Johnson Controls SABROE HeatPAC Operating Manual Download

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HeatPAC
with reciprocating compressor

Operating manual

Summary of Contents for SABROE HeatPAC

Page 1: ...HeatPAC with reciprocating compressor Operating manual EN ...

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Page 3: ...Compressor type Designation Compressor no Refrigerant R717 Oil type PAO 100 Other _____________ Approval PED 2014 68 EU Other _____________ Supply voltage Motor 3 x _________ V _________ Hz Control 1 x _________ V _________ Hz Motor IP23 IP55 Δ D VSD Power _________ kw Size IEC _________ Ex execution ATEX Both compressor and unit are safeguarded ...

Page 4: ...Vessel data Type 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 valve to customer connection based on design pressure bar _____________ Safety valve type Back pressure dependent Back pressure independent ...

Page 5: ...late 16 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 Water system 20 2 3 4 Brine 20 2 3 5 Safety during maintenance and service 20 2 3 6 Power supply 20 2 3 7 Lubricating oils 21 2 3 8 Refrigerants 21 2 3 9 Purging of heat pump 21 2 3 10 First aid for accidents with ammonia 23 2 3 11 Protecting the operator as well as the environment 24 2 3 ...

Page 6: ... 1 General information 37 4 3 2 Cleaning in place 38 4 3 3 Temperature and flow control 38 4 3 4 Water and brine treatment 38 4 3 5 R717 detector 38 5 Operating instructions 39 5 1 Personnel qualification requirements 39 5 2 Pre start check 39 5 3 Starting 39 5 3 1 Starting procedures 39 5 3 2 Normal start up procedure 40 5 3 3 Valve positions during operation 41 5 3 4 Restarting the heat pump aft...

Page 7: ...or heat pump units 47 6 3 R717 charge 47 7 Final disposal 48 7 1 Safety precautions 48 7 2 Waste disposal 48 8 Appendices 49 8 1 Monitoring of operation 49 8 2 Spare parts list for CVUA 1201 oil recovery pot 50 8 3 High pressure float valve for cascade evaporator 51 8 4 Declaration of conformity 52 8 5 Set up guide AKS 4100 280 mm for ammonia heat pump application 53 Index 61 ...

Page 8: ... 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 competent person nel only If not the warranty no longer applies 1 1 Amendments to the manual 2021 07 Version 6 Copy of declaration of conformity removed from the manual It is now only contained in the printed manua...

Page 9: ... 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 The original version of this manual is the English language version If there are any discrepancies or conflicts between the English and any othe...

Page 10: ...ent and or minor injury Note Indicates an operating procedure practice etc or portion thereof which is essential to highlight 1 3 Requirements for competent persons Personnel working on the unit must be competent in accordance with national safety rules and regulations relating to flammable refrigerants or according to EN 13313 Maintenance work must be performed according to EN 378 or ISO 5149 sup...

Page 11: ...ump unit in potentially explosive atmospheres must only take place if the heat pump is fitted with approved explosion proof equipment The compressor must only be used as a compressor within the operating limits specified in the manual or in a written agreement with Johnson Controls Denmark The compressor must only be used with the number of revolutions per minute as shown on the compressor name pl...

Page 12: ...ification 2 2 1 Identification of equipment All equipment from Johnson Controls Denmark can be identified by one or several name plates posi tioned as illustrated in the following drawings Fig 1 Pos no Designation 1 Compressor name plate 2 Vessel name plate 3 Unit Pipe system name plate 2 2 3 1 2 ...

Page 13: ...r Refrigerant Swept volume Pressure system Allowable pressure Test pressure LP side HP side No Type Year Speed bar g bar g m3 h Max rpm Fig 3 Name plate for ATEX compressor Fig 4 Name plate for compressor with EurAsian Conformity mark EAC Johnson Controls Denmark ApS Christian X s Vej 201 8270 Højbjerg Denmark www sabroe com Test pressure Allowable pressure Pressure system LP side HP side Year No ...

Page 14: ... Swept volume of the 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 pressure max The max pressure pressure relative to atmospheric pressure that the compressor has been designed for in terms of pressure strength design The maximum practical operation p...

Page 15: ...rd party notified body For EC PED approval CAT Category 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 refrigerant s For EC PED approval Designation of the refrigerant s and or the highest fluid group Group 1 or 2 according to the PED directive Allowable pressure...

Page 16: ...Test pressure Allowable pressure Category Pressure system Refrigerant charge Max Allowable temp Min Max Refrigeration unit No Type Year Fluid Group Control V Hz kg bar g bar g C LP side HP side Johnson Controls Denmark ApS Christian X s Vej 201 8270 Højbjerg Denmark www sabroe com 2516 343 Main Fig 9 Name plate for ATEX unit Установка холодильная Назначение Код стандарта сертификата Хладагент Жидк...

Page 17: ...ystem The low pressure 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 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 that the unit piping syst...

Page 18: ...cks and units are usually delivered without refrigerant and oil To protect the compressors against internal corrosion they are delivered evacuated of all atmospheric air and charged with dry Ni trogen N2 to an overpressure of 0 5 bar 7 3 PSI In such cases a yellow sign is affixed to a visible spot on the compressor The magnetic field on the rotor may affect pacemakers The motor rotor contains a po...

Page 19: ...ing refrigerant and or lubricating oil Use proper electrical safety protection Note These instructions only provide general information The owner of the refrigeration plant is re sponsible for ensuring that all codes regulations and industry standards are complied with 2 3 2 During operation Warning All safety features disengagement and interlocks must be in place and function correctly before the...

Page 20: ... 2 Safety in this manual before opening the compressor and other parts of the re frigeration plant If the switch is not locked all start buttons must be tagged with DO NOT START tags and an explanation Work on unit in progress Make sure that the motor cannot start up inadvertently Switch off all electric components on the compressor unit before starting the dismantling servicing process It is reco...

Page 21: ...the refrigeration plant always collect the used oil in containers marked waste oil and send them to an approved hazardous waste disposal site It is not recommended to reuse oil 2 3 8 Refrigerants Be very careful when dealing with refrigerants For safe handling please refer to the safety data sheets delivered by the refrigerant supplier Warning Be aware that large amounts of leaking or released ref...

Page 22: ... 22 62 009332 en 2021 07 Safety Note The occurrence of air is usually an indication of poor maintenance or lack of thoroughness at installation Note R717 systems should be purged on a regular basis to avoid atmospheric air and other non con densable gases ...

Page 23: ...bulk installations with ammonia When applying first aid the persons assisting must be duly protected to avoid further injuries First aid measures Inhalation Immediately move affected personnel into fresh air and loosen clothing restricting breathing Call a doctor ambulance with oxygen equipment Keep the patient still and warmly wrapped in blankets Do not in any way attempt to provoke vomiting or t...

Page 24: ...will attack the human 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 will thus warn personnel of their presence In high concentrations R717 causes respiratory problems When the amount of ammonia vapour in the air is between 15 and 28 vol the combination...

Page 25: ... 12 Emergency stop 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 information please see the UniSAB III manual Emergency stop Emergency stop ...

Page 26: ...rigerant Once it is charged with R717 connected to electricity and pipe connections to water brine are established it is ready for operation HeatPAC is delivered with adjustable anti vibration machine feet for installation on solid concrete floor For installation on decks special vibration dampers are often required HeatPAC is controlled by Johnson Controls Denmark s UniSAB III control and capacit...

Page 27: ...iver 5 Brine inlet evaporator 6 Brine outlet evaporator 7 Water inlet condenser 8 Water outlet condenser 9 Expansion valve 10 Compressor 11 Motor 12 UniSAB III controller and emergency stop built into the electric panel is optional 13 Electric panel 14 Oil recovery system from evaporator 15 R717 charge valve 16 Drain valve from receiver 17 Level sensor expansion valve 17 6 5 3 14 9 4 1 5 6 10 15 1...

Page 28: ...el must never be visible in the inspection glass See subsection 6 3 R717 charge and the P I diagram for correct charge 3 2 4 Cascade evaporator The evaporator can also function as a cascade cooler In this case discharge gas from a separate circuit refrigeration plant is cooled and condensed inside the cassettes The upper connection DN100 is the discharge gas inlet and the bottom connection DN100 i...

Page 29: ...r DN200 3 2 7 Air purge valve If there is air or other non condensable gases in the refrigeration heat pump plant it tends to accumulate in the receiver or the condenser On HeatPAC the air purge valve is fitted at the top of the receiver pos 2 Fig 14 and Fig 15 During air purging the air purge valve should be connected to an open vessel containing water via a re frigerant hose The air will leave t...

Page 30: ...for the receiver to be a little more than half full See subsection 8 5 for set up of the AKS 4100 280 mm level sensor Fig 16 High pressure regulation 3 2 9 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 18 is connected to t...

Page 31: ...covery pot Fig 18 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 reservoir through the small nozzle pos 2 The rising pressure forces the oil back into the suction side of the compressor To ensure proper functionin...

Page 32: ...enoid valve for operating the oil recovery system is shown in pos 1 and 2 in Fig 19 3 2 10 Automatic oil return from oil separator The oil collected in the oil separator is returned to the compressor by a timer operated solenoid valve pos 4 Fig 19 The timer can be adjusted in the UniSAB III controller DN25 1 NO N C 2 3 Oil Oil R 717 Discharge gas ...

Page 33: ...still 3 2 12 WHC circulation system The Sabroe WHC circulation system is designed to maintain optimum cooling water temperature on heat pumps and refrigeration compressors with water cooled top and side covers The system ensures a con stant cooling water temperature thus giving the compressor optimum operating conditions The system circulates water or glycol during both operation and standstill Th...

Page 34: ... the compressor both during standstill and operation During standstill and operation the heating ele ment pos 1 heats the cooling water in order to keep the compressor warm for operation During oper ation the solenoid valve pos 4 opens when the cooling water temperature gets too high in order to let in new cooling water For further information about the circulation system please see the WHC manual...

Page 35: ...ith or without vibra tion dampers according to the vibration design strategy 4 Connect all piping The piping design must include considerations regarding function suspen sion vibrations thermal expansion and pre stress after welding in order to avoid high load on the heat pump connections Mount all hoses and valves for compressor cooling 5 The safety valves are fitted on the unit from factory The ...

Page 36: ...nd coupling must be checked Misalignment of the compressor or coupling may result in stresses and vibrations which can be trans mitted to the compressor and motor bearings and cause major damage Vibrations may be caused by the following Distortion between heat pump and foundation Distortion between compressor and base frame Distortion between motor and base frame Incorrect alignment of coupling be...

Page 37: ...e actual operating range 500 1500 rpm This will in some cases result in an in creased vibration level over an interval of approximately 100 150 rpm As a rule of thumb the rpm area is skipped if the vibration level exceeds the recommended maximum vibration level see the compressor manual All HeatPAC units are tested from factory If skipping of rpm is required this has been done and noted in the set...

Page 38: ...p brine and water under observation for both evaporator and condenser 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 impurities in the system Be aware that all cooling towers and evaporative condensers experience a constant loss of water due to evaporation In order to keep the c...

Page 39: ...nts are available including operating manuals machine card log books and or other documentation required according to local rules and or EN 378 Check the following before starting the heat pump 1 Check that installation is performed in accordance with the recommendations 2 Turn on the power supply and the control voltage 3 Make sure that the heating element in the oil reservoir and heat tracing on...

Page 40: ... system conditions permit the heat pump to start 2 Press the start button on UniSAB III 3 Allow the compressor to start up and stabilise 4 Check the following on the heat pump a Mechanical tightness of the external piping bolts and valves b No oil and refrigerant leaks If not satisfactory shut down the heat pump and correct the problem Top bar Content area Info bar F key area ...

Page 41: ... R717 Closed 12 Safety relief valve condenser Closed Fixed set point 13 Safety relief valve evaporator Closed Fixed set point 14 Safety relief valve internal compressor Closed Fixed set point 15 Drain valve Closed 16 Drain valve Closed Table 1 Valve positions during operation HeatPAC Fig 23 Principle PI diagram for HeatPAC 13 10 11 5 3 1 14 2 12 9 4 6 7 8 15 16 Plate shell heat exchanger DN20 DN20...

Page 42: ...he UniSAB III display to view the data to be checked 2 Check that oil pressure is obtained and that the evaporating and condensing pressures are with in the permissible ranges 3 Check the other operating data 4 Check for abnormal noise and vibrations 5 Check the oil and refrigerant level 6 Make sure the heat pump is operating stably not fluctuating 5 4 2 Monitoring and logging of operation It is r...

Page 43: ...anged weekly Avoid high vibration level 5 6 Shutdown and alarms 5 6 1 Operating state Experience has shown that variations in pressures and temperatures within the cooling cycle can pro vide information about the operating state of a heat pump In particular suction and condensing pressures as well as the temperatures of suction and pressure gas can provide important information Often small changes...

Page 44: ...turn to the compressor It is therefore not unusual that the compressor needs to be recharged with oil If the oil continues to disappear from the compressor the oil return and recovery system must be checked Cause Solution Defect oil return oil recovery system 1 Check the function and position of the oil float switch see descrip tion of oil recovery pot When the float is up the switch must be close...

Page 45: ... cooling Reduce water flow or temperature to compressor cooling See compressor manual for more information 5 6 3 Testing of HeatPAC units HeatPAC units supplied by Johnson Controls Denmark have as far as possible been function and per formance tested A performance test consists of simultaneous measurements of cooling or heating capacity power con sumption and condenser capacity It is not a simple ...

Page 46: ...e a week Daily maintenance consists of visual inspections Inspect the heat pump unit and check that both noise and vibrations are normal To observe trends it is recommended to enter the observed operating data into a log book see subsection 8 1 Monitoring of operation Check that all operating values are within the permissible ranges Compare them with previous values to detect trends Check the oil ...

Page 47: ...dvantages High chemical stability it is suitable for long term operation Low vapour pressure lower oil carry over from the compressor High viscosity index better oil recovery from evaporator 6 3 R717 charge It is very important that the heat pump has the correct charge The P I diagram states the charge for each specific heat pump At normal operation the suction superheat should be between 1 5 and ...

Page 48: ...r 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 and refrigerant which may be toxic and or flammable 7 2 Waste disposal Machine parts When dismantling the plant it is important to properly sort the parts that should be disposed of The compressor frame containers and so on belonging to the cat...

Page 49: ...on to the items listed in the start up log all other activities of service maintenance or repair work must be entered into your logbook as required by EN 378 and national laws Checklist Along with this Operating manual we have provided a Checklist as shown in Fig 24 which will serve as a help to the service engineer and must be filled in during commissioning and start up Keep the filled in checkli...

Page 50: ...rt no Description 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 M12 x 30 9 2 1427 045 001 Threaded bar M14 10 2 1432 034 Nut M14 11 1 1344 365 Flange DN25 12 1 1336 029 Gasket DN25 NO 3247 128 3 4 5 6 7 8 11 1 2 12 NO N C 9 10 ...

Page 51: ...n the float valve housing If the housing is empty of liquid the valve will close but never seal tightly The volume of the cascade evaporator is very small which makes it very sensitive to non condensable gasses To ensure optimal performance of the cascade evaporator a by pass 2 mm orifice pos 3 in Fig 26 is mounted around the float valve The by pass eliminates the risk of non condensable gasses bu...

Page 52: ...er sion of the declaration 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 documentation The original signed declaration of conformity is sent separately in accordance with the Guide to applica tion of the Machinery Directive If more than one declaration of ...

Page 53: ...m level sensor must be performed by competent person nel only The guide is in English only Warning Incorrect set up may cause the compressor to break down The AKS 4100 contains A signal converter with HMI display and meta glass solution A process connection with probe When the process connection with probe is properly installed in the system the HMI display and signal converter should be mounted o...

Page 54: ...r a HMI display is always needed Connect the device to the power supply see the section Electrical installation connection Press 3 times Press Press or to select between SINGLE COAXIAL D14 and COAXIAL D22 Choose D22 and press Press AKS 4100 QUICK SETUP YES NO AKS 4100 D22 Press to change the PROBE LENGTH Press to change the position of the cursor Press to decrease the value or to increase the valu...

Page 55: ... distance 2 3 3 Time constant 2 5 3 Epsilon R gas constant Er gas Change to the value indicated for the temperature of the media If a media range is given choose the value of the lowest operating media temperature See the List of Er gas constant in Fig 39 2 5 7 Level threshold 4 1 1 Full area 4 1 2 Empty area The supervisor menu is protected by a passcode 1 Name the buttons on the AKS head 1 2 3 4...

Page 56: ...e how to change a parameter in the supervisor menu Change of gas constant 2 5 3 to value according to the list in Fig 39 If in doubt choose the lowest value belonging to the lower end of your operating range 1 Change the text in the upper line in the display to 2 5 3 Press Arrow right no 1 the second digit is marked see Fig 32 Fig 32 Press Arrow up no 4 until 1 has turned to 5 Press Arrow right no...

Page 57: ...wn no 3 and Arrow up no 4 see Fig 35 Fig 35 Confirm with Return no 2 see Fig 36 Fig 36 Return no 2 always takes you up one level Change the following parameters in the same way 2 3 2 Blocking distance from 50 mm to 0 mm 2 3 3 Time constant from 5 sec to 1 sec 2 5 7 Level threshold from 200 mm to 150 mm 4 1 1 Full area confirm or change to 0 mm Passcode for level 4 x x 4 3 4 2 4 1 4 1 2 Empty Area ...

Page 58: ...ur logbook Installation date Filled in values Recommended values AKS 4100 280 mm Probe D22 CO2 NO Probe length 280 mm 4 mA scale 210 mm 20 mA scale 60 mm Gas constant 2 5 3 See the list in Fig 39 heat pump approx 1 2 1 4 Blocking distance 2 3 2 0 mm Time constant 2 3 3 1 sec Level threshold 2 5 7 150 Full area 4 1 1 0 mm Empty area 4 1 2 260 mm ICAD ICAD speed i04 100 UniSAB Set point regulation 2...

Page 59: ...Operating manual HeatPAC with reciprocating compressor 009332 en 2021 07 59 62 Appendices Fig 38 AKS 4100 280 mm installed in a DN150 receiver Set point zone ...

Page 60: ...Operating manual HeatPAC with reciprocating compressor 60 62 009332 en 2021 07 Appendices Extended list Gas constant for ammonia heat pump application Fig 39 ...

Page 61: ...ustion engines application 11 Competent persons requirements 10 Compressor name plates 13 CVUA 1201 oil recovery pot 50 D Declaration of conformity 52 Detector R717 38 E Emergency stop 25 Evaporator 28 F First aid for ammonia accidents 23 L Logbook 49 Lubricating oil 21 M Maintenance 46 Monitoring 42 Monitoring of operation 49 O Oil types 21 Operating log 42 P Power supply 20 Protecting the operat...

Page 62: ... 62 009332 en 2021 07 S Safety during maintenance and service 20 Safety signs 18 Sound and noise data 36 Spare parts list 50 Starting procedures 39 Stopping for a brief period 42 T Testing 45 U Unit pipe system name plate 16 V Vessel name plate 15 W Water 38 ...

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Page 64: ...Johnson Controls Denmark ApS Sabroe Factory Christian X s Vej 201 8270 Højbjerg Denmark Phone 45 87 36 70 00 www sabroe com Version 6 ...

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