Johnson Controls SABROE ComPAC Operating Manual Download

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Page 2 of 2

TPH/20-1-2021

Letter of compliance for ECO-design, Process & Comfort Chiller

Directive 2009/125/EC

Data:

See COMP1 calculations in the document named ‘SEPR-SEER calculations’ on

www.sabroe.com

Calculation flow chart (COMP1



SEPR/SEER-tool



Validation)

Regulatory control:

www.ens.dk, www.sik.dk

and www.rp-tuebingen.de

ChillPAC28V-A

ChillPAC28V-C

ChillPAC 112LV-A

ChillPAC 12LV-C

Sabroe unit

9,30

5,05

9,40

5,00

Condenser

Inlet/outlet

Condenser

Inlet/outlet

Condenser

Inlet/outlet

Condenser

Inlet/outlet

30/35

ComPAC 151LV-A

ComPAC 193LV-A

ComPAC 193LV-C

Sabroe unit

8,02

4,60

9,77

4,72

Condenser

Inlet/outlet

Condenser

Inlet/outlet

Condenser

Inlet/outlet

Condenser

Inlet/outlet

30/35

SABlight A400-1

A400-1EG

Sabroe unit

5,02

3,73

Condenser Inlet

ChillPAC 28V-A

ChillPAC 112LV-A

ComPAC151LV-A

ComPAC 193LV-A

Sabroe unit

252

279

254

265

Condenser

Inlet/outlet

Condenser

Inlet/outlet

Condenser

Inlet/outlet

Condenser

Inlet/outlet

30/35

SABlight A340-1

Sabroe unit

161

Condenser Inlet

Medium

SEPR

-2/-8

Evaporator

Inlet/outlet

+12/+7

Evaporator

Inlet/outlet

+12/+7

Evaporator

Inlet/outlet

+12/+7

-2/-8

+12/+7

-2/-8

+12/+7

Evaporator

Inlet/outlet

Reciprocating

Screw

Evaporator

Inlet/outlet

+12/+7

Evaporator

Inlet/outlet

Eta s,c

+12/+7

Comfort Chiller, water cooled

<400kW

229 kW

Evaporator

+12/+7

Conditions

Eta s,c

Legal limit

161

<400kW

324 kW

252

Eta s,c

Legal limit

Eta s,c

Legal limit

<1500kW

1061 kW

<1500kW

927 kW

<1500kW

Screw, Air Cooled

Conditions

Comfort Chiller, water evaporator, Air cooled condenser

1455 kW

Legal limit

Eta s,c

Legal limit

200

252

Conditions

5,0

Legal limit

392 kW

High

<300kW

Conditions

SEPR

Legal limit

2,32

High

8,0

1061 kW

Legal limit

Process Chiller, Reciprocating water/brine cooled

3,93

Legal limit

529 kW

Medium

SEPR

>300kW

>400kW

113 kW

2,96

Legal limit

Medium

High

229 kW

7,0

Legal limit

<300kW

SEPR

<400kW

Process Chiller water/brine evaporator, Air Cooled condenser

Medium

Evaporator

Inlet/outlet

Evaporator

Inlet/outlet

Evaporator

Inlet/outlet

Evaporator

Inlet/outlet

Evaporator

Inlet/outlet

Evaporator

Inlet/outlet

Evaporator

Inlet/outlet

Evaporator

Inlet/outlet

+12/+7

-2/-8

Conditions

8,0

Legal limit

Conditions

SEPR

-2/-8

Conditions

3,93

Legal limit

794 kW

Conditions

<400kW

SEPR

>300kW

<1500kW

SEPR

Conditions

1455 kW

8,0

Legal limit

932 kW

High

SEPR

237

Process Chiller, Screw water/brine cooled

High

Medium

514 kW

Legal limit

3,93

Summary of Contents for SABROE ComPAC

Page 1: ...ComPAC Chiller unit with screw compressor Operating manual en...

Page 2: ......

Page 3: ...III controller You can find the compressor number and the equipment configured on your unit below Compressor type Designation Compressor no Refrigerant R717 Oil type PAO68 Other _____________ Level co...

Page 4: ...External surface m2 Design pressure bar Condenser Float housing Evaporator Liquid separator Oil separator Oil cooler Receiver Economiser Desuperheater Subcooler Other Pressure loss if any from safety...

Page 5: ...17 2 2 5 Signs 18 2 3 Safety precautions 19 2 3 1 General precautions 19 2 3 2 During operation 19 2 3 3 Cooling water systems 20 2 3 4 Cooling media 20 2 3 5 Safety during maintenance and service 20...

Page 6: ...VSD 37 4 4 Secondary system 38 4 4 1 General information 38 4 4 2 Cleaning in place 38 4 4 3 Temperature and flow control 38 4 4 4 Water and brine treatment 38 4 4 5 R717 detector 38 5 Operating instr...

Page 7: ...intenance instructions 49 6 1 Maintenance of the chiller unit 49 6 2 Selecting lubricating oil for ComPAC units 49 6 3 R717 charge 50 7 Final disposal 51 7 1 Safety precautions 51 7 2 Waste disposal 5...

Page 8: ...t 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...

Page 9: ...ction has been updated Updated version of declaration of conformity for unit 2018 01 Version 2 Name plates with EurAsian Conformity mark EAC have been added Requirements for competent persons section...

Page 10: ...injury Note Indicates an operating procedure practice etc or portion thereof which is essential to highlight 1 1 3 Requirements for competent persons Personnel working on the unit must be competent in...

Page 11: ...must only take place if the chiller is fitted with approved explosion proof equipment The compressor must only be used as a refrigeration compressor and within the operating limits specified in the ma...

Page 12: ...pment 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 Pos no Name plate for 1 Compres...

Page 13: ...jbjerg Denmark www sabroe com Fig 2 Name plate for standard unit Scope Design code Approval No Refrigerant Supply voltage Test pressure Allowable pressure Category Pressure system Refrigerant charge...

Page 14: ...ssure side of the unit piping system is referred to as the LP side The high pressure side of the unit piping system is referred to as the HP side Category For EC PED approval The maximum category of t...

Page 15: ...pt volume Pressure system Allowable pressure Test pressure LP side HP side No Type Year Speed bar g bar g m3 h Max rpm Fig 6 Name plate for ATEX compressor Fig 7 Name plate for compressor with EurAsia...

Page 16: ...e compressor at nominal speed Pressure system The low pressure side of the compressor is referred to as the LP side The high pressure side of the compressor is referred to as the HP side Allowable pre...

Page 17: ...1 2 3 or 4 according to the PED directive Side For heat exchangers only Refers to the columns Shell side and Tube side Fluid Designation of the primary refrigerant s and the secondary re frigerant s F...

Page 18: ...re usu ally delivered without refrigerant and oil To protect the compressors against internal corrosion they are delivered evacuated of all atmospheric air and charged with dry Nitrogen N2 to an overp...

Page 19: ...and or lubricating oil Use proper electrical safety protection Note These instructions only provide general information The owner of the refrigeration plant is responsible for ensuring that all codes...

Page 20: ...ad chapter 2 Safety in this manual before opening the compressor and other parts of the refrigeration plant If the switch is not locked all start buttons must be tagged with DO NOT START tags and an e...

Page 21: ...t the used oil in containers marked waste oil and send them to an approved hazard ous waste disposal site It is not recommended to reuse oil 2 3 8 Refrigerants Be very careful when dealing with refrig...

Page 22: ...Warming Potential according to the F gas regulation The so called HFOs and nat ural refrigerants do not fall under the scope of the regulation Refrigerant GWP Global Warming Potential R134a 1300 R407...

Page 23: ...to ensure that the repair has been effective Recovery of refrigerant Operators are responsible for putting in place arrangements for the proper recovery of fluorinated greenhouse gases by competent pe...

Page 24: ...ns with ammonia When applying first aid the persons assisting must be duly protected to avoid further injuries First aid measures Inhalation Immediately move affected personnel into fresh air and loos...

Page 25: ...uman nervous system When halogenated gasses come into contact with open flame or hot surfaces over approx 300 C they will decompose to produce poisonous chemicals These have a very pungent odour and w...

Page 26: ...p In case of an accident push the emergency stop button on the Unisab III controller Fig 11 Unisab III built into the electrical panel Fig 12 Unisab III as a separate device For resetting and further...

Page 27: ...frigerant Once the unit is charged with R717 connected to electricity and pipe connections to water brine are established it is ready for operation The unit is provided with adjustable anti vibration...

Page 28: ...tlet evaporator 17 Oil filter 5 Inlet evaporator 18 Oil cooler 6 Condenser 19 High level alarm 7 Outlet condenser 20 Heat recovery inlet optional 8 Inlet condenser 21 Heat recovery outlet optional 9 E...

Page 29: ...heat exchanger where plates are welded together into cas settes R717 evaporates between the two welded plates which make up the cassettes and water brine is cooled in the channels inside the cassettes...

Page 30: ...e 4 Connection for safety valves 5 Connection for manometer 6 Connection discharge pressure to oil recovery system 7 Drain including stop valve and quick closing drain valve 8 Sight glasses for liquid...

Page 31: ...under the condens er in order to obtain a compact design and a very low refrigerant charge The float valve is fixed with a screw pos 2 in Fig 14 The float valve is equipped with a turning mechanism w...

Page 32: ...t valve cover at the bottom of the condenser Fig 14 pos 3 Note The valve at the bottom of the cover Fig 14 pos 4 is used for liquid draining R717 During air purging the air purge valve should be conne...

Page 33: ...717 The float has a built in reed switch which activates the solenoid valve pos 8 in Fig 15 in the oil return line to the compressor and the solenoid valve pos 7 in Fig 15 on the hot gas line The oil...

Page 34: ...nsure proper functioning a timer delays the off signal from the float switch for a few seconds Note As shown in Fig 16 the float ball must be positioned with NO facing upwards For further information...

Page 35: ...space for operation and maintenance in accordance with GA drawing 3 Place the unit on a foundation suitable for the actual load and vibrations With or without vibration dampers according to the vibrat...

Page 36: ...es should not be completely covered by liquid Check that the suction superheat is between 0 5 and 3 K If higher carefully charge more R717 18 Check the R717 liquid level again Note The liquid level mu...

Page 37: ...ion dampers are often required In such cases it is recommended to replace the machine feet with specially designed vibration dampers Contact a vibration expert or a Johnson Controls Denmark representa...

Page 38: ...utlet pipe minimum 1 metre away from the evaporator 4 4 4 Water and brine treatment Brine and water for industrial refrigeration plants often contain impurities that can create a coat ing fouling on t...

Page 39: ...mation 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...

Page 40: ...installation of safety equipment is completed according to the installation information Make sure that all necessary documents are available including operating manuals machine card logbooks etc and o...

Page 41: ...fore start up Fig 18 Unisab III front 5 3 2 Normal start up procedure 1 Confirm that the system conditions permit the chiller to start 2 Press the start button on Unisab III 3 Allow the compressor to...

Page 42: ...ne outlet closed 418 Safety relief valve Closed Fixed set point 419 Safety relief valve Closed Fixed set point 420 Double stop valve One outlet open one outlet closed 421 Safety relief valve Closed Fi...

Page 43: ...Operating manual ComPAC 011769 en 2020 03 43 56 Operating instructions Fig 19 P I diagram for ComPAC...

Page 44: ...ked 2 Check that oil pressure is obtained and that the evaporating and condensing pressures are within the permissible ranges 3 Check the other operating data 4 Check for abnormal noise and vibrations...

Page 45: ...components electric motors valves etc Check unit installation and vibration damper adjustment Carry out functional testing of safety equipment Read the opening pressures on all safety valves and chec...

Page 46: ...and compressor weekly monthly according to below 4 If the compressor is water cooled drain of the water To reduce the risk of bearing damage it is recommended to rotate to a new position the motor an...

Page 47: ...ox 0 5 to 3 K A 1 K higher evaporating temperature results in a 4 higher cooling performance Missing oil During the first 50 hours of operation the compressor will lose oil A few litres of oil will ac...

Page 48: ...anges in compressor capacity Adjust settings for load unload compressor capacity in Unisab III Too much compressor cooling Reduce water flow or temperature to compressor cooling See compressor manual...

Page 49: ...ssible ranges Compare them with previous values to detect trends Check the oil level Check the refrigerant charge Observe for leaks of refrigerant smell of ammonia oil glycol or water Check mechanical...

Page 50: ...ecific 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 liq...

Page 51: ...when using cutting tools such as angle grinders or flame cutters during the dis mantling process as pipes and the like contain oil residue and refrigerant which may be toxic and or flammable 7 2 Wast...

Page 52: ...rts list for HP float valve Fig 21 HP float valve Pos Pcs Part no Description 1 1 1331 672 O ring 2 1 1331 126 O ring 3 040 1 1364 405 HP Float valve HFI 040 3 050 1 1364 406 HP Float valve HFI 050 3...

Page 53: ...1 3247 128 Complete pot 1 1 3445 508 Float switch 2 1 1331 433 Seal ring 3 1 3413 038 Piston 4 1 3411 009 Oil reservoir 5 1 2144 049 Spring 6 1 3411 039 Cover 7 1 1331 571 O ring 8 4 1425 018 Screw M...

Page 54: ...eclaration however not filled in with the specific data for your unit The translated version is also included in the operating manual that is available for download with the rest of the order specific...

Page 55: ...n 11 Competent persons requirements 10 Compressor 29 Compressor name plates 15 Condenser 29 Control system 29 Cooling media 20 Cooling water systems 20 CVUA 1201 oil recovery pot 53 D Declaration of c...

Page 56: ...Receiver 30 Refrigerants 21 Restarting 44 S Safety during maintenance and service 20 Safety signs 18 Selecting lubricating oil 49 Shutting down 46 Sound and noise data 36 Spare parts list 52 53 Start...

Page 57: ......

Page 58: ...Johnson Controls Denmark ApS SABROE Factory Christian X s Vej 201 8270 H jbjerg Denmark Phone 45 87 36 70 00 www sabroe com Version 4...

Page 59: ...alculations are made by spreadsheet tool version 1 5 3 date 2013 09 01 Diagram lines drawn as straight lines between legal condition points and product points See data and calculation on page 2 Degrad...

Page 60: ...or Inlet outlet 12 7 Evaporator Inlet outlet 12 7 Evaporator Inlet outlet 12 7 2 8 12 7 2 8 12 7 Evaporator Inlet outlet Reciprocating Screw Evaporator Inlet outlet 12 7 Evaporator Inlet outlet Eta s...

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