Johnson Controls Sabroe ChillPAC Air Operating Manual
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Johnson Controls Sabroe ChillPAC Air Operating Manual

Johnson Controls Sabroe ChillPAC Air Operating Manual

Chiller unit with reciprocating compressor
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ChillPAC Air
Chiller unit with reciprocating compressor

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Summary of Contents for Johnson Controls Sabroe ChillPAC Air

  • Page 1 Operating manual ChillPAC Air Chiller unit with reciprocating compressor...
  • Page 3 Manual for ChillPAC Air The Sabroe chiller unit can be configured with various types of equipment depending on its function, requirements and the outdoor temperature. Some of the equipment may be described in this manual, even though it is not featured on your particular unit. Please note that this manual does not include instructions for the: •...

  • Page 4: Table Of Contents

    Contents Introduction ...................6 Introduction to manual ..............6 1.1.1 Models covered ..............6 1.1.2 Definition of safety precautions used in this manual ....7 1.1.3 Requirements for competent persons ........7 Safety ....................8 Areas of application ..............8 2.1.1 Application ................8 Identification ................9 2.2.1 Identification of equipment .............9 2.2.2 Unit/pipe system name plate ..........9 2.2.3...
  • Page 5 Installation information ............... 21 General information ..............21 First start-up procedure .............. 21 Noise and vibrations ..............21 Secondary system ..............22 Operating instructions ................ 23 General information ..............23 Pre-start check ................23 Valve positions during operation ..........24 Starting ..................

  • Page 6: Introduction

    It is important that the operating personnel familiarise themselves with the contents of this manual in order to ensure a proper and efficient operation. Johnson Controls Den- mark is not liable for damage occurring during the warranty period where this is attribut- able to incorrect operation.

  • Page 7: 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 8: Safety

    The primary side must only be charged with refrigerant R717. • 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 attribut- able to built-in VSD solutions initiated by the customer after delivery.

  • Page 9: 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 (see the ChillPAC manual)

  • Page 10: Signs

    Safety 2.2.6 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 The compressor may be top- High voltage/ temperature Risk of electric shock High pressure heavy (about 70°C)

  • Page 11: 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 12: Design And Function

    Design and function 3. Design and function Unit design 3.1.1 General information about ChillPAC Air The ChillPAC Air unit is a complete, factory-manufactured chiller unit intended for water or brine cooling and equipped with an air-cooled condenser. ChillPAC Air only uses ammonia (R717) as refrigerant. Once the unit is charged with R717, connected to electricity, and pipe connections to water/brine have been established, it is ready for operation.

  • Page 13: Components On A Chillpac Air (Standard Unit)

    Design and function 3.1.2 Components on a ChillPAC Air (standard unit) Fig. 2: ChillPAC Air with position numbers (standard unit) Pos. no. Component Evaporator/Liquid separator Oil separator Inlet evaporator Outlet evaporator Expansion valve with built-in stop/check valve Liquid level column and level sensor Compressor UniSAB lll controller and emergency stop (built into electrical panel) Motor...

  • Page 14: Components On A Chillpac Air (Winter 1 Unit)

    Design and function 3.1.3 Components on a ChillPAC Air (winter 1 unit) Fig. 3: ChillPAC Air with position numbers (winter 1 unit) Pos. no. Component Evaporator/Liquid separator Oil separator Inlet evaporator Outlet evaporator Expansion valve (with built-in stop/check valve) Liquid level column and level sensor Compressor UniSAB lll controller and emergency stop (built into electrical panel) Motor...

  • Page 15: Components On A Chillpac Air (Winter 2 Unit)

    Design and function 3.1.4 Components on a ChillPAC Air (winter 2 unit) Fig. 4: ChillPAC Air with position numbers (winter 2 unit) Pos. no. Component Evaporator/Liquid separator Oil separator Receiver Inlet evaporator Outlet evaporator Expansion valve Liquid level column and level sensor Compressor UniSAB lll controller and emergency stop (built into electrical panel) Motor...

  • Page 16: Main Components

    Design and function Main components The ChillPAC Air consists of a unit with cooling circuit, water supplies, electrical panel and con- trol system built into a sound damping enclosure on a steel frame. It is supplied with an air- cooled condenser with pipe connections - or without pipe connections for customer manufac- ture of piping connections.
  • Page 17 Contact Johnson Controls Denmark for further information. Fig. 6: Two condenser refrigerant circuits in parallel with vertical liquid legs. Operating manual - ChillPAC Air 0015263 en 2022.11...

  • Page 18: Receiver

    Design and function Condenser with two refrigerant circuits in parallel connected to a receiver (winter 2 unit) To obtain maximum condenser efficiency under all operating conditions, follow these require- ments when installing the remote condenser: Place the condenser close to the unit with short piping to reflect the pressure drop be- tween the condenser and unit as low as possible.

  • Page 19: Air Purge Valve

    Design and function Fig. 8: Sight glass 3.2.8 Air purge valve If there is air in the refrigeration plant, it tends to accumulate in the receiver and the condenser. On ChillPAC Air, the air purge valve is fitted either on top of the receiver and/or the condenser at the highest point in the discharge line before the condenser inlets and at the condenser outlets.

  • Page 20: Safety Valves

    Design and function 3.2.13 Safety valves The safety valves are individually approved in accordance with existing standards under PED from the manufacturer. In each case, the customer must be asked if special rules apply in the user country for safety valves with release into free air as this area is governed by national rules.

  • Page 21: Installation Information

    Installation information 4. Installation information General information For assistance or information about installation, please contact your local Johnson Controls product representative. 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 minimum requirements.

  • Page 22: Secondary System

    Installation information Note: Condenser is available in two versions: 55 dB(A) or 62 dB(A). Secondary system See the ChillPAC manual for information. Operating manual - ChillPAC Air 22/35 0015263 en 2022.11...

  • Page 23: 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 .

  • Page 24: Valve Positions During Operation

    Operating instructions Valve positions during operation Valve positions on a ChillPAC Air standard unit Pos. no. Designation Position during operation Compressor suction stop valve Open Compressor discharge stop valve Open Safety relief valve internal/compressor (Closed) Fixed set point Stop valve for oil recovery/oil return Open Stop valve evaporator oil return Open...
  • Page 25 Operating instructions P&I diagram, ChillPAC Air standard unit Fig. 9: P&I diagram - ChillPAC Air standard unit Operating manual - ChillPAC Air 0015263 en 2022.11 25/35...
  • Page 26 Operating instructions Valve positions on a ChillPAC Air winter 1 unit Pos. no. Designation Position during operation Compressor suction stop valve Open Compressor discharge stop valve Open Safety relief valve internal/compressor (Closed) Fixed set point Stop valve for oil recovery/oil return Open Stop valve evaporator oil return Open...
  • Page 27 Operating instructions P&I diagram, ChillPAC Air winter 1 unit Fig. 10: P&I diagram - ChillPAC Air winter 1 unit Operating manual - ChillPAC Air 0015263 en 2022.11 27/35...
  • Page 28 Operating instructions Control of valves at start and stop A start request from UniSAB releases the discharge valve, pos. 32, to open. Open feed- back from the discharge valve releases the compressor to start, and the pressure can be built up in the condenser. Operating manual - ChillPAC Air 28/35 0015263 en 2022.11...
  • Page 29 Operating instructions Valve positions on a ChillPAC Air winter 2 unit Pos. no. Designation Position during operation Compressor suction stop valve Open Compressor discharge stop valve Open Safety relief valve internal/compressor (Closed) Fixed set point Stop valve for oil recovery/oil return Open Stop valve evaporator oil return Open...
  • Page 30 Operating instructions P&I diagram, ChillPAC Air winter 2 unit Fig. 11: P&I diagram - ChillPAC Air winter 2 unit Operating manual - ChillPAC Air 30/35 0015263 en 2022.11...

  • Page 31: Starting

    Operating instructions Control of valves at start and stop A start request from UniSAB releases the discharge valve, pos. 31, to open. Open feed- back from the discharge valve releases the compressor to start, and the pressure can be built up in the condenser. A start request from UniSAB simultaneously gives a signal to a timer in the electrical panel, and after a given time delay, the valve pos.

  • Page 32: Shutdowns And Alarms

    Operating instructions Shutdowns and alarms See the ChillPAC manual for shutdowns and alarms. Troubleshooting Too high condensing pressure Cause Solution Overcharge of refrigerant in the plant or Remove refrigerant from the plant condenser Lack of air through the condenser Clean the condenser See the ChillPAC manual for further troubleshooting.

  • Page 33: Maintenance Instructions

    Maintenance instructions 6. Maintenance instructions Maintenance of the chiller unit Read chapter 2. Safety carefully before performing any maintenance on the chiller unit. To ensure that the chiller unit operates without problems throughout a long service life, the sys- tem of maintenance presented in the following instructions must be followed. Daily maintenance is normally performed by the operating personnel.

  • Page 34: 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 knowl- edge of refrigeration systems and the risks involved are required.

  • Page 35: Appendices

    Spare parts list for ChillPAC Air See submanuals for information. Declaration of conformity Johnson Controls Denmark declares on the signed declaration of conformity that the unit is manufactured and CE-marked in conformity with relevant directives and standards in one of the following ways.
  • Page 36 Johnson Controls Denmark ApS Sabroe Factory Christian X's Vej 201 ∙ 8270 Højbjerg Denmark Phone +45 87 36 70 00 www.sabroe.com Version 1...

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