Johnson Controls SABROE ChillPAC User manual

ChillPAC Air
Chiller unit with reciprocating compressor
Operating manual EN

Operating manual - ChillPAC Air
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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:
• ChillPAC
• Compressor
• UniSAB III controller
• Enclosure
• Air-cooled condenser
You can find the compressor number and the equipment configured on your unit in the
ChillPAC manual uploaded with your order.
ChillPAC Air type Standard Winter 1 Winter 2

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Contents
1. Introduction...........................................................................................6
1.1 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
2. Safety ....................................................................................................8
2.1 Areas of application......................................................................8
2.1.1 Application ...........................................................................8
2.2 Identification ................................................................................9
2.2.1 Identification of equipment.....................................................9
2.2.2 Unit/pipe system name plate..................................................9
2.2.3 Compressor name plate ........................................................9
2.2.4 Vessel name plate ................................................................9
2.2.5 Condenser name plate ..........................................................9
2.2.6 Signs ................................................................................. 10
2.3 Safety precautions ..................................................................... 11
2.3.1 General precautions............................................................ 11
2.3.2 During operation ................................................................. 11
3. Design and function ............................................................................12
3.1 Unit design ................................................................................ 12
3.1.1 General information about ChillPAC Air ................................ 12
3.1.2 Components on a ChillPAC Air (standard unit) ......................13
3.1.3 Components on a ChillPAC Air (winter 1 unit)........................ 14
3.1.4 Components on a ChillPAC Air (winter 2 unit)........................ 15
3.2 Main components ...................................................................... 16
3.2.1 Enclosure........................................................................... 16
3.2.2 Compressor and oil separator.............................................. 16
3.2.3 Control system ................................................................... 16
3.2.4 Evaporator .........................................................................16
3.2.5 Condenser .........................................................................16
3.2.6 Receiver ............................................................................ 18
3.2.7 Sight glass in the liquid line.................................................. 18
3.2.8 Air purge valve ................................................................... 19
3.2.9 Low pressure (LP) regulating system....................................19
3.2.10 Automatic oil recovery system from evaporator ..................... 19
3.2.11 Automatic oil return from the oil separator ............................. 19
3.2.12 Alarm for high level in the evaporator....................................19
3.2.13 Safety valves...................................................................... 20

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4. Installation information ....................................................................... 21
4.1 General information ................................................................... 21
4.2 First start-up procedure ..............................................................21
4.3 Noise and vibrations................................................................... 21
4.4 Secondary system .....................................................................22
5. Operating instructions ........................................................................23
5.1 General information ................................................................... 23
5.2 Pre-start check .......................................................................... 23
5.3 Valve positions during operation.................................................. 24
5.4 Starting ..................................................................................... 31
5.4.1 Starting procedures............................................................. 31
5.4.2 Normal start-up procedure...................................................31
5.5 During operation ........................................................................31
5.6 Stopping procedures .................................................................. 31
5.7 Shutdowns and alarms ............................................................... 32
5.8 Troubleshooting.........................................................................32
6. Maintenance instructions .................................................................... 33
6.1 Maintenance of the chiller unit..................................................... 33
6.2 Selecting lubricating oil for ChillPAC Air units ............................... 33
6.3 R717 charge.............................................................................. 33
7. Final disposal...................................................................................... 34
7.1 Safety precautions .....................................................................34
7.2 Waste disposal .......................................................................... 34
8. Appendices ......................................................................................... 35
8.1 Spare parts list for ChillPAC Air ................................................... 35
8.2 Declaration of conformity ............................................................ 35

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Introduction
1. Introduction
1.1 Introduction to manual
This manual describes operating conditions for the unit, including:
• Dangers resulting from failure to comply with safety precautions when operating the
equipment and performing maintenance tasks.
• How to start, operate and stop the equipment safely.
• How to act when problems occur during operation.
• Scheduled maintenance tasks for the equipment and when/how to carry them out
safely.
This manual is primarily intended for operators and engineers.
To prevent accidents, assembly and disassembly of components should be carried out by com-
petent personnel only.
• 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.
• All compressor intervention within the warranty period must be performed by competent
personnel only. If not, the warranty no longer applies.
1.1.1 Models covered
The ChillPAC Air manual covers three types of air-cooled chillers:
• ChillPAC Air standard:
Normal operation condition, with adjusted refrigerant charge.
• ChillPAC Air winter 1:
Winterization below 0°C down to -10°C ambient temperature, with valves and adjusted
refrigerant charge.
• ChillPAC Air winter 2:
Winterization below -10°C ambient temperature, with valves and receiver with addition-
al refrigerant charge.
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 [phone]
CVR No 19 05 61 71
www.sabroe.com
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 purpo-
ses. Contravention will be prosecuted.
The original version of this manual is the English language version. If there are any discrepan-
cies or conflicts between the English and any other version that has been translated into anoth-
er language, the English version will prevail.

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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.
Caution!
Indicates a potentially hazardous situation or practice which, if not avoided, will result in dam-
age to equipment and/or minor 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 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 supported by
evidence of appropriate training.
• Assign only competent personnel instructed in safety and all machine functions to oper-
ate or service the compressor/unit according to EN 13313.
• Operators and maintenance personnel must carefully read, understand and fully com-
ply with all alarms and instructions.

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Safety
2. Safety
2.1 Areas of application
2.1.1 Application
To prevent unintentional application which could injure personnel or damage equipment, the
following must be observed:
• The unit must only be used as a liquid refrigeration unit intended for water or brine
cooling.
• The unit must not be installed in areas where the relative humidity (RH) may exceed
85% (95% if the motor is made for 100% RH).
• 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.
• The secondary side on the evaporator is only intended for water or brine as cooling me-
dium. The secondary medium is stated on the P&I diagram. Deviations are only permit-
ted with a written permission from Johnson Controls Denmark.
• Installation of the chiller in potentially explosive atmospheres 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 oper-
ating limits specified in the manual or in a written agreement with Johnson Controls
Denmark.
• The compressor must only be used with the rpm shown on the compressor name plate.
• The unit is designed for outdoor installation on a roof or at ground level. (Follow EN
378-1, ISO 5149-1 or EN 60079-10.)
• The secondary side on the condenser is only intended for air as cooling medium.
The compressor must NOT be used:
• To evacuate the refrigeration plant of air and moisture.
• To put the refrigeration plant under air pressure in view of a pressure testing.
• As an air compressor.

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Safety
2.2 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
Pos. no. Name plate for
1 Compressor (see the ChillPAC manual)
2 Evaporator (see the ChillPAC manual)
3 Oil separator (see the ChillPAC manual)
4Receiver (see the ChillPAC manual)
5Unit/pipe system (see the ChillPAC manual)
6 Enclosure (see the enclosure manual) - not shown
7Air-cooled condenser (see the condenser manual) - not shown
2.2.2 Unit/pipe system name plate
See the ChillPAC manual.
Depending on the type of declaration of conformity, the unit can be identified as follows:
• Complete unit with one declaration of conformity and one overall name plate, (see sec-
tion 8.2).
• Separate units with partial declaration of conformity and separated name plates for
each unit, (see section 8.2).
2.2.3 Compressor name plate
See the ChillPAC manual.
2.2.4 Vessel name plate
See the ChillPAC manual.
2.2.5 Condenser name plate
See air-cooled condenser manual.

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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.
Risk of electric shock High voltage/
High pressure
High surface
temperature
(about 70°C)
The compressor may be top-
heavy
Internal overpressure Hazardous substance Cold surfaces Dangerous noise level, use
hearing protectors
Do not step on surface No open flame Flammable gas The unit IS filled with refrig-
erant R290
Gas under pressure Corrosive Toxic Dangerous to the
environment
No unauthorised
access
Internal protection Pacemaker users keep out
Compressor blocks 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
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
powerful magnetic field. This field may af-
fect digital devices such as watches and
mobile phones.
Assembly or maintenance of the rotor
must not be carried out by people with
pacemakers or any other implanted medi-
cal electronic device.
The VSD contains capacitors capable of
storing electrical energy, meaning that
there is a risk of electric shock within 15
minutes after the drive has been turned
off.

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Safety
2.3 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
• National safety rules and regulations.
Read and understand all safety instructions before setting up, operating or servicing/perform-
ing maintenance on the compressor/unit. Assign only competent personnel instructed in safety
and all machine functions to operate or service the compressor/unit.
Operators and maintenance personnel must carefully read, understand and fully comply with
all alarm and instruction plates mounted on the compressor/unit.
• Observe the safety warnings.
• Use ear protection when operating the compressor/unit.
• Use safety equipment. Wear appropriate gloves as well as eye and face protection
when working with parts containing 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 be-
fore the equipment is put into operation. Never by-pass or wire around any safety device.
Ventilation
Before operating the unit, always check, where relevant, the function of the ventilation system
and refrigerant detectors used in the area where the compressor/unit is located (machine room
inside the ventilated enclosure).
For further information, see the ChillPAC Mk 3 manual.

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Design and function
3. Design and function
3.1 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.
The unit is provided with adjustable anti-vibration machine feet for installation on a solid con-
crete floor. For installation on decks, special vibration dampers are often required.
ChillPAC Air is delivered as a split unit. The chiller section is pressure and function tested from
the factory without condenser, according to existing EU directives (CE marked).
For specific dimensions and size of connections, see the P&I diagram and GA drawing.
Area of operation
The chiller is available in three different designs made for operation in different outdoor tem-
perature ranges.
ChillPAC Air standard - The standard unit is designed for ambient conditions down to 0° C
with adjusted refrigerant charge and without receiver.
ChillPAC Air winter 1 - The winter 1 unit is designed for ambient conditions below 0°C down
to -10°C, with adjusted refrigerant charge and without receiver. An electrical motor valve in the
discharge line and a stop/check valve in the liquid line ensures that refrigerant from the evapo-
rator does not flow to the condenser when the condenser is located colder than the evaporator
in periods when the compressor is not operating.
ChillPAC Air winter 2 - The winter 2 unit is designed for ambient conditions below -10°C, with
a receiver and additional refrigerant charge. Electrical motor valves in the discharge line, liquid
line and equalization line secure that refrigerant from the evaporator and receiver does not flow
to the condenser when the condenser is located colder than the evaporator in periods when
the compressor is not operating.

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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
1 Evaporator/Liquid separator
2 Oil separator
4 Inlet evaporator
5Outlet evaporator
6 Expansion valve with built-in stop/check valve
7 Liquid level column and level sensor
8 Compressor
9 UniSAB lll controller and emergency stop (built into electrical panel)
10 Motor
11 Oil recovery system (from evaporator)
12 Liquid inlet (from condenser)
14 Oil return system (from oil separator)
15 R717 charge valve
16.a Drain valve (from liquid line)
17 Electrical panel
18 High level alarm
19 Discharge outlet (to condenser)
22 Sight glass (liquid line)

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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
1 Evaporator/Liquid separator
2 Oil separator
4 Inlet evaporator
5Outlet evaporator
6 Expansion valve (with built-in stop/check valve)
7 Liquid level column and level sensor
8 Compressor
9 UniSAB lll controller and emergency stop (built into electrical panel)
10 Motor
11 Oil recovery system (from evaporator)
12 Liquid inlet (from condenser)
14 Oil return system (from oil separator)
15 R717 charge valve
16.a Drain valve (from liquid line)
17 Electrical panel
18 High level alarm
19 Discharge outlet (to condenser)
20 Electrical motor valve (discharge line)
22 Sight glass (liquid line)

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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
1 Evaporator/Liquid separator
2 Oil separator
3 Receiver
4 Inlet evaporator
5Outlet evaporator
6 Expansion valve
7 Liquid level column and level sensor
8 Compressor
9 UniSAB lll controller and emergency stop (built into electrical panel)
10 Motor
11 Oil recovery system (from evaporator)
12 Liquid inlet (from condenser)
13 Equalizing receiver (from condenser)
14 Oil return system (from oil separator)
15 R717 charge valve
16 Drain valve (from receiver)
16.a Drain valve (from liquid line)
17 Electrical panel
18 High level alarm
19 Discharge outlet (to condenser)
20 Electrical motor valve (discharge line)
21 Electrical motor valve (liquid line)
22 Sight glass (liquid line)
23 Solenoid valve (equalizing line)

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Design and function
3.2 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.
The ChillPAC Air chiller unit and condenser must be level, and it is therefore recommended to
install the units on machine feet.
For further information, see the ChillPAC Mk 3 manual.
3.2.1 Enclosure
The enclosure is made of aluminium profiles, mounted with perforated galvanised steel plates
inside and aluzinc plates outside. The base frame is hot-dip galvanised in weather-resistant
design. Isolation thickness is 50 mm in panels and 40 mm in doors.
The enclosure is equipped with mechanical ventilation to ensure sufficient air change inside
the enclosure to avoid accumulation of refrigerant gases.
3.2.2 Compressor and oil separator
The ChillPAC Air is equipped with a Sabroe SMC reciprocating compressor, complete with stop
valves, motor, etc. and a standard separate oil separator built into the enclosure. For more in-
formation, see the compressor operating manual.
3.2.3 Control system
The ChillPAC Air is delivered with UniSAB III monitoring, safety and capacity regulating system
and supplemented with an independent condenser controller to control fan speed.
3.2.4 Evaporator
The ChillPAC Air is equipped with a standard evaporator, fully welded plate heat exchanger as
described in the ChillPAC Mk 3 operating manual.
The R717 droplets are separated from the vapour in the separator room above the plates. The
evaporator has one or two sets of brine connections depending on size and operating condi-
tions. A sight glass is mounted at the end cover.
3.2.5 Condenser
The ChillPAC Air is equipped with an air-cooled V-coil condenser. The heat exchanger is made
of stainless steel pipes with aluminium fins, and it is built into an enclosure of galvanised steel
plate (painted).
The condenser is equipped with speed-regulated axial fans with EC motors, protection class
IP54.
Fig. 5: V-coil condenser with two refrigerant circuits

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Design and function
Condenser with two refrigerant circuits in parallel (standard and winter 1 unit)
To obtain maximum condenser efficiency under all operating conditions, follow these require-
ments when installing the remote condenser:
1. 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. Elevate the condenser to increase air
flow and to obtain sufficient height of the vertical liquid legs.
2. The height “H” of the vertical liquid legs from each coil outlet should be min. 1 m for am-
monia R717 to equalize any difference in coil outlet pressure. All reductions in liquid
drain lines must be made in vertical piping.
3. Liquid pipe connection between the condenser and the ChillPAC Air enclosure.
4. The discharge piping should be as symmetrical as possible in order to equalize the
pressure drop to each individual condenser circuits.
Note: If it is not possible to place the condenser close to the unit, and the discharge lines are
long and have a large pressure design drop, allowance must be made in either the compressor
or condenser selection.
Contact Johnson Controls Denmark for further information.
Fig. 6: Two condenser refrigerant circuits in parallel with vertical liquid legs.

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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:
1. 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. Elevate the condenser to increase air
flow and to obtain sufficient height of the vertical liquid legs.
2. To equalize difference in coil outlet pressures it is essential to use trapped vertical liquid
legs from each condenser outlet to the receiver. The height “H” of the vertical liquid legs
from each coil outlet should be min. 1 m for ammonia R717 to equalize any difference
in coil outlet pressure. All reductions in liquid drain lines must be made in vertical
piping.
3. Liquid pipe connection between the condenser and the ChillPAC Air enclosure.
4. The discharge piping should be as symmetrical as possible in order to equalize the
pressure drop to each individual condenser circuits.
5. The equalizing line equalizes the pressure between the receiver and both condenser
coil outlets to obtain a free flow of refrigerant liquid from the condenser outlet to the re-
ceiver. The pressure equalizing is connected in parallel without U-trap as close to both
coil outlets as possible after the flange connections at the top of the vertical legs. See
detail drawing below.
Fig. 7: Two condenser refrigerant circuits in parallel with vertical liquid legs and pressure equalising.
3.2.6 Receiver
The ChillPAC Air standard unit and winter 1 unit are equipped with adjusted refrigerant charge
without a receiver.
The ChillPAC Air winter 2 unit is equipped with a receiver to accumulate the refrigerant liquid
coming from the condenser.
Please see the ChillPAC manual for information about connections and sight glasses, which
are all located on the flat end cover.
3.2.7 Sight glass in the liquid line
The ChillPAC Air standard unit and winter 1 unit are equipped with a sight glass positioned in
the liquid line close to the LP regulating system for view of the liquid flow. If a gas/liquid mixture
(bubbles) is detected in the sight glass, it indicates that the subcooling is insufficient and can
be solved by charging more refrigerant.

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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.
During air purging, the air purge valve should be connected to an open vessel containing water
via a refrigerant hose. The air will leave the water as bubbles, whereas the R717 gas will be
absorbed by the water.
See the ChillPAC manual for more information.
3.2.9 Low pressure (LP) regulating system
The ChillPAC Air is equipped with an LP regulating system.
The principal function of the LP regulating system is to keep a constant level of R717 in the
evaporator.
See the ChillPAC manual for further information.
3.2.10 Automatic oil recovery system from evaporator
See the ChillPAC manual for further information.
3.2.11 Automatic oil return from the oil separator
See the ChillPAC manual for further information.
3.2.12 Alarm for high level in the evaporator
The ChillPAC Air has a level switch.
See the ChillPAC manual for further information.

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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.