Johnson Controls SABROE HeatPAC User manual

HeatPAC
with reciprocating compressor
Operating manual EN

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Manual for HeatPAC
Unit type HeatPAC with reciprocating compressor
Compressor type
Designation
Compressor no.
Refrigerant R717
Oil type PAO 100 Other _____________
Approval PED (2014/68/EU) Other _____________
Supply voltage Motor 3 x _________ V/ _________ Hz
Control 1 x _________ V / _________ Hz
Motor IP23 IP55 Δ / D VSD
Power _________ kw Size IEC _________
Ex-execution (ATEX) Both compressor and unit are safeguarded

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Safety valve:
Data for calculation of down-
stream line according 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 Amendments to the manual ..........................................................8
1.2 Definition of safety precautions used in this manual ......................10
1.3 Requirements for competent persons .......................................... 10
2. Safety .................................................................................................. 11
2.1 Areas of application.................................................................... 11
2.1.1 Application of the heat pump................................................ 11
2.1.2 Application of combustion engines ....................................... 11
2.2 Identification .............................................................................. 12
2.2.1 Identification of equipment...................................................12
2.2.2 Compressor name plates .................................................... 13
2.2.3 Vessel name plate ..............................................................15
2.2.4 Unit/pipe system name plate................................................ 16
2.2.5 Signs ................................................................................18
2.3 Safety precautions .....................................................................19
2.3.1 General precautions............................................................ 19
2.3.2 During operation .................................................................19
2.3.3 Water system .....................................................................20
2.3.4 Brine.................................................................................. 20
2.3.5 Safety during maintenance and service ................................ 20
2.3.6 Power supply...................................................................... 20
2.3.7 Lubricating oils ................................................................... 21
2.3.8 Refrigerants ....................................................................... 21
2.3.9 Purging of heat pump ..........................................................21
2.3.10 First aid for accidents with ammonia..................................... 23
2.3.11 Protecting the operator as well as the environment ................ 24
2.3.12 Emergency stop.................................................................. 25
3. Design and function ............................................................................26
3.1 Unit design ................................................................................26
3.1.1 General HeatPAC information.............................................. 26
3.1.2 HeatPAC description ........................................................... 27
3.2 Main components ...................................................................... 28
3.2.1 Compressor ....................................................................... 28
3.2.2 Control system ................................................................... 28
3.2.3 Evaporator .........................................................................28
3.2.4 Cascade evaporator............................................................ 28
3.2.5 Condenser .........................................................................28
3.2.6 Receiver ............................................................................28
3.2.7 Air purge valve ................................................................... 29

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3.2.8 High-pressure regulation system (electrical).......................... 30
3.2.9 Automatic oil recovery system from evaporator ..................... 30
3.2.10 Automatic oil return from oil separator .................................. 32
3.2.11 By-pass function during start-up...........................................33
3.2.12 WHC circulation system ......................................................33
4. Installation information ....................................................................... 35
4.1 Installation................................................................................. 35
4.1.1 General information ............................................................ 35
4.1.2 First start-up procedure .......................................................35
4.2 Sound and vibrations .................................................................36
4.2.1 General information ............................................................ 36
4.2.2 Sound and noise data ......................................................... 36
4.2.3 Foundation.........................................................................36
4.2.4 Vibration dampers............................................................... 36
4.2.5 HeatPAC with variable 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 operation...........................................41
5.3.4 Restarting the heat pump after power interruption ................. 42
5.3.5 Restarting the heat pump after alarm stop (shutdown) ...........42
5.4 During operation ........................................................................42
5.4.1 Checks to be performed during operation .............................42
5.4.2 Monitoring and logging of operation...................................... 42
5.5 Stopping procedures .................................................................. 42
5.5.1 Stopping for a brief period.................................................... 42
5.5.2 Shutting down for a long standstill period .............................. 43
5.6 Shutdown and alarms.................................................................43
5.6.1 Operating state................................................................... 43
5.6.2 Troubleshooting.................................................................. 43
5.6.3 Testing of HeatPAC units ..................................................... 45

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6. Maintenance instructions .................................................................... 46
6.1 Maintenance of heat pump units.................................................. 46
6.2 Selecting lubricating oil for heat pump units.................................. 47
6.3 R717 charge.............................................................................. 47
7. Final disposal...................................................................................... 48
7.1 Safety precautions .....................................................................48
7.2 Waste disposal .......................................................................... 48
8. Appendices ......................................................................................... 49
8.1 Monitoring of operation............................................................... 49
8.2 Spare parts list for CVUA 1201 oil recovery pot ............................ 50
8.3 High-pressure float valve for cascade evaporator .........................51
8.4 Declaration of conformity ............................................................ 52
8.5 Set-up guide — AKS 4100 280 mm
for ammonia heat pump application ............................................. 53
Index ................................................................................................... 61

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Introduction
1. Introduction
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 competent
personnel only.
• It is important that the operating personnel familiarise themselves with the contents of this man-
ual in order to ensure a proper and efficient operation. Johnson Controls Denmark is not liable
for damage occurring during the warranty period where this is attributable to incorrect operation.
• All compressor intervention within the warranty period must be performed by competent person-
nel only. If not, the warranty no longer applies.
1.1 Amendments to the manual
2021.07 Version 6
• Copy of declaration of conformity removed from the manual. It is now only contained in the
printed manual delivered with the unit and the pdf version uploaded with the order specific
documentation.
• Various minor changes and new coverpage design.
2019.04 Version 5
• Updated designs/drawings of receivers, high-pressure regulation, by-pass function during
start-up and WHC circulation system.
• Set-up guide for AKS 4100 - 280 mm level sensor included.
• Various corrections/changes.
2018.12 Version 4
• Updated version of declaration of conformity for unit.
2017.12 Version 3
• Name plates with EurAsian Conformity mark (EAC) have been added.
• ‘Requirements for competent persons’ section has been added.
• Updated version of declaration of conformity for unit.
• And more.

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Introduction
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.
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 language, the
English version will prevail.

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Introduction
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.
1.3 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 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 of the heat pump
To prevent unintentional application, which could injure personnel or damage equipment, the following
must be observed:
• The unit must only be used as a heat pump intended for heating and cooling of water or brine.
• 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 compressor unit
and plant parts caused by torsional oscillation or the like which is attributable to built-in VSD sol-
utions initiated by the customer after delivery.
• The secondary side on the evaporator and condenser is only intended for water or brine as proc-
ess medium. The secondary medium is stated in the P&I diagram. Deviations are only permitted
with a written permission from Johnson Controls Denmark.
• Installation of the heat pump/unit in potentially explosive atmospheres must only take place if
the heat pump is fitted with approved explosion-proof equipment.
• The compressor must only be used as a compressor within the operating limits specified in the
manual or in a written agreement with Johnson Controls Denmark.
• The compressor must only be used with the number of revolutions per minute, as shown on the
compressor name plate.
The compressor must NOT be used:
• To evacuate the heat pump of air and moisture
• To put the heat pump 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 destroy 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 posi-
tioned as illustrated in the following drawings:
Fig. 1
Pos. no. Designation
1Compressor name plate
2Vessel name plate
3Unit / Pipe system name plate
223
1
2

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Safety
2.2.2 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. 2: 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. 3: Name plate for ATEX compressor
Fig. 4: Name plate for compressor with EurAsian Conformity
mark (EAC)
Johnson Controls Denmark ApS
Christian X's Vej 201
8270 Højbjerg, Denmark
www.sabroe.com
Test pressure
Allowable pressure
Pressure system
LP side HP side
Year No
Type
Refrigerant
Compressor
Swept Volume
Speed
psig
psig
rpm
cfm
2516-347
Max.
Fig. 5: 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 calculat-
ing swept volume. For the actual allowed operating speed, please refer
to the operating limits and Matchmaster's calculation on the actual op-
erating 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 maximum
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 designed
in accordance with the EC ATEX directive.
EAC
The EurAsian Conformity mark (EAC) indicates that the compressor is
in compliance with all relevant technical regulations of the Eurasian
Customs Union.

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Safety
2.2.3 Vessel name plate
Fig. 6: 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. 7: 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 refrigerant
(s).
For EC PED approval: Designation of the refrigerant(s) and/or the
highest fluid group (Group 1 or 2) according to the PED directive.
Allowable pressure, PS The min. and max. pressures (pressure relative to atmospheric pres-
sure) 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 Eurasian Cus-
toms 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
2.2.4 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. 8: 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. 9: 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. 10: 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 on-
ly, 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 maximum
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 com-
pliance 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
2.2.5 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 refriger-
ant R290
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 Ni-
trogen (N2) to an overpressure of 0.5 bar
[7.3 PSI].
In such cases, a yellow sign is affixed to a
visible spot on the compressor.
The magnetic field on the rotor may affect
pacemakers. The motor rotor contains a
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 pace-
makers 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 mi-
nutes 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 included 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 mainte-
nance 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 work-
ing 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 re-
sponsible for ensuring that all codes, regulations and industry standards are complied with.
2.3.2 During operation
Warning!
All safety features, disengagement and interlocks must be in place and function correctly before the
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 refrig-
erant 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 compres-
sor/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 system 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 Water system
Warning!
The recirculation water system may contain chemicals or biological contaminants, including legionella,
which can be harmful if inhaled or ingested. Water systems should only be operated with an effective bi-
ological treatment programme.
2.3.4 Brine
In recent years alcohol, glycol and halogenated compounds have been used in the production of brine.
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.
Never empty brines down a sewer or into the environment.
The brine must be collected in suitable containers clearly marked with the contents and sent to an ap-
proved incineration plant.
2.3.5 Safety during maintenance and service
• Personnel must be competent according to national safety rules and regulations and perform
the maintenance work according to EN 378 and EN 13313/ISO 22712.
• Read chapter 2. Safety in this manual before opening the compressor and other parts of the re-
frigeration plant. If the switch is not locked, all start buttons must be tagged with “DO NOT
START” tags and an explanation: “Work on unit in progress”.
• Make sure that the motor cannot start up inadvertently. Switch off all electric components on the
compressor/unit before starting the dismantling/servicing process. It is recommended 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 working con-
dition. 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 lethal.
Extreme care must be taken at all times when working with or close to the drive. Specific warn-
ings 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.