SAB 157 HR

Screw compressor unit

Opera tin g man ual

en
 
Manual for SAB 157 HR screw compressor

Unit no.

Compressor
157 HR

Refrigerant
R717 R744 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
Vi 1.7 Vi 2.2 Vi 2.9 Vi 4.0

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 _________

Motor

Anti condensation heater

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

Approval
PED (97/23/EC) Others ________

Coalescer element
pcs.

Separator velocity ref. _______

Unisab setting values

Separator velocity ref. CR _______

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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
downstream line accord- Oil cooler
ing to EN 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 to operating manual 5

1.1.1 Safety precautions definitions used in this manual 7

2. Areas of application of screw compressor

unit 8
2.1.1 Application 8
2.1.2 Application of combustion engines 8

3. Identification 9
3.1.1 Unit/pipe system name plate 9
3.1.2 Compressor name plate 11
3.1.3 Vessel name plate 12

4. Safety precautions 13
4.1.1 Signs 13
4.1.2 During operation 14
4.1.3 Maintenance safety/safety at servicing 16
4.1.4 Lubricating oils 17
4.1.5 Purging a refrigeration plant 18
4.1.6 F-gas regulation (flourinated greenhouse gases) 18

5. Sound measurement and noise data 20

5.1.1 Noise data 20
5.1.2 Noise data for screw compressors 20

6. Installation 21

7. Operating instructions 22
7.1.1 Description of unit 22
7.1.2 Principle P&I diagram 24
7.1.3 Descriptions of main components and systems 27
7.1.4 Compressor 27
7.1.5 Compressor lubrication system 28
7.1.6 Capacity regulation and fixed volume ratio Vi 28
7.1.7 No pump oil system 28
7.1.8 Oil pump (optional) 28
7.1.9 Compressor oil separation system 29
7.1.10 Automatic oil return valve 30
7.1.11 Cold-start system 32
7.1.12 Suction check valve by-pass 32

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 7.1.13 Operation at low ambient and high condensing tempera-
ture 33
7.1.14 Start-up 34
7.1.15 Stopping routine 36
7.1.16 Long term storage 36

8. Troubleshooting 37
8.1.1 Troubleshooting 37

9. Maintenance instructions 41
9.1.1 Maintenance of compressor unit 41
9.1.2 Operations log 44
9.1.3 Oil 45
9.1.4 Motor 48

10. Final disposal 49

11. Appendices 50
11.1.1 Declaration of conformity 50

Index 53

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Introduction to operating manual

1. Introduction to operating manual

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.
The purpose of this manual is to describe:
• Dangers resulting from failure to comply with safety precautions when operating the
equipment and performing maintenance tasks.
• How to start, operate and stop the equipment safely.
• How to act when problems occur during operation.
• Scheduled maintenance tasks for the equipment and when/how to carry them out
safely.
This manual is primarily intended for operators and service engineers.
• It is important that the operating personnel familiarize themselves with the contents
of this manual in order to ensure proper and efficient operation. Johnson Controls
Denmark is not liable for damage occurring during the warranty period where this is
attributable to incorrect operation.
• All compressor intervention within the warranty period must be performed by author-
ised personnel only. If not, the warranty no longer applies.
This manual does not describe:
• Control systems. A specific operating manual is delivered with the compressor.
• Safety when handling refrigerants and oils.
• Installation.
• Service and repair including spare part lists.
For further information, see www.sabroe.com.
This manual covers the following type of unit:

EU designation US designation
Model No.
SAB 157 HR HPS 42 and HPS 60
Both types of designation may occur in the description.
American standards are used in all P&I diagrams in this manual.

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 Introduction to operating manual

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 © 2012 Johnson Controls Denmark ApS
This manual must not be copied without the written permission of Johnson Controls Denmark
ApS and the contents must not be imparted to a third party nor be used for any unauthorized
purposes. Contravention will be prosecuted.
The original version of this manual is the English language version. If there are any discrepan-
cies or conflicts between the English and any other version that has been translated into an-
other language, the English version will prevail.

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Introduction to operating manual

1.1.1 Safety precautions 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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 Areas of application of screw compressor unit

2. Areas of application of screw compressor unit

2.1.1 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, as 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.
• 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

2.1.2 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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Identification

3. Identification
3.1.1 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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 Identification

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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Identification

3.1.2 Compressor name plate

Fig. 2

Fig. 1

Note: The compressor is fitted with a Frick name plate, Fig. 1, and one of the two refrigerant
name plates illustrated in Fig. 2.
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

Geometrical
Rotor Max. swept volume
Compr. dia. Rotor Speed drive shaft end CFM M3/H
model mm L/D rpm Ft3/Rev. M3/Rev. 3550 rpm 2950 rpm
HPSH 1510 157 1.0 6,000 0.05847 0.00165 207.5 292.8
Table 1: Geometrical swept volume

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 Identification

3.1.3 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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Safety precautions

4. Safety precautions
4.1.1 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

General
Use these precautions as a supplement to the safety precautions and warnings included 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. Assign only qualified personnel instructed in safety and
all machine functions to operate or service this compressor.
Operators and maintenance personnel must carefully read, understand and fully comply with
all warnings and instruction plates mounted on the machine.
• Observe the safety warnings on the compressor/unit.
• Use ear protection when operating the unit.
• Use safety equipment. Wear appropriate gloves as well as eye and face protection
when working with parts containing refrigerant and/or lubricating oil.
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.

4.1.2 During operation

Warning!
All safety features, disengagement and interlocks must be in place and function correctly be-
fore the equipment is put in operation. Never by-pass or wire around any safety device.

Ventilation
Before operating the unit, always check 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.

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Safety precautions

Pressure

Danger!
A compressor unit comprises a pressurized system. Never loosen threaded joints while the
system is under pressure and never open pressurized system parts.

Note: Whenever a by-pass valve/safety valve has been activated we recommend recalibrat-
ing it. This must be carried out by authorized personnel only. See also EN 378 and existing
national 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

4.1.3 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 4. 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

Power supply

Danger!
HIGH VOLTAGE!
Before removing or opening any electrical enclosures, covers, plates, doors or working on any
electrical circuits, place the main switch of the compressor/unit in the "OFF" position and lock
it. Dismantle the main fuses to the compressor unit.

An electrician must analyse the electrical system to determine the possible use of power re-
taining devices such as capacitors. Such power retaining devices must be disconnected, dis-
charged or made safe before maintenance is performed.

4.1.4 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
See Sabroe oil recommendation for recommended type of oil.

Warning!
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.

Refrigerants
Be very careful when dealing with refrigerants. For safe handling please refer to the safety
data sheets etc. delivered by the refrigerant supplier.

Danger!
Pay close attention to the fact that large amounts of escaping (or released) refrigerant entail
risk of suffocation. Body contact with leaking liquid refrigerant entails high risk of injuries
caused by intense cold.

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 Safety precautions

4.1.5 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 authorized 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.

4.1.6 F-gas regulation (flourinated 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.
Flourinated 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
• 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 flourinated greenhouse gases, the following
conditions apply depending on type of plant and amount of charge:

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Safety precautions

• Applications containing 3 kg or more of fluorinated greenhouse gases must be

checked for leakage at least once every 12 months.
• Applications containing 30 kg or more of fluorinated greenhouse gases must be
checked for leakage at least once every 6 months.
• Applications containing 300 kg or more of fluorinated greenhouse gases must be
checked for leakage at least once every 3 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: By 4 July 2008 the member states must establish certification
and training programs for personnel involved in leakage inspections and the recovery, recy-
cling, 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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 Sound measurement and noise data

5. Sound measurement and noise data

5.1.1 Noise data
In the following tables the noise data of the compressors is stated in:
- A-weighted sound power level Lw
(Sound Power Level)
- A-weighted sound pressure level Lp
(Sound Pressure level).
The values for Lw constitute an average of a large number of measurements on various units.
The measurements are carried out in accordance with ISO 9614-2.
The values are also stated as average sound pressure in a free field above a reflecting plane
at a distance of 1 meter from a fictional frame around the unit.
Normally, the immediate sound pressure lies between the Lw and Lp values and can be calcu-
lated, provided that the acoustic data of the machine room is known.

5.1.2 Noise data for screw compressors

Evaporating temperature TE -47°C

Condensing temperature TC -7°C
Refrigerant R744
Speed 6000 rpm

Lw Lp
Type of unit
(dBA) (dBA)
SAB 157 HR On request On request
Table 2: Noise data - CO2

Evaporating temperature TE +17°C

Condensing temperature TC +63°C
Refrigerant R717
Speed 6000 rpm

Lw Lp
Type of unit
(dBA) (dBA)
SAB 157 HR On request On request
Table 3: Noise data - Ammonia

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Installation

6. Installation
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.
The main issues/check points for installation of the compressor unit are as follows:
1. Lifting the unit. Only use the lifting lugs marked with red.
Warning! This screw compressor unit may be top-heavy. Use caution to prevent
unit from turning over.
2. Place the unit with sufficient free space for operation and maintenance.
3. Place the unit on a foundation suitable for the actual load and vibrations with or with-
out vibration dampers according to the vibration design strategy.
4. Welding on suction piping, discharge piping and other oil cooling system pipings.
The piping design must include proper design considerations regarding function, vi-
brations, thermal expansion and pre-stress after welding in order to avoid high load
on the compressor unit connections.
5. Leak and pressure test according to the applied/local codes and rules. Isolate the
compressor unit from the test pressure or disconnect pressure transducers and safety
valves. Never exceed the test pressure of the unit stated on the unit name plate.
6. Connect power supply wiring (compressor motor, oil pump motor (optional) and con-
trol system) according to electrical diagrams.
7. Make a final check of all relevant components, connections, electrical connections,
safety functions, ie safety valve, safety high pressure cut-out (below compressor safe-
ty overflow valve and not above 0.9 x max. allowable pressure) and the machine
room safety equipment.
8. Evacuate the unit.
9. Charge oil (type according to Sabroe oil recommendation).
10. Charge refrigerant.
11. Connect power supply.
12. Set up the control system settings including calibration according to the control sys-
tem manual.
13. Check the direction of rotation of the compressor motor and oil pump (optional).
14. Mount the coupling.
For a detailed description, please see separate Installation manual.

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 Operating instructions

7. Operating instructions
Read chapter 4. Safety precautions carefully before operating the unit.
7.1.1 Description of unit

Control system
The compressor unit is controlled by an electronic control system (EC) see Fig. 3. The control
system is described in a separate manual, delivered with the unit.

Principle drawing

102 126 104 105 192

EC

119 116 160 106 161 193

117

Fig. 3

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Operating instructions

Not shown

101 129 191 108

123 195 124 194

Fig. 4

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 Operating instructions

7.1.2 Principle P&I diagram

158
113

115

101

129
151

192 191

159 159

124

152 201
157
108
104 105

102 103
107
126
116 163

193 160
117

161 154
106
155 119

125 153

195

123 122
194
156

200

Fig. 5: SAB 157 HR general piping diagram

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Operating instructions

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

AS Air supply PM Pump motor
C Compressor PS Pressure switch control
CV Check valve PS Auto cycle
DP Discharge pressure PSV High pressure safety valve
F Filter or filter drier RTD Resistence temp detector
FG Flow glass SP Suction pressure
HV Hand valve STR Strainer
HTR Heater TAH High temperature alarm
LG Level glass TAHH High temperature shutdown
LSL Low oil level switch TAL Low oil temperature alarm
LSLL Separator low oil level shutdown TALL Low oil temperature shutdown
M Motor TCV Thermal control valve
1MC Motor control centre TE Temperature element
2MC Motor control centre TI Temperature indicator
OP Oil pressure TS Temperature switch
P Demand pump TSH Temperature switch high alarm
PAH High discharge pressure alarm TT Temperature transmitter
PAHH High discharge pressure shutdown TW Thermowell
PAL Low pressure alarm YY Solenoid valve
PALL Low pressure shutdown VI Vi control
PCV Pressure control valve WS Water supply
PDSLL Compressor low diff. pressure cut-out XE Vibration element
PE Pressure transducer XT Vibration transmitter
PI Pressure indicator XAH Vibration high alarm
PIC Pressure indicator controller XAHH Vibration high shutdown

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 Operating instructions

Valve position during operation

Pos. no. Designation In-operation position
101 Suction stop valve Open
102 Stop valve after oil separator Open
103 Change over valve Open to safety valve - no.1 or no.2
104 / PSV1 Safety relief valve (Closed) Fixed set point
105 / PSV 1 Safety relief valve (Closed) Fixed set point
106 Service valve for oil drainage Closed
107 Purging valve Closed
108 Service valve - “pump out” Closed
113 Service valve - pressure transducer Open
115 Check valve Open
119 Stop valve before oil filter Open
122 Service valve - pressure transducer Open
123 Stop valve after oil filter Open
124 Regulating valve (oil flow) Open (partly) Adjusted acc. to manual
125 Service valve - pressure transducer Open
126 Cold-start valve Open
129 Suction check valve Automatic
200 Stop valves - oil return Open
Dual oil filter (optional):
135 / 136 Stop valve before oil filter Oil filter 1:
Open 135 - 123
Close: 136 - 138
123 / 138 Stop valve after oil filter Oil filter 2:
Open 123 - 135
Close: 138 - 136
137 Service valve - oil filter Closed
Oil pump (optional):
149 Stop valve before oil pump Open

Liquid injection (optional):

Single port
165 Liquid stop valve Open
170 Stop valve Open
Dual port
165 Liquid stop valve Open
170 Stop valve Open
172 Stop valve Open
173 Stop valve Open
175 Stop valve Closed
Table 4: Position during operation

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Operating instructions

7.1.3 Descriptions 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
The information in this section of the manual provides the logical step-by-step instructions to
properly start up and operate the screw compressor unit.

7.1.4 Compressor
The Frick HPSH rotary screw compressor utilizes mating asymmetrical profile helical rotors to
provide a continuous flow of vapour and is designed for both high-pressure and low-pressure
applications. The compressor incorporates the following features:
• Designed for variable speed drive, 1000 to 6000 rpm. Fixed speed: 2950 rpm or 3550
rpm possible.
• No slide valve for capacity regulation - just a simple robust capacity control plug valve
to reduce starting torque requirement and provide overload protection. Plug valve is
operated with a 4-way solenoid valve.
• Fixed volume vi ratio: 1.7, 2.2, 2.9 and 4.0 are available as standard. No moveable
slide stop valve.
• High capacity roller bearings to carry radial loads at both the inlet and outlet ends of
the compressor.
• Heavy duty angular contact ball bearings to carry axial loads on the rotors.
• Balance piston located in the inlet end of the male rotor reduces axial loads on the
male axial bearings.
• Housings are designed for 60 bar (870 psig) working pressure.
• Economizer port at 1.05 Vi.
• Liquid injection port at 1.30 Vi.
• Two main oil injection ports at 1.05 and 1.30 to meet application requirements.
• All bearing and control oil vented to lower pressure locations inside compressor allow-
ing operation without an oil pump for most applications.
• Shaft seal housing designed to maintain operating pressure on seal well below dis-
charge pressure for increased seal life.
• Oil injected into the rotors to maintain good volumetric and adiabatic efficiency.
• Shaft rotation clockwise facing compressor drive end, suitable for all types of drives.

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 Operating instructions

Warning!
Compressor rotation is clockwise when facing the compressor drive shaft. The compressor
should never be operated in reverse rotation, as damage will result.

• Suction flange is ANSI B16.1 Class 400. Discharge flange is ANSI B16.1 Class 600.
• Integral suction strainer.

7.1.5 Compressor lubrication system

The lubrication system on a HPSH screw compressor unit performs several functions:
• Provides lubrication to bearings and seal.
• Provides a cushion between the rotors to minimize noise and vibrations.
• Helps keep the compressor cool and prevent overheating.
• Provides oil supply to hydraulically operate the plug valve on and off.
• Provides oil pressure to the balance piston to help increase bearing life.
• Provides an oil seal between the rotors to prevent rotor contact or gas bypassing.

7.1.6 Capacity regulation and fixed volume ratio Vi

The design without a moveable slide valve under the rotors provides a very robust design.
However, the fixed volume ratio must be selected close to the ideal value to provide reliable
and efficient operation. The simple plug valve is provided to allow start-up and safe operation
at low differential pressure and other not normal operations.
All capacity regulation is with variable speed - the plug valve can be used but the effect is
limited. Operating with a fixed-speed motor is possible, but be aware that the compressor will
start with high capacity and starting torque and additional controls in the unit may have to be
provided.

7.1.7 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.

7.1.8 Oil pump (optional)

A demand oil pump is required for low differential pressure applications (CoolWare will pro-
vide a warning when the oil differential pressure is too low). Oil being supplied to the
compressor from the oil separator is at system discharge pressure. Within the compressor, oil
porting to all parts of the compressor is vented back to a location in the compressor body that
is at a pressure lower than compressor discharge pressure. All oil entering the compressor is
moved by the compressor rotors, out the compressor outlet, and back to the system oil sepa-
rator.

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Operating instructions

7.1.9 Compressor oil separation system

The compressor is an oil flooded screw compressor. Most of the oil discharged by the com-
pressor separates from the gas flow in the oil charge reservoir. Some oil, however, is dis-
charged as a mist which does not separate readily from the gas flow and is carried past the oil
charge reservoir. One or more coalescer elements then coalesce the oil mist into droplets
which fall to the bottom of the coalescer section of the oil separator. See Fig. 6. The return of
this oil to the compressor is controlled by a throttling valve on both high stage and booster
applications.
Note: Original: Open needle valves only enough to keep coalescer end of separator free from
oil.
The sight glass located near the bottom of the coalescer section of the oil separator should re-
main empty during normal operation. If the oil level rises and remains in the sight glass,
there is a problem in the oil return separation system or compressor operation. Refer to chap-
ter 9. Maintenance instructions for information on how to correct the problem.
Note: Automatic: Open service valves completely to keep coalescer end of separator free of
oil.
The sight glass in the valve indicates flow variations.
Note: Normal operating oil level is halfway in the top sight glass, which is located midway
along the oil separator shell.

Note: Original only!

Throttling valve

Motor
Compressor

Demister
A
53
Separator Vessel

52
Fine oil separator
element pos. 55
OF-1 To oil cooler

From oil pump/oil cooler

Fig. 6: Principle oil separation system

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 Operating instructions

7.1.10 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. 7

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. 8.
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 equalized 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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Operating instructions

6 8 10
2

1
5
Out In

9 7

4 3

Fig. 8

Note: The sectional view shows the valve structure. Not all internal oil channels are visible.

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 Operating instructions

7.1.11 Cold-start system

The unit is equipped with a special "cold-start" discharge valve, see Fig. 9. This valve ensures
a rapid development of oil pressure at initial start-up in order to lubricate the compressor
without requiring an oil pump, even in cold ambient temperatures with all pressures equal-
ized.
For discharge pressures above 40 bar, only the non-return valve function is used.

High-stage units
For high-stage units, the cold-start valve is equipped with a large spring which creates a 2.0
bar [30 psi] pressure in the oil separator (above suction pressure) for lubrication of the com-
pressor.
Once the compressor is running it will begin to force gas to the condenser at connection P2.
As the condenser heats up, the pressure will begin to rise as the compressor suction pulls
down in pressure. As soon as a differential pressure has developed between the condenser
and suction side, these pressures will act across a piston inside the cold-start valve to partial-
ly overcome 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
operating pressure drop.
The unit is also equipped with a suction check valve by-pass. The oil separator will slowly
bleed down to approximate 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 section 7.1.12. Suction check valve by-pass for operation.
Note: For alarm descriptions and shutdown or cut-out parameters, see separate control sys-
tem manual.

P3 - TO SUCTION P3

CLOSED OPEN

P2 - TO
CONDENSER P2

P1 - FROM P1
OIL SEPARATOR

Fig. 9: Cold-start valve

7.1.12 Suction check valve by-pass

The unit is equipped with a low-pressure-drop suction check valve bolted directly to the com-
pressor housing. Units will be piped as shown in Fig. 10. During normal operation, valve NV-1
is closed. This is a pump-out connection to allow refrigerant removal to the system suction
prior to evacuation for servicing. In most systems, valve NV-2 must be open at all times. It

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Operating instructions

should normally be cracked open to allow the oil separator to slowly bleed down to approxi-
mately system suction pressure when the unit is stopped (having this valve cracked open al-
lows the compressor drive motor to have an easier start and the discharge check valve will
seat more tightly). If the drive coupling backspins, start closing the valve until the backspin
stops. If the separator oil level foams excessively on shutdown, NV-2 should be closed slight-
ly. If the separator takes more than 20-30 minutes to equalize to suction pressure after shut-
down, NV-2 can be opened slightly. See Fig. 10.

TO THE COMPR.
SUCTION GAS

FROM
SEPARATOR
COLD-START
VALVE

COMPRESSOR END VIEW

Fig. 10: Suction check valve by-pass

Check valve CV-4 is installed on all units with suction pressure below atmospheric or installed
with economizer option utilized on multiple compressor plants.
On high-stage systems, check valve CV-4 should be installed with a 3.1 bar [45 psi] spring to
avoid the possibility of back-feeding to a shutdown compressor from a common economizer
vessel.
NV-2 must be closed if the oil pump should run for long periods of time when the compressor
is stopped. This is important in order to avoid oil being pumped up the suction line.

7.1.13 Operation at low ambient and high condensing temperature

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] or below the saturation temperature at equalizing pressure, insulat-
ing and/or heat tracing of the compressor lubricating oil systems 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.

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 Operating instructions

7.1.14 Start-up

Preparations before start up

1. Turn on the power voltage and the control voltage. Check the emergency stop button.
2. Check the oil level in the oil separator. Oil level visible in the upper sight glass.
3. Check that all valves are positioned in accordance with Table 4: Position during opera-
tion, including secondary side of oil cooler.
4. Reset all alarms according to the control system instructions.
5. Check the control display to see that the compressor capacity control system is in
minimum slide position 0-4%.

Initial start-up procedure

Personnel who is going to start up the plant must be well-qualified and have a thorough
knowledge of refrigeration technique. Prior to start-up, the prestart check must be accom-
plished.
Having performed the checkpoints on the installation and preparation before start check list,
the compressor unit is ready to start up. It is important that an adequate refrigerant load is
available to load test the unit at normal operating conditions. The following points should be
kept in mind during initial start-up.
During the initial start-up of the unit, it is imperative that the hand expansion valve on the
main oil injection line is fully open to ensure adequate oil flow. Using a demand oil pump it
may be necessary to throttle in order to half open valve before start-up.
There is still an orifice installed in the compressor to control maximum oil flow. At initial start-
up of the compressor, the hand expansion valve must be fully open. After initial start-up of
the unit, the hand expansion valve must be adjusted.
Before the initial start-up of the compressor, close the hand expansion valve completely.
Open the valve back up and count the turns that it takes to fully open the valve. After the ini-
tial start-up close the valve to achieve approximately 82°C [180°F] discharge temperature or
the theoretical temperature from CoolWare. Do not fully close the valve at any time while the
compressor is running.

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Normal start-up procedure

1. Check/perform the Preparations before start-up.
2. Confirm that the system conditions permit the compressor to start.
3. Press the start button.
4. Allow the compressor to start up and stabilize.
5. Observe the compressor unit for mechanical tightness of the external piping, bolts and
valves. Ensure that the unit is clean from oil and refrigerant leaks. If not satisfactory,
shut down the compressor and correct the problem using good safety precautions.
Restarting compressor unit after control power interruption (plant power failure)
• Check variable set points.
• Follow normal start-up procedure.

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 Operating instructions

7.1.15 Stopping routine

Brief stop
The compressor can be stopped at any capacity setting. However, under normal conditions it
is recommended to reduce the capacity to a minimum before stopping the compressor.
Leave all valves in their “in-operation positions”. Do not turn off the power to the screw com-
pressor unit as the oil heater must be connected to keep the correct oil temperature.

Shutting down for a long period

Follow the Brief stop instructions and:
• Disconnect oil heater
• Close suction and discharge valve
(and liquid line for ECO and liquid injection) (optional)
To perform servicing and repair work, the necessary valves must be closed.
To reduce the risk of bearing damage it is recommended to rotate (to a new position) the mo-
tor and compressor on a monthly basis. If the screw compressor unit is exposed to vibrations
during a long shutdown period, the interval should be changed to weekly.
Avoid high vibration level.

7.1.16 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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Troubleshooting

8. Troubleshooting
8.1.1 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.
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 5: Refrigeration plant - general

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Compressor unit - general
Symptom Probable cause
Electrical supply.
Compressor cannot
start Alarm in control system.
Oil level too low.
Compressor starts
Oil system failure (temperature,
but stops immedi-
pressure, level)
ately
Oil filter differential
Oil filter clogged.
pressure too high
Valves in oil system are not fully
open.
3-way oil temperature control
valve. (Water-cooled or refrigerant-
cooled (Thermosyphon)).
Insufficient oil cooling function
(water-cooled).
Oil temperature too
high (and high dis-
charge tempera- Insufficient oil cooling function
ture) (refrigerant-cooled)
Insufficient oil cooling function
(liquid injection).
Compressor protection valve is
open or leaking.
Discharge tempera-
Excessive liquid in suction line
ture very low. Oil
/ liquid slugging.
temperature low
and oil may be
foaming in oil sepa-
Liquid injection (optional) overfeed-
rator
ing.
Compressor protection valve is
Suction pressure
opening or leaking.
high and insufficient
refrigeration capaci-
Oil return valve fully open.
ty
Suction strainer clogged.
Table 6: Compressor unit - general
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Troubleshooting
Correction
Check main switch and fuses. Re-
set emergency stop switch etc.
Register the alarm, correct if nec-
essary and reset (refer to the Con-
trol manual).
Charge oil.
Check oil level.
Check valve positions.
Replace oil filter
Check stop valves and opening po-
sition of the oil regulation valve
Check function, replace the sensor
element.
Check oil cooler, fouling, water in-
let temperature, (too high), water
flow (too low).
Check/drain accumulated oil in the
oil cooler. Check that the gravity
feeded refrigerant system is full
flooded.
Check the settings in control sys-
tem, valves and strainer in Liquid
injection line,
Check the discharge pressure safe-
ty cut-out settings. Check the pilot
and main protection valve.
Check evaporator (and economizer
(optional)) and expansion valve
function. Decrease the rate of
evaporator temperature “pull
down”.
Check the settings in control sys-
tem (increase the set point). Check
the stability of the liquid injection.
Check the discharge pressure safe-
ty cut-out settings. Check the pilot
and main protection valve.
Adjust the regulating valve accord-
ing to manual.
Clean strainer
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Troubleshooting

Compressor unit - oil separation

Symptom Probable cause Correction
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 economized unit: economizer
Repair or replace.
check valve not working.
Shaft seal leakage Leakage exceeds normal allowable
Replace seal.
rate of 7 drops per minute.
Table 7: Compressor unit - oil separation

Compressor block
Symptom Probable cause Correction
Main oil injection valve may be
Open valve.
closed.
Main oil injection valve may be
Adjust.
open too far.
Excessive noise and
Bearing damage or excessive wear. Replace bearings.
vibration
Tighten coupling. Replace if dam-
Coupling loose on shaft.
aged.
Refrigerant flood back (Liquid slug-
Correct system problem.
ging).
Table 8: Compressor block

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 Troubleshooting

Demand oil pump system (optional)

Symptom Probable cause Correction
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 9: Demand oil pump system (optional)

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Maintenance instructions

9. Maintenance instructions
9.1.1 Maintenance of compressor unit
Read chapter 4. 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 section 9.1.2. Operations log. Check that all oper-
ating values are within the permissible ranges. Compare 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 10: Maintenance intervals.
3. Major overhaul
For major maintenance tasks such as compressor overhauls, 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 10: 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 strainer 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)

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x Every 6 months, more frequently if levels increase
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 11 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.
Maintenance instructions

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Operating manual - SAB 157 HR
Maintenance instructions

Discharge flange to
Suction flange
EU Compressor separator flange
designation model Torque Torque
Bolt size Bolt size
(Nm) (Nm)

SAB 157 HR HPSH 1510 M20 x 2.5 190 M22 x 2.5 298

Table 11: Torque requirements

Note: * Based on:

a. Gaskets-Garlock® Blue-Gard® 3300
b. Bolts-class 8.8 or stronger hex head bolts, lightly oiled and clean

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 Maintenance instructions

9.1.2 Operations log

To ensure satisfactory operation, it is recommended to enter the following routines in a log-
book. The service engineer will need this information in connection with e.g. error reports. In
addition to the data mentioned in Table 12, all other activities of service, maintenance or re-
pair work must be entered into the logbook as required by EN 378 and national laws.

Compressor type/no.: _______________

Refrigerant: _______________
Oil type: _______________

Check list Normal Date and time

level
From To
Suction pressure (bar)
Suction temperature (°C)
Superheating, suction gas (K)
Discharge pressure (bar)
Discharge temperature (°C)
Oil pressure, compressor (bar)
Oil diff. pressure, filter (bar)
Oil temperature (°C)
Oil level (upper/lower glass)
Charged oil (litre)
Operation time (hours)
Volume ratio
Capacity load, %
Other observations
Refrigerant leaks
Oil leaks
Oil drain bottle (shaft seal)
Vibration/noise
Unisab control:
Alarm/Shutdown
Other service
or repair work
Table 12: Monitoring of operation

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Maintenance instructions

9.1.3 Oil
The oil separator in the screw compressor unit has an integrated oil reservoir. The oil is used
for lubrication, cooling, sealing and regulation of the capacity slide.
• Only use oil according to Sabroe oil recommendation.
• Oil is added via the oil pump/oil charging valve.
• Check the oil level in the oil separator. It must not be higher than the upper sight
glass. Oil must be added when the level reaches the lower sight glass. The correct
level appears only when the unit is operating.
• If the oil level is too low, check for leaks and possible insufficient oil return from the
refrigeration plant.
• The oil level will rise approx. 10 mm if the indicated amount of oil is charged, see Ta-
ble 13: Oil charging.

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.

Type of unit Basic Basic Amount of oil Amount of oil

oil charge oil charge per 10 mm per 10 mm
Litres Gal. Litres Gal.
SAB 157 HR 170 45 8 2
Table 13: Oil charging

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 Maintenance instructions

Oil charging pump

Oil charging is carried out by means of a portable oil charging pump as described below. See
Fig. 11: Oil charging.
1. Connect the high-pressure hose, pos. 7, to the charge valve, pos. 24, on the unit via
non-return valve, pos. 12. Use correct reduction nipple. See Fig. 12: Oil charging dia-
gram.
2. Place the free end of the suction hose from the pump, pos. 1, together with the by-
pass hose, pos. 2, in the oil barrel.
3. Ball valve pos. 9, and the charge valve, pos. 24, will open and the pump, pos. 5, will
start.
4. The oil now circulates until the system is free from air bubbles after which the ball
valve, pos. 9, will close. The oil will now be charged to the unit.
5. When the desired amount of oil has been charged, the pump will stop and the charge
valve, pos. 24, will close.
6. Open the ball valve, pos. 9, carefully so that the pressure is equalized. The hoses can
now be dismounted.
7. Loosen the non-return valve carefully so that the remaining pressure is equalized. Re-
member 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. 11: Oil charging

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Maintenance instructions

24

20

12

7 5

Fig. 12: Oil charging diagram

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 Maintenance instructions

9.1.4 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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Final disposal

10. Final disposal

10.1.1 Safety precautions

Danger!
Before dismantling the plant, read the safety precautions carefully.

Dismantling a cooling unit to be scrapped must be carried out safely.

Authorized 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.

10.1.2 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 national
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.

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 Appendices

11. Appendices
All relevant instructions for products supplied by sub-suppliers are collected here.

11.1.1 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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Appendices

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 Appendices

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Index

B
Batteries 49
Brief stop 36

C
Cold-start system 32
combustion engines 8
Compressor name plate 11
Cooling water system 15

D
Declaration of conformity 50
Descriptions of main components and systems 27
Disposal 49
During operation 14

E
Electrical components 49

F
F-gas regulation 18

H
High stage units 32

L
Long term storage 36
Lubricating oils 17

M
Maintenance intervals 42
Maintenance of compressor unit 41
Maintenance safety/safety at servicing 16
Motor lubrication 48

N
Noise data 20
Normal start-up procedure 35

O
Oil and refrigerant 49
Oil charging pump 46
oil return valve 30

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Operation at low ambient and high condensing temperature 33
Operations log 44

P
Power supply 17
Pressure 15
pump oil system 28
Purging 18

R
Refrigerants 17
Replacing motor bearings 48
Rotating parts 14

S
Safety precautions 7, 49
Shutting down for a long period 36
Signs 13
Stopping routine 36

U
Unit/pipe system name plate 9

V
Vessel name plate 12
Vibration and noise 14

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