Johnson Controls SABROE ComPAC User manual

ComPAC
Chiller unit with screw compressor
Operating manual
en

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Manual for ComPAC with screw compressor
The chiller unit can be configured with various types of equipment depending on its function and
requirements.
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:
Compressor
Unisab 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 control Mechanical float valve Electronic valve
Approval PED (2014/68/EU) Other _____________
Supply voltage Motor 3 x _________ V/ _________ Hz
Control 1 x _________ V / _________ Hz
Drive type Fixed speed Variable speed
Motor IP23 IP55
Power _________ kw Size IEC _________
Ex-execution
Both compressor and unit are safeguarded
ECO-design Standard process chillers only:
EER A_______ SEPR _______

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Safety valve:
Data for calculation of
downstream line accord-
ing to EN 13136
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

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Contents
1. Introduction ..................................................................................... 8
1.1 Introduction to the manual ..................................................... 8
1.1.1 Amendments to the manual............................................. 9
1.1.2 Definition of safety precautions used in this
manual............................................................................ 10
1.1.3 Requirements for competent persons ........................... 10
2. Safety............................................................................................... 11
2.1 Areas of application ............................................................... 11
2.1.1 Application...................................................................... 11
2.1.2 Application of combustion engines ................................ 11
2.2 Identification ......................................................................... 12
2.2.1 Identification of equipment............................................ 12
2.2.2 Unit/pipe system name plate......................................... 13
2.2.3 Compressor name plates ............................................... 15
2.2.4 Vessel name plate .......................................................... 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
2.3.6 Power supply .................................................................. 20
2.3.7 Lubricating oils ............................................................... 21
2.3.8 Refrigerants.................................................................... 21
2.3.9 Purging a refrigeration plant .......................................... 21
2.3.10 F-gas regulation (fluorinated greenhouse
gases) ............................................................................. 22
2.3.11 First aid for accidents with ammonia ............................. 24
2.3.12 Protecting the operator as well as the
environment ................................................................... 25
2.3.13 Emergency stop.............................................................. 26
3. Design and function ...................................................................... 27
3.1 Unit design............................................................................. 27
3.1.1 The ComPAC unit in general........................................... 27
3.1.2 Components on a ComPAC (water-cooled
condenser)...................................................................... 28
3.2 Main components .................................................................. 29
3.2.1 Compressor .................................................................... 29
3.2.2 Control system ............................................................... 29

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3.2.3 Evaporator ...................................................................... 29
3.2.4 Condenser ...................................................................... 29
3.2.5 Receiver .......................................................................... 30
3.2.6 HP regulating system (water-cooled
condenser)...................................................................... 31
3.2.7 Air purge valve ............................................................... 32
3.2.8 Automatic oil recovery system from evaporator........... 33
3.2.9 Alarm for high level in the evaporator ........................... 34
4. Installation information .............................................................. 35
4.1 General information .............................................................. 35
4.2 First start-up procedure ........................................................ 35
4.3 Noise and vibration................................................................ 36
4.3.1 General information ....................................................... 36
4.3.2 Sound and noise data..................................................... 36
4.3.3 Foundation...................................................................... 37
4.3.4 Vibration dampers.......................................................... 37
4.3.5 ComPAC with variable speed drive (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 instructions ................................................................. 40
5.1 General information .............................................................. 40
5.2 Pre-start................................................................................. 40
5.2.1 Pre-start check ............................................................... 40
5.3 Starting .................................................................................. 41
5.3.1 Starting procedures ....................................................... 41
5.3.2 Normal start-up procedure ............................................ 41
5.3.3 Valve positions during operation, ComPAC ................... 42
5.3.4 Restarting the chiller after power interruption.............. 44
5.3.5 Restarting chiller unit after alarm stop
(shutdown) ..................................................................... 44
5.4 During operation ................................................................... 44
5.4.1 Checks to be performed during operation..................... 44
5.4.2 Monitoring of operation.................................................. 44
5.5 Stopping procedures ............................................................. 46
5.5.1 Stopping for a brief period ............................................. 46
5.5.2 Shutting down for a long standstill period..................... 46

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5.6 Shutdowns and alarms.......................................................... 46
5.6.1 Operating state............................................................... 46
5.6.2 Troubleshooting.............................................................. 47
5.6.3 Testing of chillers............................................................ 48
6. Maintenance 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....................................................................... 51
8. Appendices ..................................................................................... 52
8.1 Spare parts list for HP float valve.......................................... 52
8.2 Spare parts list for CVUA 1201 oil recovery pot ................... 53
8.3 Declaration of conformity...................................................... 54
Index................................................................................................ 55

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Introduction
1. Introduction
1.1 Introduction to the 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 compe-
tent 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.
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 purposes.
Contravention will be prosecuted.

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Introduction
1.1.1 Amendments to the manual
2020.03 Version 4
• The copy of the declaration of conformity (Unit) is now only contained in the printed
manual delivered with the unit and the pdf version uploaded with the order specific
documentation.
• Various minor changes.
2018.10 Version 3
• The ‘Cooling media’ subsection 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 has been added.
• ‘F-gas regulation’ section has been updated.
• Updated version of declaration of conformity for unit.
• And more.
The original version of this manual is the English language version. If there are any discrepancies
or conflicts between the English and any other version that has been translated into another lan-
guage, 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 damage
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 evi-
dence of appropriate training.
• Assign only competent personnel instructed in safety and all machine functions to operate
or service the compressor/unit according to EN 13313.
• Operators and maintenance personnel must carefully read, understand and fully comply
with all alarms and instructions.