
- excessively high condenser, refrigerant charge (too
Malfunctioning of condenser.
much), water/air inlet temperature
(too high), water/air flow (too low).
Air/non-condensable gasses in the Purge the air from the condenser
system. side.
Table 31: Refrigeration plant - general

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Compressor unit - general

Check main switch and fuses. Re-
Electrical supply.
set emergency stop switch etc.
Compressor cannot Register the alarm, correct if nec-
start Alarm in control system. essary and reset (refer to the Con-
trol manual).
Oil level too low. Charge oil.
Compressor starts
Oil system failure (temperature, Check oil level.
but stops immedi-
pressure, level). Check valve positions.
ately
Oil filter differential
Oil filter clogged. Replace oil filter.
pressure too high
Valves in oil system are not fully Check stop valves and opening po-
open. sition of the oil regulation valve.
3-way oil temperature control
Check function, replace the sensor
valve. (Water-cooled or refrigerant-
element.
cooled (Thermosyphon)).
Check oil cooler, fouling, water in-
Insufficient oil cooling function
let temperature, (too high), water
(water-cooled).
Oil temperature too flow (too low).
high (and high dis- Check/drain accumulated oil in the
charge tempera- Insufficient oil cooling function oil cooler. Check that the gravity
ture) (refrigerant-cooled). fed refrigerant system is full floo-
ded.
Check the settings in control sys-
Insufficient oil cooling function
tem, valves and strainer in liquid
(liquid injection).
injection line.
Check the discharge pressure safe-
Compressor protection valve is
ty cut-out settings. Check the pilot
open or leaking.
and main protection valve.
Check evaporator (and economiser
Discharge tempera- (optional)) and expansion valve
Excessive liquid in suction line
ture very low. Oil function. Decrease the rate of
/ liquid slugging.
temperature low evaporator temperature “pull
and oil may be down”.
foaming in oil sepa- Check the settings in control sys-
Liquid injection (optional) overfeed-
rator tem (increase the set point). Check
ing.
the stability of the liquid injection.
Check the discharge pressure safe-
Compressor protection valve is
Suction pressure ty cut-out settings. Check the pilot
opening or leaking.
high and insufficient and main protection valve.
refrigeration capaci- Adjust the regulating valve accord-
Oil return valve fully open.
ty ing to manual.
Suction strainer clogged. Clean strainer.
Table 32: Compressor unit - general

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Compressor unit - oil separation

Lower level by opening/adjusting
Maintaining too high oil level.
the oil return valve.
Refrigerant carry-over or liquid in-
Correct operation.
Gradual oil loss with jection overfeeding.
an oil level in the Loss of suction superheat. Adjust evaporator feeds.
coalescer section Contaminated oil, damaged or not
Replace oil charge and coalescers.
sight glass seated coalescer elements.
Coalescer return valve closed. Open return valve.
Coalescing oil return line strainer
Clean strainer.
blocked.
On shutdown, compressor unit suc-
Repair valve.
tion check valve did not close.
Rapid loss with no Suction check valve bypass open
Close valve.
oil level in the coa- too far.
lescer section sight Coalescers loose or not seated
Correct or replace.
glass properly.
On economised unit: economiser
Repair or replace.
check valve not working.
Shaft seal leakage Leakage exceeds normal allowable
Replace seal.
rate of 7 drops per minute.
Table 33: Compressor unit - oil separation
Compressor block
Main oil injection valve may be
Open valve.
closed.
Main oil injection valve may be
Adjust.
open too far.
Bearing damage or excessive wear. Replace bearings.
Excessive noise and Slide valve/slide stop out of cali-
vibration bration (over or under compres- Calibrate.
sion).
Tighten coupling. Replace if dam-
Coupling loose on shaft.
aged.
Refrigerant flood back (Liquid slug-
Correct system problem.
ging).
Oil pressure is not sufficient. Check oil pressure.
Capacity slide valve
Solenoid coils may be burned out. Replace.
and/or slide stop
Incorrect setting of valves in the Check according to hydraulic sys-
will not move.
hydraulic system. tem description.
Cannot unload/load
Malfunction of 4-way control valve Check according to description of
or both
of slide components. main components.
Table 34: Compressor block

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Demand oil pump system (optional)

Pump rotation. Check.
Service valves closed. Open valve.
Check pressure difference across
Filter cartridges may be blocked.
Pump will not pro- filters.
duce enough oil Strainer may be blocked. Clean strainer.
pressure to start Oil pressure regulator set too low
Readjust or repair.
compressor or stuck open.
Pump worn out. Repair or replace.
Hand expansion valve (pos. 124)
Throttle the valve.
may be opened too much.
Oil pressure rapidly
drops off when
Main oil injection throttling valve
compressor starts.
too wide open or oil pressure regu- Readjust both valves.
Results in compres-
lating valve improperly adjusted.
sor differential
alarm
Oil pressure fluctu- Liquid injection overfeeding or re- Make necessary adjustments or
ates frigerant flood back from system. corrections.
Pump strainer blocked. Clean strainer.
Noise and vibra-
Liquid refrigerant overfeed. Adjust liquid injection.
tions
Pump worn out. Repair or replace.
Grease leaks from Normal leakage which will cease af-
If leakage exceeds normal allowa-
vent port in the ter initial operation. Black oil leak-
ble rate of 7 drops per minute, re-
side of the pump ing from this vent indicates oil seal
place seal.
body wear or failure.
Filters clogged with dirt. Replace filters.
Main filter pressure
Oil is too cold. Allow oil to warm up.
difference is too
Service valve on filter outlet is par-
high Open valves fully.
tially closed.
Table 35: Demand oil pump system (optional)

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Service instructions
13. Service instructions

Please contact Johnson Controls about service related issues.

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Transport instructions
14. Transport instructions

• Dangers which may occur if the transport instructions and safety precautions are not
observed.
• How to assemble and transport this equipment in a safe way.
This chapter is primarily intended for transport supervisors, authorities and personnel in-
volved in loading, unloading and transporting the equipment.
Danger!
Danger!
Risk of injury to personnel and damage to equipment! In addition to the safety precautions in
this document, always read the safety precautions belonging to this equipment before trans-
port. Failure to comply with safety precautions may cause death or injury to personnel. It may
also cause damage to or destruction of the equipment.

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14.1.2 Transport data

Weight and dimensions
When dispatched, the unit is placed on a wooden frame and covered by plastic film. The
wooden frame is adjusted to the size of the unit.
Height
Lenght
Width
For dimension, see Table 6 in chapter 6.1.2. Data for SAB 151.
For compressor weight, see Table 7 in chapter 6.1.3. Other data.
14.1.3 Personnel requirements

Personnel who will be handling the unit during loading, transport and unloading must have
taken the necessary courses in crane operation.
14.1.4 Handling of compressor and unit

The compressor is equipped with a threaded hole for mounting of the lifting eye. For compres-
sor weight, see Table 7: Electric motor weight.
Fig. 65: Lifting ring, SAB 151
Warning!
Only the compressor block alone must be lifted in the lifting eye. The same applies to the mo-
tor. The unit is lifted by using the lifting devices delivered with the unit, see Fig. 66.

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14.1.5 Loading instructions
Warning!
This screw compressor package may be top-heavy. Use caution when rigging and handling to
prevent the unit from turning over.
When unpacked, the unit can be lifted with a crane. The unit must be lifted in the lifting eyes
on the unit. Never lift in the lifting eyes on the compressor or the motor separately.
If a motor is mounted, you must make appropriate adjustment in the lifting point to compen-
sate for the motor weight. Adjustment of the lifting point must also be made for any extra
weight added to the standard package such as an external oil cooler, etc. The extra weight
will affect the centre of balance.
Fig. 66
As a minimum the lifting capacity of the crane and the loading capacity of the chains, straps,
lifting eyes and shackles must correspond to the weight of the unit + the weight of the elec-
tric motor.
14.1.6 Preparations before lifting

Before lifting the unit, make sure that straps/chains are properly secured to lifting eyes/
shackles and that the lifting equipment is in good condition.
14.1.7 Loading
Be very careful not to damage the unit when loading it. Note in particular that the instrumen-
tation of the unit is very vulnerable to impacts.

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14.1.8 Transport instructions
Danger!
Risk of injury to personnel and damage to equipment! Johnson Controls Denmark is not liable
for injury to personnel or damage to equipment caused by the use of transport methods
which are not recommended in this document or stated in a separate agreement between a
transport company and Johnson Controls Denmark.
14.1.9 Transport regulations

It is the transport company's responsibility that all transport regulations are complied with.
It is also the transport company's responsibility that the unit or parts of the unit are properly
secured and do not shift during transport and thus get damaged.
Unloading instructions
The same rules apply as when loading the unit. See therefore 14.1.5. Loading instructions.
14.1.10 Unpacking and inspecting the unit

On receipt the unit is wrapped in PE film. After unpacking the unit, check for transport dam-
age. Check also whether the delivered goods correspond to the specification. Check in particu-
lar that the control system and valves fitted on the outside of the unit are not damaged.
Check that the following parts are included:
- Vibration dampers and the drawing indicating the position of the dampers.
- Parts for coupling series 52, i.e. intermediate piece, inner and outer screen and per-
haps loose coupling hub for motor.

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14.1.11 Moving the equipment to the mounting site
after unloading and unpacking
Warning!
This screw compressor package may be top-heavy. Use caution to prevent unit from turning
over.
After unloading and unpacking the unit it must only be lifted in the lifting device mounted on
the frame, see 14.1.4. Handling of compressor and unit If the unit is moved with e.g. a forklift
truck, it must be positioned on a pallet intended for the purpose. Secure the unit and make
sure that it does not tip over when starting, turning and braking the forklift truck.
Do not lift directly under the unit.
14.1.12 Storage
On delivery the compressor units are charged with a protective gas (N2) with an overpressure
of 0.2 bar to prevent moisture from entering the compressor. If the equipment is going to be
stored for a long time, the compressor should be equipped with a service manometer on the
evacuation valve so that the pressure can be checked. If the pressure falls below 0.1 bar, re-
charge with nitrogen (N2).
Place the unit on a level foundation and cover it to protect it from dust and dirt. The unit must
not be stored with objects which give off acidic vapours or the like as this can have a corro-
sive effect on the unit. It is further required that the store room is dry and frost-free.
When stored, the unit must be inspected at regular intervals. Every two weeks the compres-
sor and motor must be rotated 8-10 turns to prevent the oil in the bearings from drying out.
As far as the motor is concerned, check the lubricating nipples and lubricate them if necessa-
ry.

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Commissioning instructions
15. Commissioning instructions

• The dangers which may occur when the commissioning instructions and safety pre-
cautions are not observed.
• How to start-up this equipment in a safe way.
• How to prepare a safe and effective start-up.
This document is primarily intended for inspectors and supervisors.
Danger!
Risk of injury to personnel and damage to equipment! In addition to the safety precautions in
this document, always read the safety precautions belonging to this equipment before start.
Failure to comply with safety precautions may cause death or injury to personnel. It may also
cause damage to or destruction of the equipment.
15.1.2 Preparations for commissioning
Final check of installation

Before the plant is put into operation, the installation must be checked one last time, see sec-
tion 7.1.30. Final installation check.
Personnel requirements
The personnel who are going to start up the plant must be well-qualified and have a thorough
knowledge of refrigeration technique. It is moreover necessary that the personnel know the
refrigeration plant and its construction and mode of operation. The instructions in this manual
must be read before start-up.
Johnson Controls Denmark offers courses which deal with operation of and service on the unit
in question. It is recommended that both the supervisor and the operator take these courses.
Training
It must be made sure that all personnel have been trained so that the requirements listed un-
der Personal Requirements above are complied with.

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Documentation
In addition to this manual personnel should be in possession of the following documentation
before putting the plant into operation:
• SAB 355 Operating manual
• Unisab III Operating manual
• Certificates regarding the screw compressor unit
• Installation drawings and functional descriptions for the plant
15.1.3 Preparations on the mounting site
Final check of the plant

The check includes an examination of all parts of the plant and all the connections to the com-
pressor. Check in particular that
• the piping connections are made as indicated in the installation drawings.
• all electrical connections have been checked.
• the unit and the plant have been pressure tested.
• the coupling between motor and compressor are set up as indicated in
chapter 7. Installation instructions.
• the insulation has been carried out correctly.
• the paint is in order, the screens have been mounted correctly, etc.
Please see Commissioning guide, controls (005202) - which is available from the login area on
www.sabroe.com - for preparations before first start-up or contact Johnson Controls Den-
mark.
Danger!
Inadequate or incorrect setting of pressure transducers may result in compressor breakdown
or personal injury.
15.1.4 Evacuation and charging of refrigerant

Check that the plant is evacuated to a pressure lower than 5 mm Hg. Pressure testing and
evacuation of the plant is described in detail in chapter 7, Installation Instructions.
Check that the prescribed refrigerant corresponds to the specification on the compressor
name plate. Charge the prescribed refrigerant. After charging the refrigerant, check all con-
nections and valves for leaks by means of a leak detector.
15.1.5 Start-up
The plant can now be put into operation, See Operating Manual.
After five hours of operation the alignment between motor and compressor must be checked
again while the compressor is still warm. Before letting the plant start to work, activate the
emergency stop and dismount the main fuses to ensure that the motor does not start unin-
tentionally.
Important! Note the procedures for reducing the evaporating pressure.

142/157 008983 - en 2014.03
15.1.6 Commissioning set

As impurities in the piping are released during start-up of the plant, experience has shown
that both the suction filter and oil filter will clog up quickly. Consequently, a commissioning
set is delivered with the compressor unit. This set includes a new filter and the necessary O-
rings and gaskets for the oil filter and suction filter. The spare parts included in the set are
marked in the parts list with a *.
15.1.7 Checks to be performed after start-up
Check list ÷
Are settings and configuration correct?
Have alarm and warning limits been set correctly?
Have pressure transducers been calibrated?
Is the direction of rotation of the motor correct?
Has the coupling been aligned correctly?
Have the safety valves been adjusted correctly?
Has the plant been evacuated and dried before charging of refrigerant?
Does the plant contain enough oil?
Have valves been set correctly?
Is the capacity regulation correct?
Free passage for cooling water/refrigerant to e.g. oil cooler?
Is the plant tight?

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Compliance instructions
16. Compliance instructions

16.1.1 Declaration of conformity
Johnson Controls Denmark declare on the signed declaration of conformity that the machine is
manufactured and CE-marked in conformity with relevant directives and standards.
On the next two pages you can see a declaration of conformity, however not filled in with the
specific data. It may occur that the original signed declaration of conformity is sent separate-
ly. If so, it will be based on a clear written agreement between the customer and Johnson
Controls Denmark.

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146/157 008983 - en 2014.03
Certificates
17. Certificates
The purpose of this chapter is to make an overall view of all certificates belonging to SAB 355.
This document is primarily intended for inspecting bodies and authorities.
The compressors are made according to the basic specifications of the individual compressor
type.
The products comply with current legislation with regard to pressure and material testing.
If the product should be supplied with a certificate, the certificate must be requested at the
time of the order. It will not be possible to make a separate certificate for the compressor at a
later time.
17.1.1 Approvals
• Compressor units
Available in a design complying with the prevailing rules in the following countries:
Denmark
Germany
Sweden
France
and with the rules of the following classification societies:
Lloyd’s Register of Shipping
Det Norske Veritas
Germanischer Lloyd
Nippon Kaiji Kyokai
American Bureau of Shipping
On request, compressor units can be designed to fulfil standards of other countries and classi-
fication societies than the ones mentioned above.

008983 - en 2014.03 147/157
Spare parts list
18. Spare parts list

18.1.1 Please see separate Spare parts manual

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Spare parts drawings
19. Spare parts drawings

19.1.1 Please see separate Spare parts manual

008983 - en 2014.03 149/157
Final disposal
20. Final disposal

The purpose of this chapter is to describe the safe disposal of this equipment or part of it.
This chapter is primarily intended for decommissioning engineers and authorities.
Danger!
Before dismantling the plant, read the safety precautions carefully.
Dismantling a cooling unit to be scrapped must be carried out safely.

Authorised refrigeration personnel must participate in the first part of the dismantling process
as fundamental knowledge of refrigeration systems and the risks involved is required.
Before dismantling the plant, refrigerant and oil must be drained into suitable containers. Dis-
connect all electrical connections to the unit, and remove fuses in the main switchboard.
During the dismantling process, the individual machine parts and components must be sorted
to ensure proper disposal. All waste must be transported to receiving stations which comply
with the prevailing national rules and regulations.
Danger!
Be very careful when using cutting tools such as angle grinders or flame cutters during the
dismantling process as pipes and the like contain oil residue, which may ignite. Refrigerant
residue also involves a great risk, as HFC and HCFC refrigerants develop toxic gasses when
heated. Make sure that there are no air traps, as heating results in a pressure rise.
20.1.2 Disposal of
• Machine parts
When dismantling the plant, it is important to sort the parts to be disposed of. Com-
pressor, frame, containers, etc. belonging to the category of iron and metal scrap
must be brought to an approved scrap dealer, who complies with the prevailing na-
tional rules and regulations.
• Oil and refrigerant
Oil and refrigerant must be brought to a receiving station for hazardous waste for de-
struction or regeneration. This also applies to used oil filters. The receiving station
must comply with the prevailing rules and regulations of the individual country. Do
not transport oil in open vessels in a closed car.
• Electrical components
Electrical and electronic products, e.g. wiring, panels, hardware etc., must be brought
to a receiving station approved to handle electronic waste. The receiving station must
comply with the prevailing rules and regulations of the individual country.
• Batteries
Used batteries from e.g. the backup of the computer control must be brought to a re-
ceiving station for destruction. The receiving station must comply with the prevailing
rules and regulations of the individual country.

150/157 008983 - en 2014.03
Appendices
21. Appendices
The purpose of this chapter is to collect all relevant supplier documentation.
21.1.1 Appendix
This section includes data sheets and instructions concerning the components and torque ta-
bles.
1. List of torque
2. Valves
Valves, type SCV 40-200
3. Diagrams and sketches

Piping diagram.................................................................... order specific
Wiring diagram................................................................... order specific
Dimension sketch................................................................ order specific
Placing of vibration dampers................................................. order specific
4. Electric motor
Instruction for motor............................................................ order specific
Torque for screws and bolts
Metric thread (ISO 8.8)

M 4 5 6 8 10 12 14 16 18 20 22 24 27
Kpm 0.28 0.53 0.94 2.2 4.1 7.0 11 15 23 30 38 52 68
ft.lbf. 2.1 3.9 6.8 16 30 50 80 110 170 220 270 370 490
Nm 2.7 5.2 9.2 22 40 69 108 147 225 295 375 510 670
Metric thread (ISO 12.9)
M 4 5 6 8 10 12 14 16 18 20 22 24 27
Kpm 0.42 0.78 1.4 3.2 6.1 10 16 23 34 44 55 76 100
ft.lbf. 3.0 5.7 10 23 44 75 120 160 240 320 400 550 720
Nm 4.1 7.6 14 31 60 98 157 225 335 430 540 745 980

008983 - en 2014.03 151/157
Index
A
Accessories 95
accidents with ammonia 25
accidents with HFC/HCFC 26
after start-up 143
Alignment 97
Ammonia 28
Appendix 151
Application 18
Approvals 147
B
Base frame 114
Batteries 150
Brief stop 119
C
Capacity control 40
Carbon dioxide 28
charging of refrigerant 142
Check list 113, 143
Cold-start system 48
Cold-start valve 48
combustion engines 18
Commissioning 141, 142
COMP1 114
COMP1 calculation program 45
Compressor 33
Compressor description 31
compressor flow 78
Compressor name plate 14
Condensing pressure 122
Control system 32, 116
Cooling water system 20
coupling 106
D
Daily maintenance 118
Data for compressor 75
Declaration of conformity 144
Design/Construction 30
dimension data 75

152/157 008983 - en 2014.03
Dimensional outline 69
dimensions 137
Direction of rotation 84
Disposal 96, 150
Documentation 142
double oil filter 39
Dual dip tube method 52
E
Economizer 57, 114
electric motor 81
Electric motor 76, 103
Electrical components 150
Electrical connections 72
electricity supply 109
Emergency stop 84
Evacuation 112, 142
Evaporating pressure 121
External oil filter 39
F
Fault-finding 130
F-gas regulation 23
Final check 142
First aid 25, 26
first start-up 94
flange loads 66
foundation 97, 98
foundation block 99
Frequency 88
G
gravity 101
greenhouse gases 23
H
Handling 137
heat exchangers 55
Heating rods element 46
HFC/HCFC 28
High-stage compressor 51
hydraulic system 40
Hydro carbons (HC) 28

008983 - en 2014.03 153/157
I
Installation 94, 96
installation check 113
Instrumentation 33, 63
K
kip angle 101
L
Legend 62
lifting 138
Lifting 96
liquid injection 42
Liquid injection adjustment 42
Liquid injection oil cooling 50, 51
List of components 73
loading 96
Loading 138
Loading range 105
Long term storage 119
Low ambient temperature operation 44
lubricating oil 46, 123, 126
Lubricating oils 22
lubrication system 35
M
machine room 77, 100
main components 32
Maintenance intervals 120
Maintenance of compressor unit 118
Maintenance safety/safety at servicing 21
Major overhaul 118
Marine plant 100
measured values 88
Motor 81
Motor lubrication 129
mounting site 95
Moving the equipment 96, 140
N
noise 90, 91
Noise 87
Noise and vibration 121

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Noise data 85, 86
O
oil 123, 124
Oil and refrigerant 150
Oil carry-over 45
Oil change 128
Oil charging 112, 126
oil cooler 55
Oil cooler 102, 128
Oil coolers 114
oil cooling system 42
Oil cooling system 50
oil filter 39
Oil filter 102, 128
Oil level 46
Oil level switch 47
Oil pump 56, 102, 114
Oil return system 37
oil return valve 38
oil separation system 35
oil separator 101
Oil separator 36, 114, 128
Oil vessel 37
Operating limits 80
P
Periodic maintenance 118
Personnel requirements 141
Physical and connection data 65
Piping connections 107
piping diagram 59, 61
piping layout 50
port locations 70
Position of valves and components 63
Power supply 22
pressure levels 93
Pressure testing 110
protecting system 49
Protecting the operator 27
pump oil system 35
Purging 23

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R
refrigerants 28
Refrigerants 23
Replacing motor bearings 129
Reverberation time 91
S
Safety equipment 95
Safety precaution definitions 10
Safety precautions 150
screw compressor 30
Shaft rotation 34
Signs 16
Signs and warnings 11
Sound 87, 88
sound data 90
Space requirements 96
Start-up 142
Stopping routine 119
Storage 140
Suction check valve bypass 44
suction isolation valve 67
suction side 69
support reactions 101
swept volume 76
T
Technical data 75
Test pressure 75
Test pressure levels 93
Thermosyphon oil cooling 50, 52
Tools 95
torque 81, 83
Torque 108
Torque for screws and bolts 151
Training 141
Transmission system 114
Transport 136
Transport data 137
Transport regulations 139
Troubleshooting 130
Tubesystem 128

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U
Unisab III 32, 74, 115
unit 68
Unit 75
Unit/pipe system name plate 12
Unpacking 96, 139
V
Variable speed drive 34
Vessel name plate 15
vibration dampers 99, 101, 105
Vibration data 92
Visual inspection 121
Volumizer 41
W
Water-cooled oil cooling 50, 54
Weight 137
Weight of electric motor 65
Work area safety 19

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Engi n e e r i n g , S e r v i c e a n d Ma int e nan ce m an ual

Screw compressor unit

Refrigerant cooled oil cooler Water cooled oil cooler

Liquid injection in compressor Single port Dual port

Motor 3 x _________V / _________ Hz

Heating elements (phasing)1 x _________V / ________ Hz

Power ______ kw Size IEC ______ Pole no. 4 Pole no. 2

Anti condensation heater

Max. rel. humidity = 85% (Std.) Max. rel. humidity = 100%

Engineering, Service and Maintenance - SAB 151 A-frame

External surface Design pressure

Pressure loss, if any, from safety valve to customer connection

(based on design pressure, [bar] _____________

Safety valve type:

Back pressure dependent Back pressure independent

2. Signs and warnings 11

Engineering, Service and Maintenance - SAB 151 A-frame

5. Physical and connection data 65

Engineering, Service and Maintenance - SAB 151 A-frame

10. Operating instructions 117

11. Maintenance instructions 118

12. Fault-finding instructions 130

13. Service instructions 135

14. Transport instructions 136

15. Commissioning instructions 141

16. Compliance instructions 144

17. Certificates 147

18. Spare parts list 148

19. Spare parts drawings 149

20. Final disposal 150

21. Appendices 151

Engineering, Service and Maintenance - SAB 151 A-frame

1.1.2 Main users

1.1.3 Manufacturer's information

Engineering, Service and Maintenance - SAB 151 A-frame

1.1.4 Safety precaution definitions used in this manual

Engineering, Service and Maintenance - SAB 151 A-frame

2. Signs and warnings

This chapter describes:

2.1.1 Main users

1. Compressor name plate

Engineering, Service and Maintenance - SAB 151 A-frame

2.1.3 Unit/pipe system name plate

Engineering, Service and Maintenance - SAB 151 A-frame

Category For EC - PED approval:

Engineering, Service and Maintenance - SAB 151 A-frame

2.1.4 Compressor name plate

Engineering, Service and Maintenance - SAB 151 A-frame

2.1.5 Vessel name plate

Engineering, Service and Maintenance - SAB 151 A-frame

Dangerous noise level,

The unit IS filled with

Internal protection Pacemaker users keep out

Påfyldt be skytte lsesgas N2

Engineering, Service and Maintenance - SAB 151 A-frame

Engineering, Service and Maintenance - SAB 151 A-frame

3.1. Areas of application

3.1.2 Application of combustion engines

Motor 3 x _V / _ Hz

Heating elements (phasing)1 x _V / Hz

Power kw Size IEC Pole no. 4 Pole no. 2