Johnson Controls SABROE ComPAC Operating Manual
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Johnson Controls SABROE ComPAC Operating Manual

Chiller unit with screw compressor
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  • Page 1 Operating manual ComPAC Chiller unit with screw compressor...
  • Page 3 Manual for ComPAC with screw compressor The chiller unit can be configured with various types of equipment depending on its function and requirements. Some of the equipment may be described in this manual even though it is not featured on your particular unit.
  • Page 4 Vessel data Design pressure External surface Type [bar] Condenser Float housing Evaporator Liquid separator Oil separator Oil cooler Safety valve: Data for calculation of Receiver downstream line accord- ing to EN 13136 Economiser Desuperheater Subcooler Other Pressure loss, if any, from safety valve to customer connection (based on design pressure) [bar] _____________ Safety valve type: Back-pressure dependent...

  • Page 5: Table Of Contents

    Contents Introduction ..................8 Introduction to the manual ............. 8 1.1.1 Amendments to the manual ..........9 1.1.2 Definition of safety precautions used in this manual ................10 1.1.3 Requirements for competent persons ......10 Safety ....................11 Areas of application ............... 11 2.1.1 Application ..............
  • Page 6 3.2.3 Evaporator ..............29 3.2.4 Condenser ..............29 3.2.5 Receiver ................30 3.2.6 HP regulating system (water-cooled condenser) ..............31 3.2.7 Air purge valve ............... 32 3.2.8 Automatic oil recovery system from evaporator ... 33 3.2.9 Alarm for high level in the evaporator ......34 Installation information ..............
  • Page 7 Shutdowns and alarms ............46 5.6.1 Operating state ............... 46 5.6.2 Troubleshooting .............. 47 5.6.3 Testing of chillers ............48 Maintenance instructions ............49 Maintenance of the chiller unit ..........49 Selecting lubricating oil for ComPAC units ......49 R717 charge ................50 Final disposal .................

  • Page 8: Introduction

    Copyright © 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 unauthorised purposes. Contravention will be prosecuted.

  • Page 9: Amendments To The Manual

    Introduction 1.1.1 Amendments to the manual 2020.03 Version 4 • The copy of the declaration of conformity (Unit) is now only contained in the printed manual delivered with the unit and the pdf version uploaded with the order specific documentation. •...

  • Page 10: Definition Of Safety Precautions Used In This Manual

    Introduction 1.1.2 Definition of safety precautions used in this manual Danger! Indicates an imminently hazardous situation which, if not avoided, will result in death or serious injury. Warning! Indicates a potentially hazardous situation or practice which, if not avoided, will result in death or serious injury.

  • Page 11: Safety

    However, check with the local authorities as exemptions to this rule may be granted. Warning! Johnson Controls Denmark is not liable for injuries to personnel or damage to equipment resulting from using the equipment for other purposes than the ones stated above. Operating manual - ComPAC 011769 en 2020.03...

  • Page 12: Identification

    Safety Identification 2.2.1 Identification of equipment All equipment from Johnson Controls Denmark can be identified by one or several name plates positioned as illustrated in the following drawing: Fig. 1: Identification of equipment Name plate for Pos. no. Compressor Evaporator/Cascade cooler...

  • Page 13: Unit/Pipe System Name Plate

    Safety 2.2.2 Unit/pipe system name plate Johnson Controls Denmark ApS 2516-343 Johnson Controls Denmark ApS 2516-342 Christian X's Vej 201 Christian X's Vej 201 8270 Højbjerg, Denmark 8270 Højbjerg, Denmark www.sabroe.com www.sabroe.com Refrigeration unit Year Refrigeration unit Year Type Type...
  • Page 14 Safety The unit name plate is positioned on the frame and contains this information: Refrigeration unit No. Identification no. (serial no.) Year of manufacturing. Year Type Manufacturer's type designation. For EC PED/EAC approval: ‘Unit & Piping’ means that the CE/EAC mark applies to the complete unit including the piping system.

  • Page 15: Compressor Name Plates

    Test pressure Test pressure bar g bar g Fig. 5: Name plate for standard compressor Fig. 6: Name plate for ATEX compressor Johnson Controls Denmark ApS 2516-347 Christian X's Vej 201 8270 Højbjerg, Denmark www.sabroe.com Year Compressor Type...
  • Page 16 Safety The compressor name plate is positioned on the compressor and contains this information: Compressor no. Identification no. (serial no). Year of manufacturing. Year Type Manufacturer's type designation. Allowable refrigerant or refrigerants for the compressor. Refrigerant (The actual refrigerant for the unit is stated on the unit name plate).

  • Page 17: Vessel Name Plate

    Safety 2.2.4 Vessel name plate Johnson Controls D e n m ar k ApS Johnson Controls Denmark ApS Christian X 's V e j 201 Christian X's Vej 201 2516-331 8 270 Højbj e rg, D e n m ark 8270 Højbjerg, Denmark...

  • Page 18: Signs

    Safety 2.2.5 Signs All signs which may be found on your equipment are shown below. The number of signs, however, may vary from one product to another. High surface High voltage/ The compressor may be temperature Risk of electric shock High pressure top-heavy (about 70°C)

  • Page 19: Safety Precautions

    Safety Safety precautions 2.3.1 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 •...

  • Page 20: Cooling Water Systems

    Use the prescribed tools, and check that they are properly maintained and in good work- ing 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. •...

  • Page 21: Lubricating Oils

    Safety • 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 unscheduled stop. •...

  • Page 22: F-Gas Regulation (Fluorinated Greenhouse Gases)

    Safety Note: The occurrence of air is usually an indication of poor maintenance or lack of thoroughness at installation. Note: Ammonia systems should be purged on a regular basis to avoid atmospheric air and other non-condensable gases. 2.3.10 F-gas regulation (fluorinated greenhouse gases) In the European F-gas regulation, No 517/2014, about reduction of harmful gases in the atmos- phere, the European Parliament (EU) has established guidelines for the regulation of certain fluo- rinated greenhouse gases.
  • Page 23 Safety • for equipment that contains fluorinated greenhouse gases in quantities of 5 tonnes of eq or more, but of less than 50 tonnes of CO eq: at least every 12 months; or where a leakage detection system is installed, at least every 24 months •...

  • Page 24: First Aid For Accidents With Ammonia

    Safety 2.3.11 First aid for accidents with ammonia (Chemical formula: NH , 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 people. As ammonia is self-alarming, it serves as its own warning agent so that no person stays voluntar- ily in hazardous concentrations.

  • Page 25: Protecting The Operator As Well As The Environment

    Safety 2.3.12 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 environ- ment.

  • Page 26: Emergency Stop

    Safety 2.3.13 Emergency stop In case of an accident, push the emergency stop button on the Unisab III controller. Emergency stop Fig. 11: Unisab III built into the electrical panel Emergency stop Fig. 12: Unisab III as a separate device For resetting and further information, please see the Unisab III manual.

  • Page 27: Design And Function

    The unit is provided with adjustable anti-vibration machine feet for installation on a solid concrete floor. For installation on decks, special vibration dampers are often required. The ComPAC units are controlled by Johnson Controls Denmark’s Unisab III control and capacity regulating system.

  • Page 28: Components On A Compac (Water-Cooled Condenser)

    Design and function 3.1.2 Components on a ComPAC (water-cooled condenser) Pos. Pos. Component Component Motor Electrical panel Compressor VSD panel Evaporator/liquid separator Oil separator Outlet evaporator Oil filter Inlet evaporator Oil cooler Condenser High level alarm Outlet condenser Heat recovery inlet (optional) Inlet condenser Heat recovery outlet (optional) Expansion valve...

  • Page 29: Main Components

    Design and function Main components 3.2.1 Compressor The compressor is a Johnson Controls Denmark standard compressor, complete with stop valves, motor, etc. For further information, see the compressor operating manual. 3.2.2 Control system Chillers are delivered with Unisab III monitoring, safety and capacity regulating system.

  • Page 30: Receiver

    Design and function 3.2.5 Receiver The ComPAC (external condenser) is equipped with a receiver. The purpose of the receiver is to accumulate the liquid coming from the condenser. The receiver has the following connections and sight glasses, all located on the flat end cover: Fig.

  • Page 31: Hp Regulating System (Water-Cooled Condenser)

    Design and function 3.2.6 HP regulating system (water-cooled condenser) The ComPAC (water-cooled condenser) unit is equipped with a mechanical HP float valve. This valve controls the expansion between the LP and HP sides of the refrigeration plant. The mechanical float valve, pos. 1 in Fig. 14, is fitted in the float valve housing under the condens- er in order to obtain a compact design and a very low refrigerant charge.

  • Page 32: Air Purge Valve

    Design and function 3.2.7 Air purge valve If there is air in the refrigeration plant, it tends to accumulate in the receiver or the condenser. On ComPAC (water-cooled condenser), the air purge valve is fitted at the top of the HP float valve cover at the bottom of the condenser, Fig.

  • Page 33: Automatic Oil Recovery System From Evaporator

    Design and function 3.2.8 Automatic oil recovery system from evaporator The relatively small amount of oil leaving the compressor and oil separator with the discharge gas is gradually collected at the bottom of the evaporator. An oil recovery pot, Fig. 16, is connected to the evaporator by a pipe. From the recovery pot, the oil is automatically returned to the compressor.

  • Page 34: Alarm For High Level In The Evaporator

    Design and function When the oil level in the recovery pot, Fig. 16, is high, the float switch, pos. 1, is activated. The switch turns on the solenoid valve in the oil recovery system. Incoming discharge gas pushes down the piston, pos. 3, which blocks the oil drain inlet port. Discharge gas is led into the oil reser- voir through the small nozzle, pos.

  • Page 35: Installation Information

    Installation information 4. Installation information General information For assistance or information about installation, please contact your local Johnson Controls Den- mark product representative. First start-up procedure Installation in terms of mechanical work (refrigeration system and piping), electrical work and in- stallation of safety equipment must be performed in accordance with local codes/rules and/or ac- cording to EN 378-3 and EN 378-4 as minimum requirements.

  • Page 36: Noise And Vibration

    Installation information Evacuate the unit. 10. Charge oil if not charged from factory.* 11. Charge refrigerant. The P&I diagram states the charge for each specific chiller. Start out by charging 75% of the specified R717 charge. The quality of the refrigerant must be appropriate for refriger- ation applications;...

  • Page 37: Foundation

    Contact a vibration expert or a Johnson Controls Denmark representative for more information. U n loa d e d s t a te Lo a d e d s t a te L o ck n u t Fig.

  • Page 38: Secondary System

    It is therefore important to keep brine and water under observation for both evaporator and con- denser. Consult a water treatment expert concerning additives to the system. The liability of Johnson Controls Denmark does not include any damage that may occur due to harmful impur- ities in the system.
  • Page 39 Installation information • risk of damaging secondary piping and components material (corrosion) • secondary refrigerant e.g. glycol in case of leakage Leak detectors should be selected, installed and maintained in cooperation and accordance with the recommendations of the detector supplier. Operating manual - ComPAC 011769 en 2020.03 39/56...

  • Page 40: Operating Instructions

    Operating instructions 5. Operating instructions General information Note: Read chapter 2. Safety, carefully before operating the unit. Qualification requirements Before operating a chiller unit, all personnel must have studied the unit manuals carefully. The operator must be confident operating a Unisab III controller. Prior to start-up and running of the chiller unit, the pre-start check must be accomplished, see subsection 5.2.1 Pre-start check.

  • Page 41: Starting

    Operating instructions Starting 5.3.1 Starting procedures Starting and stopping can only be carried out from Unisab III. The operator must always make sure that the appropriate external starting conditions exist before start-up. Top bar Content area Info bar F-key area Fig.

  • Page 42: Valve Positions During Operation, Compac

    Operating instructions 5.3.3 Valve positions during operation, ComPAC (water-cooled condenser) Pos. no. Designation Position during operation Compressor unit valves Please see the compressor manual Compressor suction stop valve Open Compressor discharge stop valve Open Ball valve - heat recovery Closed Ball valve - heat recovery Closed Ball valve...
  • Page 43 Operating instructions Fig. 19: P&I diagram for ComPAC Operating manual - ComPAC 011769 en 2020.03 43/56...

  • Page 44: Restarting The Chiller After Power Interruption

    Operating instructions 5.3.4 Restarting the chiller after power interruption When the power supply returns after a short power interruption, restarting depends on the Unisab III settings. If Unisab III is set in AUTO running mode, the chiller will normally start up when needed by the automatic control and when relevant timer/delay has expired.
  • Page 45 Operating instructions Checklist Checklist Checklist for commissioning of compressor, chiller and heat pump units Start-up log: Monitoring of operation at start-up Compressor serial no.: Date: Name: Compressor serial no.: Date: Name: Check before start-up Observation Value Read and understand all Sabroe manuals (compressor, Unisab, chiller, etc.) Operation time [hours ] Read and understand manuals for third party components (electric motors, valves,...

  • Page 46: Stopping Procedures

    Operating instructions Stopping procedures 5.5.1 Stopping for a brief period In automatic mode Unisab III will occasionally stop the chiller depending on the cooling require- ment. This is normal and does not require any action by the operator of the plant. The chiller can be stopped manually on Unisab III at any capacity setting.

  • Page 47: Troubleshooting

    Operating instructions 5.6.2 Troubleshooting Too high condensing pressure Cause Solution Insufficient water flow through the Adjust water supply, or clean the condenser. condenser Fouling in the condenser Clean the condenser. Check cooling tower system, or reduce compressor Too high cooling water temperature capacity.

  • Page 48: Testing Of Chillers

    See compressor manual for more information. 5.6.3 Testing of chillers Chillers supplied by Johnson Controls Denmark have been function and performance tested, as far as possible. A performance test consists of simultaneous measurements of cooling capacity, power consump- tion and condenser capacity.

  • Page 49: Maintenance Instructions

    PAO oil is a synthetic oil with low vapour pressure. Usually, the ComPAC units are charged with oil from factory. Do not switch to a different oil type or brand without first consulting Johnson Controls Denmark. Oil changes are described in detail in the compressor manual.

  • Page 50: R717 Charge

    Maintenance instructions R717 charge It is very important that the chiller has the correct charge. The P&I diagram states the charge for each specific chiller. At normal operation the suction superheat should be between 0.5-3°K. In the evaporator, droplets should come out of the top of the plates. The plates must not be com- pletely covered by liquid.

  • Page 51: Final Disposal

    Final disposal 7. Final disposal Safety precautions Danger! Before dismantling the plant, read the safety precautions carefully. Dismantling a refrigeration unit to be scrapped must be carried out safely. Only competent refrigeration personnel must perform the dismantling as fundamental knowledge of refrigeration systems and the risks involved are required.

  • Page 52: Appendices

    Appendices 8. Appendices Spare parts list for HP float valve Fig. 21: HP float valve Pos. Pcs. Part no. Description 1331.672 O-ring 1331.126 O-ring 3-040 1364.405 HP Float valve HFI 040 3-050 1364.406 HP Float valve HFI 050 3-060 1364.407 HP Float valve HFI 060 3-070 1364.408...

  • Page 53: Spare Parts List For Cvua 1201 Oil Recovery Pot

    Appendices Spare parts list for CVUA 1201 oil recovery pot NO: 3247--128 Fig. 22: Oil recovery pot Pos. Pcs. Part no. Description 3247.128 Complete pot 3445.508 Float switch 1331.433 Seal ring 3413.038 Piston 3411.009 Oil reservoir 2144.049 Spring 3411.039 Cover 1331.571 O-ring 1425.018...

  • Page 54: Declaration Of Conformity

    Appendices Declaration of conformity Johnson Controls Denmark declares on the signed declaration of conformity that the unit is manu- factured and CE-marked in conformity with relevant directives and standards. The printed version of this operating manual, which is delivered with the unit, contains a trans- lated version of the declaration, however not filled in with the specific data for your unit.

  • Page 55: Index

    Index Air purge valve ........................... 32 Amendments to the manual ......................9 Ammonia accidents - first aid ..................... 24 Application ..........................11 Automatic oil recovery ....................... 33 Batteries ............................ 51 Brine ............................38 Cleaning in place ........................38 Combustion engines - application ....................11 Competent persons - requirements....................
  • Page 56 Maintenance..........................49 Monitoring of operation ......................44 Oil types ............................. 21 Power supply ..........................20 Pre-start check........................... 40 Protecting the operator ......................25 Purging ............................21 R717 charge..........................50 Receiver ............................. 30 Refrigerants ..........................21 Restarting ..........................44 Safety during maintenance and service..................20 Safety signs ..........................
  • Page 58 Johnson Controls Denmark ApS SABROE Factory Christian X's Vej 201 ∙ 8270 Højbjerg Denmark Phone +45 87 36 70 00 Version 4 www.sabroe.com...
  • Page 59 Letter of compliance for ECO-design, Process & Comfort chiller Directive 2009/125/EC Manufacturer: Johnson Controls Denmark ApS, SABROE Factory Christian X’s Vej 201 · 8270 Højbjerg · Denmark Phone +45 87 36 70 00 We hereby declare that our products within the scope of eco-design, implemented according to regulation No 2015/1095 for low (-25°C) and medium (-8°C) temperatures and No 2016/2281 for high temperatures...
  • Page 60 Letter of compliance for ECO-design, Process & Comfort Chiller Directive 2009/125/EC Data: Process Chiller, Reciprocating water/brine cooled High Medium High Medium <400kW ChillPAC28V-A 229 kW <300kW ChillPAC28V-C 113 kW >400kW ChillPAC 112LV-A 1061 kW >300kW ChillPAC 12LV-C 529 kW Sabroe unit Legal limit Sabroe unit Legal limit...

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