Johnson Controls SABROE NS-HPAC User manual

NS-HPAC/DualPAC
with reciprocating compressors
Operating manual EN

Operating manual – DualPAC with reciprocating compressors
0012201 en 2021.04 3/64
Manual for DualPAC heat pump
Unit type
Compressor types
Designations
Compressor nos.
Refrigerant R717
Oil type PAO 100 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
Motor IP23 IP55 Δ/D VSD
Power: ______ kW Size IEC: ______
Ex-execution
Both compressor and unit are safeguarded

Operating manual – DualPAC with reciprocating compressors
4/63 0012201 en 2021.04
Safety valve:
Data for calculation of
downstream line accord-
ing to EN 13136
Vessel data
Type External surface
[m2]
Design pressure
[bar]
Condenser HP
Condenser LP
Evaporator
Oil separator HP
Oil separator LP
Oil cooler
Intermediate vessel
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

Operating manual – DualPAC with reciprocating compressors
0012201 en 2021.04 5/63
Contents
1. Introduction ..................................................................................... 8
1.1 Definition of safety precautions used in this manual ............. 9
1.2 Requirements for competent persons .................................... 9
2. Safety............................................................................................... 10
2.1 Area of application................................................................. 10
2.1.1 Application of the DualPAC pump .................................. 10
2.1.2 Application of combustion engines ................................ 10
2.2 Identification ......................................................................... 11
2.2.1 Identification of equipment............................................ 11
2.2.2 Compressor name plates ............................................... 12
2.2.3 Vessel name plate .......................................................... 14
2.2.4 Unit/pipe system name plate......................................... 15
2.2.5 Signs .............................................................................. 17
2.3 Safety precautions ................................................................ 18
2.3.1 General precautions ....................................................... 18
2.3.2 During operation ............................................................ 18
2.3.3 Water system.................................................................. 19
2.3.4 Brine................................................................................ 19
2.3.5 Safety during maintenance and service ........................ 19
2.3.6 Power supply .................................................................. 19
2.3.7 Lubricating oils ............................................................... 20
2.3.8 Refrigerants .................................................................... 20
2.3.9 Purging of DualPAC......................................................... 20
2.3.10 First aid for accidents with ammonia ............................. 22
2.3.11 Protecting the operator as well as the
environment ................................................................... 23
2.3.12 Emergency stop.............................................................. 24
3. Design and function ...................................................................... 25
3.1 Unit design............................................................................. 25
3.1.1 General DualPAC information ........................................ 25
3.1.2 DualPAC description ....................................................... 26
3.2 Main components .................................................................. 27
3.2.1 Compressors................................................................... 27
3.2.2 Control system ............................................................... 27
3.2.3 Evaporator ...................................................................... 27
3.2.4 GHUR intermediate cooler ............................................. 27
3.2.5 Condenser ...................................................................... 27
3.2.6 Receiver .......................................................................... 28
3.2.7 Air purge valve ............................................................... 28
3.2.8 Pressure regulation system (electrical)......................... 29

Operating manual – DualPAC with reciprocating compressors
6/63 0012201 en 2021.04
3.2.9 Automatic oil recovery system from evaporator........... 30
3.2.10 Automatic oil return from oil separator ......................... 31
3.2.11 By-pass function during start-up................................... 31
3.2.12 WHC circulation system ................................................. 31
3.2.13 Discharge check valve.................................................... 33
3.2.14 Function of CVP valves ................................................... 34
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.......................................................... 37
4.2.5 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 DualPAC after power interruption................ 42
5.3.5 Restarting DualPAC after alarm stop
(shutdown) ..................................................................... 42
5.3.6 Stopping for a brief period ............................................. 43
5.4 During operation ................................................................... 43
5.4.1 Checks to be performed during operation..................... 43
5.4.2 Monitoring and logging of operation.............................. 43
5.5 Stopping procedures ............................................................. 43
5.5.1 Stopping for a brief period ............................................. 43
5.5.2 Shutting down for a long standstill period..................... 44

Operating manual – DualPAC with reciprocating compressors
0012201 en 2021.04 7/63
5.6 Shutdown and alarms ........................................................... 45
5.6.1 Operating state............................................................... 45
5.6.2 Troubleshooting.............................................................. 45
5.6.3 Testing of DualPAC units ................................................ 46
6. Maintenance instructions............................................................ 47
6.1 Maintenance of DualPAC units .............................................. 47
6.2 Selecting lubricating oil for DualPAC units ........................... 48
6.3 R717 charge........................................................................... 48
7. Final disposal ................................................................................. 49
7.1 Safety precautions ................................................................ 49
7.2 Waste disposal....................................................................... 49
8. Appendices ..................................................................................... 50
8.1 Monitoring of operation ......................................................... 50
8.2 Control description - DualPAC............................................... 51
8.3 Spare parts list for CVUA 1201 oil recovery pot ................... 52
8.4 Declaration of conformity...................................................... 53
8.5 Set-up guide — AKS 4100 280 mm
for ammonia heat pump application ..................................... 54
Index................................................................................................ 62

Operating manual – DualPAC with reciprocating compressors
8/63 0012201 en 2021.04
Introduction
1. Introduction
This manual is primarily intended for operators and engineers.
It describes the combined service of a HeatPAC heat pump and a ChillPAC chiller when these are
operating as a DualPAC.
To prevent accidents, assembly and disassembly of components should be carried out by compe-
tent persons 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.
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.

Operating manual – DualPAC with reciprocating compressors
0012201 en 2021.04 9/63
Introduction
1.1 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.
1.2 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.

Operating manual – DualPAC with reciprocating compressors
10/63 0012201 en 2021.04
Safety
2. Safety
2.1 Area of application
2.1.1 Application of the DualPAC pump
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 DualPAC intended for heating and cooling of water or con-
densing refrigerant gas in the evaporator.
• 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
process 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 DualPAC is fitted with approved explosion-proof equipment.
• The compressor must only be used as a compressor within the operating limits specified
in the compressor 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 DualPAC 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.