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.

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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 fol-
lowing 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 compres-
sor unit and plant parts caused by torsional oscillation or the like which is attributable to
built-in VSD solutions initiated by the customer after delivery.
• The secondary side on the evaporator and condenser is only intended for water or brine as
cooling medium. The secondary medium is stated on the P&I diagram. Deviations are only
permitted 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 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 plate.
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.
2.1.2 Application of combustion engines
According to EN 378/ISO 5149, no other machinery should be installed in a refrigeration machine
room. Some refrigerant types may, to a certain extent, be absorbed by the fuel in a combustion
engine, and when the contaminated fuel reaches the fuel pumps, the refrigerant will “flash out”
(separate) and react on the increased temperature and pressure by creating acids, which will de-
stroy the pumps. However, check with the local authorities as exemptions to this rule may be
granted.
Warning!
Johnson Controls Denmark is not liable for injuries to personnel or damage to equipment resulting
from using the equipment for other purposes than the ones stated above.

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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
1Compressor
2Evaporator/Cascade cooler
3Condenser/Receiver
4Float housing
5Vessel
6 Vessel
7Unit/piping system
8Motor

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Safety
2.2.2 Unit/pipe system name plate
Scope
Design code
Approval No
Refrigerant
Supply voltage
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
2516-342 Johnson Controls Denmark ApS
Christian X's Vej 201
8270 Højbjerg, 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
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. 3: Name plate for ATEX unit
Установка холодильная
№
Назначение
Код стандарта
№ сертификата
Хладагент
Жидкость
Группа
Напряжение питания Сеть
Управ
ление В/Гц
Заправка хладагентом
Кг
Давление
бар
бар
Допустимое давление
Давление ислытания
Сторона НД
макс
Сторона ВД
Категория
° С
Допустимая темп
мин/макс
Год
Тип
2516-344
Johnson Controls Denmark ApS
Christian X's Vej 201
8270 Højbjerg, Denmark
www.sabroe.com
Fig. 4: Name plate for unit with EurAsian Conformity
mark (EAC)

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Safety
The unit name plate is positioned on the frame and contains this information:
Refrigeration unit No. Identification no. (serial no.)
Year Year of manufacturing.
Type Manufacturer's type designation.
Scope
For EC PED/EAC approval: ‘Unit & Piping’ means that the CE/EAC
mark applies to the complete unit including the piping system.
’Piping’ means that the CE/EAC mark applies to the piping system
only, and it is the sole responsibility of the owner to ensure and
declare that the complete unit is in conformity with the provisions
of all relevant rules.
Design code Design code used for the unit and piping system.
Approval no. If the unit/manufacture has been approved by a 3rd party/notified
body.
Refrigerant - Fluid Refrigerant of the unit.
Refrigerant designation according to ISO 817.
Refrigerant - Group For EC PED approval:
Fluid group 1 or 2 according to the PED directive.
Supply voltage - Control Supply voltage and frequency of the control system.
Refrigerant charge
Weight of the refrigerant charge on the unit.
This is only stated if the unit includes an evaporator and/or a
condenser.
Pressure 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 system has been designed for in terms of
pressure strength design.
The maximum practical operation pressure is lower than the maxi-
mum allowable pressure depending on the operating conditions
and safety equipment settings.
Test pressure The test pressure that the unit/piping system has been strength
tested with.
Allowable temperature,
min./max.
The minimum and maximum temperatures that the unit/piping
system has been designed for at the indicated maximum allowable
pressures.
CE xxxx
The CE mark appears on the name plate for EC PED approval only.
The four digits make up the registration no. of the notified body/
3rd party in charge.
Ex If the unit is designed in accordance with the EC ATEX directive,
there is an Ex mark on the name plate.
EAC
The EurAsian Conformity mark (EAC) indicates that the unit is in
compliance with all relevant technical regulations of the Eurasian
Customs Union.
Note: Main supply voltage can be found on the motor and/or electrical panel name plate.

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Safety
2.2.3 Compressor name plates
Compressor
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
2516-345
Fig. 5: Name plate for standard compressor
Compressor
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. 6: Name plate for ATEX compressor
Fig. 7: 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 No
Type
Refrigerant
Compressor
Swept Volume
Speed
psig
psig
rpm
cfm
2516-347
Max.
Fig. 8: Name plate for compressor to the USA

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Safety
The compressor name plate is positioned on the compressor and contains this information:
Compressor no. Identification no. (serial no).
Year Year of manufacturing.
Type Manufacturer's type designation.
Refrigerant
Allowable refrigerant or refrigerants for the compressor.
(The actual refrigerant for the unit is stated on the unit name
plate).
Speed
Specific rotational speed. Specific rotational speed is used for cal-
culating swept volume. For the actual allowed operating speed,
please refer to the operating limits and Matchmaster's calculation
on the actual operating condition.
Swept volume 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 pressure is lower than the maxi-
mum allowable pressure, depending on the operating conditions
and safety equipment settings.
Test pressure The test pressure the compressor has been strength tested with.
CE and Ex The CE and Ex marks indicate that the compressor has been de-
signed in accordance with the EC ATEX directive.
EAC
The EurAsian Conformity mark (EAC) indicates that the compres-
sor is in compliance with all relevant technical regulations of the
Eurasian Customs Union.

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Safety
2.2.4 Vessel name plate
Fig. 9: Name plate for vessel
Пpoeкт пo cтaндapтy
Design code
Утвepждeн пoд N °
Approval No
Oбъeм /Volume
Cpeдa /Fluid
Тип /Type
PS
TS
V
M асса пустого cocy д a
Empty weight
/ Кат .
/Cat.
Nº cocy д a
Vessel No
год
2516-331
кг
Cтopoнa oбeчaйки
Shell side Tube side
Cтopoнa тpyбок
п
l
MПа
MPa
°C
P a б o ч ee двп e ни e Макс ./ Мин .
Allowable pressure Max./Min.
P aбoчaя тeмпepaтypa Макс ./ Мин .
Allowable temperature Max./Min.
Kg
Year
Johnson Controls Denmark ApS
Christian X's Vej 201
8270 Højbjerg, Denmark
www.sabroe.com
Fig. 10: Name plate for vessel with EurAsian Conformity
mark (EAC)
The pressure vessel name plate is positioned on the shell of the vessel and contains this
information:
Vessel no. Identification no. (serial no.)
Empty weight The empty weight of the vessel in kg.
Year Year of manufacturing.
Type Manufacturer's type designation.
Design code Design code used for the pressure vessel.
Approval no./CAT
The approval no. of the vessel issued by the relevant 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 pressure, PS The min. and max. pressures (pressure relative to atmospheric
pressure) that the vessel or vessel part has been designed for.
Allowable temperature,
TS
The min. and max. temperatures that the vessel or vessel part has
been designed for.
Volume The volume of the vessel or vessel part.
CE xxxx
The CE mark appears on the name plate for EC PED approval.
The four digits make up the registration no. of the notified body/
3rd party in charge.
EAC
The EurAsian Conformity mark (EAC) indicates that the vessel is
in compliance with all relevant technical regulations of the Eura-
sian Customs Union.
Note: Depending on the supplier of the pressure vessel/heat exchanger, the layout and content
of the vessel name plate may differ from the Sabroe name plate above.
Johnson Controls D e n m ar k ApS
Christian X 's V e j 201
8 270 Højbj e rg, D e n m ark
www.sabro e .com

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Safety
2.2.5 Signs
All signs which may be found on your equipment are shown below. The number of signs, however,
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 re-
frigerant R290
Internal protection Pacemaker users keep out
Compressor 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 powerful magnetic field.
This field may affect 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
medical 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/performing
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 before
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).
Rotating parts
Warning!
Safety guards, shields, barriers, covers and protective devices must not be removed while the
compressor/unit is operating.
Vibration and noise
During operation, pay attention to the compressor unit process. Excessive vibrations, unusual
sounds, etc. may indicate problems requiring your immediate attention.
Pressure
Danger!
A compressor/unit comprises a pressurised system. Never loosen threaded joints while the sys-
tem is under pressure, and never open pressurised system parts.

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Safety
Note: Whenever a relief valve/safety valve has been activated, we recommend recalibrating it.
This must be carried out by competent personnel only. See also EN 378 and existing national
legislation.
2.3.3 Cooling water systems
Warning!
The recirculation water system may contain chemicals or biological contaminants, including le-
gionella, which can be harmful if inhaled or ingested. Water systems should only be operated with
an effective biological treatment programme.
2.3.4 Cooling media
Cooling media (brines) often consist of alcohol, glycol and halogenated compounds.
In general, all brines must be considered harmful to nature, and they must be used with caution.
Be very careful when charging or purging a refrigeration plant.
Disposal of brine
The brine must be collected in suitable containers clearly marked with the contents and sent to an
approved hazardous waste disposal site. However, in some cases, if approved by the local author-
ities, brine can be discharged into the sewage system.
2.3.5 Safety during maintenance and service
• Personnel must be competent according to national safety rules and regulations and per-
form the maintenance work according to EN 378.
• Read 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 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 recom-
mended to remove all main fuses.
• Make sure that there is no over-pressure and no refrigerant in the part to be dismantled.
Close all necessary stop valves.
• Use the prescribed tools, and check that they are properly maintained and in good work-
ing condition. In explosion-proof areas, use tools suited for this specific purpose.
• Use only Johnson Controls Denmark original spare parts; other parts may impair the
safety of the compressor/unit.
• Use gloves and protective goggles, and make sure to have a gas mask close at hand.
2.3.6 Power supply
Danger!
•The voltage used in the drive can cause severe electric shock and/or burns and may be le-
thal. Extreme care must be taken at all times when working with or close to the drive. Spe-
cific warnings are given wherever relevant in this manual.
•The drive line is connected to voltage. Be aware of live circuits.
•Pay close attention to the electrical installation and system maintenance to avoid hazards
both during normal operation or in the event of equipment malfunctioning.