Johnson Controls SABROE DualPAC, Operating Manual

Page 1: ...NS HPAC DualPAC with reciprocating compressors Operating manual EN ...

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Page 3: ...es Designations Compressor nos Refrigerant R717 Oil type PAO 100 Other Level control Mechanical float valve Electronic valve 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 Both compressor and unit are safeguarded ...

Page 4: ...data Type External surface m2 Design pressure bar Condenser HP Condenser LP Evaporator Oil separator HP Oil separator LP Oil cooler Intermediate vessel 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: ...ions 18 2 3 1 General precautions 18 2 3 2 During operation 18 2 3 3 Water system 19 2 3 4 Brine 19 2 3 5 Safety during maintenance and service 19 2 3 6 Power supply 19 2 3 7 Lubricating oils 20 2 3 8 Refrigerants 20 2 3 9 Purging of DualPAC 20 2 3 10 First aid for accidents with ammonia 22 2 3 11 Protecting the operator as well as the environment 23 2 3 12 Emergency stop 24 3 Design and function ...

Page 6: ...e speed drive 37 4 3 Secondary system 37 4 3 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 ope...

Page 7: ...6 1 Maintenance of DualPAC units 47 6 2 Selecting lubricating oil for DualPAC units 48 6 3 R717 charge 48 7 Final disposal 49 7 1 Safety precautions 49 7 2 Waste disposal 49 8 Appendices 50 8 1 Monitoring of operation 50 8 2 Control description DualPAC 51 8 3 Spare parts list for CVUA 1201 oil recovery pot 52 8 4 Declaration of conformity 53 8 5 Set up guide AKS 4100 280 mm for ammonia heat pump a...

Page 8: ...but able to incorrect operation All compressor intervention within the warranty period must be performed by competent personnel only If not the warranty no longer applies For further information see www sabroe com This manual is produced by Johnson Controls Denmark ApS Christian X s Vej 201 8270 Højbjerg Denmark Phone 45 87 36 70 00 CVR No 19 05 61 71 www sabroe com Copyright Johnson Controls Denm...

Page 9: ...ent and or minor injury Note Indicates an operating procedure practice etc or portion thereof which is essential to highlight 1 2 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 10: ...ion of the heat pump unit in potentially explosive atmospheres must only take place if the DualPAC is fitted with approved explosion proof equipment The compressor must only be used as a compressor within the operating limits specified in the compressor 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...

Page 11: ... 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 drawings Fig 1 Positioning of name plates on DualPAC Pos no Designation 1 Compressor name plate 2 Vessel name plate 3 Unit Pipe system name plate ...

Page 12: ...or 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 Con formity 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 N...

Page 13: ...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 pr...

Page 14: ...3rd 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 re frigerant 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 pressu...

Page 15: ... 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 Жид...

Page 16: ...system 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 sys...

Page 17: ...blocks and units are 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 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...

Page 18: ...ining refrigerant 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 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 th...

Page 19: ...r 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 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 20: ...raining oil from the vessel of the refrigeration plant al ways collect 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 refrigerants For safe handling please refer to the safety data sheets delivered by the refrigerant supplier Warning Be aware that large a...

Page 21: ...s 0012201 en 2021 04 21 63 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 condensable gases ...

Page 22: ... 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 ...

Page 23: ... 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 combinatio...

Page 24: ...3 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 25: ...o water brine are established the unit is practically ready for operation DualPAC is controlled by Johnson Controls Denmark s UniSAB III control and capacity regulating system and before start up the settings must be checked by a refrigeration engineer to make sure they are in accordance with the Sabroe settings list U set document DualPAC is delivered with adjustable anti vibration machine feet f...

Page 26: ...ted on the left drawing are not standard equipment Pos no Description 1 Evaporator Liquid separator 2 Oil separator 3 Condenser 4 GHUR intermediate cooler 5 Brine inlet evaporator 6 Brine outlet evaporator 7 Water inlet condenser 8 Water outlet condenser 9 Expansion valve see Fig 15 10 Compressor 11 Motor 12 UniSAB III controller and emergency stop built into the electrical panel is optional 13 El...

Page 27: ...s inside the cassettes The R717 droplets are separated in a demister above the plates The evaporator has two sets of brine connections and can be ordered with a manifold A sight glass is mounted at the end cover Note The liquid level 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 GHUR intermediate cooler The GHUR intermedia...

Page 28: ...it has a built in subcooler Fig 14 DualPAC receiver 3 2 7 Air purge valve If there is air or other non condensable gases in the refrigeration heat pump plant it tends to ac cumulate in the receiver or the condenser On DualPAC the air purge valve is fitted at the top of the receiver pos 2 in Fig 14 During air purging the air purge valve should be connected to an open vessel containing water via a r...

Page 29: ...evel the level sensor signals to an electrical regulator in the electrical panel which signals the expansion valve pos 1 Fig 15 to open and vice versa During normal operation the receiver should be a little more than half filled with liquid In UniSAB III the set point for the liquid level must be set at 20 in order for the receiver to be a little more than half filled with liquid See subsection 8 ...

Page 30: ...ttom of the evaporator An oil recovery pot Fig 18 and Pos 9 Fig 17 is connected to the evaporator by a pipe From the recovery pot the oil is automatically returned to the compressor A float is fitted in the oil recovery pot pos 3 Fig 17 It has the exact density which allows it to float on the collected oil and sink in R717 The float has a built in reed switch which activates the solenoid valve pos...

Page 31: ... collected in the oil separator is returned to the compressor by a timer operated solenoid valve The timer can be adjusted in the UniSAB III controller 3 2 11 By pass function during start up The R717 charge on DualPAC is very low The DualPAC is therefore equipped with a by pass from the bottom of the oil separator to the GHUR intermediate cooler R717 condensed in the oil sepa rator during standst...

Page 32: ...the circuit so that oil and discharge tem peratures do not exceed the fixed limits The system ensures optimum cooling water temperature and minimum water consumption 1 2 3 4 6 6 10 7 8 9 5 Fig 19 Water circuit The pump Fig 19 pos 2 is running constantly and it circulates the cooling water on the side and top covers of the compressor both during standstill and operation During standstill and oper a...

Page 33: ...charge check valve In the discharge line to the GHUR cooler there is a controlled check valve see Fig 20 The valve opens when it has 2 bar differential pressure and stays open at a differential pressure of approximately 0 02 bar When the compressor stops the valve closes Fig 20 Check valve in the discharge line ...

Page 34: ... flash gas This introduces the risk of trapped liquid when the DualPAC is stopped The CVP valve will open the ICS valve if the pressure rises to above 20 bar The oil recovery pot is pressurised from both the ChillPAC and the HeatPAC In order to avoid the pressure rising above 22 bar a CVP valve is installed in a pressure relieve line to the liquid injec tion to the GHUR intermediate cooler For adj...

Page 35: ... to the vibration design strategy 4 Connect all piping The piping design must include considerations regarding function sus pension vibrations thermal expansion and pre stress after welding in order to avoid high load on the DualPAC connections Mount all hoses and valves for compressor cooling 5 The safety valves are fitted on the unit from factory The pipe connection to the valve dis charge branc...

Page 36: ...plets should come out of the top of the plates The plates should not be covered by liquid DualPAC units may only be charged with PAO oils 4 2 Sound and vibrations 4 2 1 General information To ensure the compressor and motor a long life and a low noise and vibration level alignment of the compressor and coupling must be checked Misalignment of the compressor or coupling may result in stresses and v...

Page 37: ...ocating compressor where the motor drive speed is controlled by a frequency inverter is also called a rotatune compressor in UniSAB terminology See the UniSAB III Engineering manual for further description For some DualPAC models with reciprocating compressors mechanical vibrations caused by reso nance may occur in the actual operating range 500 1800 rpm This will in some cases result in an increa...

Page 38: ... on the heat transferring surfaces This reduces the heat transmission and in some cases the coating causes corrosion of the heat transferring surfaces 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...

Page 39: ...g books and or other documentation required according to local rules and or EN 378 Check the following before starting the DualPAC 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 pipes and ves sels has been activated for six to eight hours 4...

Page 40: ... the system conditions permit the DualPAC 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 DualPAC a Mechanical tightness of the external piping bolts and valves b No oil and refrigerant leaks If not satisfactory shut down the DualPAC and correct the problem Top bar Content area Info bar F key area ...

Page 41: ... discharge gas 4 Open 7 Stop valve for oil drain oil separator 2 Open 8 Stop valve for oil recovery compressor suction 2 Open 9 Stop valve expansion 4 Open 10 Stop valve for evaporator oil drainage 1 Open 11 Charge drain valve R717 1 Closed 12 Safety relief valve condenser 2 Closed Fixed set point 13 Safety relief valve evaporator 2 Closed Fixed set point 14 Safety relief valve internal compressor...

Page 42: ...y start up when needed by the automatic control and when the relevant timer delay has expired If UniSAB III is set in MANUAL running mode the operator must start up using the manual start key on UniSAB III 1 Check variable set points 2 UniSAB III should display READY 3 Follow the normal start up procedure Note A long stop requires a long term stop procedure as described in the following 5 3 5 Rest...

Page 43: ...orating and condensing pressures are within 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 DualPAC is operating stably not fluctuating 5 4 2 Monitoring and logging of operation It is recommended that the plant and the heat pump unit are monitored by a competent person at regular intervals The m...

Page 44: ...tandstill period Follow the Stopping for a brief period instructions and 1 Turn off the oil heater and heat tracing 2 Close suction and discharge valves 3 Rotate the motor 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 and compressor on a monthly bas...

Page 45: ... regular intervals 5 6 2 Troubleshooting Too high condensing pressure Cause Solution Insufficient water flow through the condenser Adjust water supply or clean the condenser Fouling in the condenser Clean the condenser Too high hot water temperature Check hot water system or reduce compressor capacity Air or non condensable gases in the system Remove air from the condenser A 1 K lower condensing t...

Page 46: ... the compressor than during full load At part load operation the oil will settle easier because of less boiling in the evaporator Drop in oil temperature Cause Solution Wet suction gas due to too high R717 charge Reduce charge Wet suction gas due to fluctuating load Check secondary system Wet suction gas due to quick changes in compressor capacity Adjust settings for load unload compressor capacit...

Page 47: ... a week Daily maintenance consists of visual inspections Inspect the DualPAC unit and check that both noise and vibrations are normal To observe trends it is recommended to enter the observed operating data into a logbook see subsection 8 1 Monitoring of operation Check that all operating val ues are within the permissible ranges Compare them with previous values to de tect trends Check the oil le...

Page 48: ...l 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 DualPAC has the correct charge The P I diagram states the charge for each specific compressor At normal operation the suction superheat should be between 0 5 and 3 K for the LP side and...

Page 49: ...er Be very careful 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 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 c...

Page 50: ... OK Vibrations 0 100 capacity OK not OK Brine temperature outlet Evaporator C Brine temperature outlet Condenser C Refrigerant charge Kg Please fill in this form file it and send a copy to Noreply Sabroe jci com Checklist 2 2 011198 en 2014 10 Checklist for commissioning of compressor chiller and heat pump units Compressor serial no Date Name Check before start up Read and understand all Sabroe ma...

Page 51: ...vaporator When the temperature gets outside range the compressor will regulate capacity up or down The capacity mode should be set to speed in order to regulate most fluently HeatPAC is controlled by intermediate pressure suction pressure When the pressure gets out side range the compressor will regulate capacity up or down Capacity mode should be set to speed in order to regulate most fluently Ho...

Page 52: ...art 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 53: ...d version 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 application of the Machinery Directive If more than one declaration of...

Page 54: ... mm level sensor must be performed by competent personnel 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 ...

Page 55: ...er 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 val...

Page 56: ...g 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 con stant in Fig 38 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...

Page 57: ...le how to change a parameter in the supervisor menu Change of gas constant 2 5 3 to value according to the list in Fig 38 If in doubt choose the low est 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 31 Fig 31 Press Arrow up no 4 until 1 has turned to 5 Press Arrow right ...

Page 58: ...own no 3 and Arrow up no 4 see Fig 34 Fig 34 Confirm with Return no 2 see Fig 35 Fig 35 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 59: ...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 38 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 60: ...Operating manual DualPAC with reciprocating compressors 60 63 0012201 en 2021 04 Appendices Fig 37 AKS 4100 280 mm installed in a DN150 receiver Set point zone ...

Page 61: ...Operating manual DualPAC with reciprocating compressors 0012201 en 2021 04 61 63 Appendices Extended list Gas constant for ammonia heat pump application Fig 38 ...

Page 62: ... 10 Competent persons requirements 9 Compressor name plates 12 Control description 51 CVP valves 34 CVUA 1201 oil recovery pot 52 D Declaration of conformity 53 Detector R717 38 Discharge check valve 33 E Emergency stop 24 Evaporator 27 F First aid for ammonia accidents 22 G GHUR intermediate cooler 27 L Logbook 50 Lubricating oil 20 M Maintenance 47 Monitoring 43 Monitoring of operation 50 O Oil ...

Page 63: ...supply 19 Protecting the operator 23 R Refrigerants 20 S Safety during maintenance and service 19 Safety signs 17 Sound and noise data 36 Spare parts list 52 Starting procedures 39 Stopping for a brief period 43 T Testing 46 U Unit pipe system name plate 15 V Vessel name plate 14 W Water 38 ...

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 2 ...