Johnson Controls SABROE HicaHP User manual

Sabroe heat pump units
HicaHP and NS HPAC
Operating manual EN

Operating manual - Sabroe heat pump units
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Manual for Sabroe heat pump unit
Refrigerant R717 Other
Compressor type
Compressor no.
Condenser type Number of cassettes
Evaporator type Number of cassettes
HP control Mechanical float valve
Electronic injection
LP control
Oil cooling
Built into the condenser
Water-cooled plate heat exchanger
Ex-execution (ATEX) Both compressor and unit are safeguarded

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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 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 Compressor name plates .................................................... 14
2.2.3 Vessel name plate ..............................................................16
2.2.4 Unit/pipe system name plate................................................ 17
2.2.5 Signs ................................................................................19
2.3 Safety precautions .....................................................................20
2.3.1 General precautions............................................................ 20
2.3.2 During operation ................................................................. 20
2.3.3 Cooling water systems ........................................................ 21
2.3.4 Cooling media .................................................................... 21
2.3.5 Safety during maintenance and service ................................ 21
2.3.6 Power supply...................................................................... 22
2.3.7 Lubricating oils ................................................................... 22
2.3.8 Refrigerants ....................................................................... 22
2.3.9 Purging a refrigeration plant................................................. 23
2.3.10 First aid for accidents with ammonia..................................... 24
2.3.11 Protecting the operator as well as the environment ................ 25
2.3.12 Emergency stop.................................................................. 26
3. Design and function ............................................................................27
3.1 Unit design ................................................................................27
3.1.1 General information about the Sabroe heat pump unit ...........27
3.1.2 Illustration of a Sabroe heat pump unit.................................. 28
3.2 Main components ...................................................................... 29
3.2.1 Compressor ....................................................................... 29
3.2.2 Control system ................................................................... 29
3.2.3 Evaporator .........................................................................29
3.2.4 Liquid separator.................................................................. 30
3.2.5 Condenser .........................................................................30
3.2.6 Liquid receiver .................................................................... 30
3.2.7 HP regulating system (electrical).......................................... 31

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3.2.8 LP regulating system (electrical) .......................................... 31
3.2.9 Subcooler........................................................................... 32
3.2.10 Suction superheater............................................................ 32
3.2.11 Economiser ........................................................................33
3.2.12 Mechanical high-pressure float valve....................................33
3.2.13 Intermediate cooler ............................................................. 34
3.2.14 Automatic oil recovery system from evaporator ..................... 34
3.2.15 Oil equalisation system ....................................................... 36
3.2.16 Oil level ............................................................................. 37
3.2.17 Service and maintenance .................................................... 37
3.2.18 Pressure equalisation during standstill.................................. 37
3.2.19 Purging the refrigeration plant .............................................. 38
4. Installation information ....................................................................... 39
4.1 Installation................................................................................. 39
4.1.1 General information ............................................................ 39
4.1.2 First start-up procedure .......................................................39
4.2 Sound and vibrations .................................................................40
4.2.1 General information ............................................................ 40
4.2.2 Sound and noise data ......................................................... 41
4.2.3 Foundation.........................................................................41
4.2.4 Vibration dampers............................................................... 41
4.2.5 Heat pump with variable speed drive (VSD) .......................... 41
4.3 Primary system.......................................................................... 42
4.3.1 R717 detector.....................................................................42
4.3.2 Tightness of Sabroe equipment............................................42
4.4 Secondary system .....................................................................43
4.4.1 General information ............................................................ 43
4.4.2 Guideline for control of secondary sides ............................... 43
4.4.3 Cleaning in place ................................................................ 43
4.4.4 Temperature and flow control...............................................44
4.4.5 Water and brine treatment ...................................................44
4.4.6 Handling the Sabroe heat pump...........................................44
5. Operating instructions ........................................................................46
5.1 Personnel qualification requirements ...........................................46
5.2 Pre-start check .......................................................................... 46
5.3 Starting ..................................................................................... 47
5.3.1 Starting procedures............................................................. 47
5.3.2 Normal start-up procedure...................................................47
5.3.3 Restarting the heat pump after power interruption ................. 47
5.3.4 Restarting the heat pump after alarm stop (shutdown) ...........48

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5.4 During operation ........................................................................48
5.4.1 Checks to be performed during operation .............................48
5.4.2 Monitoring and logging of operation...................................... 48
5.5 Stop procedures ........................................................................48
5.5.1 Stopping for a brief period.................................................... 48
5.5.2 Shutting down for a long standstill period .............................. 48
5.6 Shutdowns and alarms ............................................................... 49
5.6.1 Operating state................................................................... 49
5.6.2 Troubleshooting.................................................................. 49
5.6.3 Testing of heat pump units ...................................................51
6. Maintenance instructions .................................................................... 52
6.1 Maintenance of heat pump units.................................................. 52
6.2 Selecting lubricating oil for heat pump units.................................. 53
6.3 R717 charge.............................................................................. 53
7. Final disposal...................................................................................... 54
7.1 Safety precautions .....................................................................54
7.2 Waste disposal .......................................................................... 54
8. Appendices ......................................................................................... 55
8.1 Monitoring of operation............................................................... 55
8.2 Set-up guide - AKS 4100
for ammonia heat pump application ............................................. 56
8.3 Declaration of conformity ............................................................ 66
Index ................................................................................................... 67

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Introduction
1. Introduction
1.1 Introduction to manual
The Sabroe heat pump 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.
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.

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Introduction
1.1.1 Amendments to the manual
2023.02 Version 4
• The title of the manual has been changed from ‘Sabroe heat pump with screw com-
pressor’ to ‘Sabroe heat pump units, HicaHP and NS HPAC’.
• The compressor, vessel and unit pipe system name plates have been updated
• Chapter 3. Design and function has been updated.
• Chapter 4. Installation information has been updated.
• Chapter 5. Operating instructions has been updated.
• Additional minor updates.
2018.10 Version 3
• ‘Cooling media’ section updated.
• Updated version of declaration of conformity for unit.
2018.02 Version 2
• The name ‘HeatPAC’ has been replaced by ‘Sabroe heat pump’ in this manual. Our
heat pump portfolio has been redefined and now comprises two product families:
HeatPACs and Sabroe heat pumps.
• 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.
This manual does not include instructions for the:
• Compressor
• UniSAB III controller
• Chiller and Heat Pump Plant Controller (CHPPC).
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.