Sabroe ChillPAC Air Operating instructions

Brand: Sabroe

Model: ChillPAC Air

Type: Operating instructions

ChillPAC Air

Chiller unit with reciprocating compressor

Operating manual EN

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Manual for ChillPAC Air

The Sabroe chiller unit can be configured with various types of equipment depending on its

function, requirements and the outdoor temperature. 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:

• ChillPAC

• Compressor

• UniSAB III controller

• Enclosure

• Air-cooled condenser

You can find the compressor number and the equipment configured on your unit in the

ChillPAC manual uploaded with your order.

ChillPAC Air type Standard Winter 1 Winter 2

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Contents

1. Introduction...........................................................................................6

1.1 Introduction to manual..................................................................6

1.1.1 Models covered ....................................................................6

1.1.2 Definition of safety precautions used in this manual .................7

1.1.3 Requirements for competent persons .....................................7

2. Safety ....................................................................................................8

2.1 Areas of application......................................................................8

2.1.1 Application ...........................................................................8

2.2 Identification ................................................................................9

2.2.1 Identification of equipment.....................................................9

2.2.2 Unit/pipe system name plate..................................................9

2.2.3 Compressor name plate ........................................................9

2.2.4 Vessel name plate ................................................................9

2.2.5 Condenser name plate ..........................................................9

2.2.6 Signs ................................................................................. 10

2.3 Safety precautions ..................................................................... 11

2.3.1 General precautions............................................................ 11

2.3.2 During operation ................................................................. 11

3. Design and function ............................................................................12

3.1 Unit design ................................................................................ 12

3.1.1 General information about ChillPAC Air ................................ 12

3.1.2 Components on a ChillPAC Air (standard unit) ......................13

3.1.3 Components on a ChillPAC Air (winter 1 unit)........................ 14

3.1.4 Components on a ChillPAC Air (winter 2 unit)........................ 15

3.2 Main components ...................................................................... 16

3.2.1 Enclosure........................................................................... 16

3.2.2 Compressor and oil separator.............................................. 16

3.2.3 Control system ................................................................... 16

3.2.4 Evaporator .........................................................................16

3.2.5 Condenser .........................................................................16

3.2.6 Receiver ............................................................................ 18

3.2.7 Sight glass in the liquid line.................................................. 18

3.2.8 Air purge valve ................................................................... 19

3.2.9 Low pressure (LP) regulating system....................................19

3.2.10 Automatic oil recovery system from evaporator ..................... 19

3.2.11 Automatic oil return from the oil separator ............................. 19

3.2.12 Alarm for high level in the evaporator....................................19

3.2.13 Safety valves...................................................................... 20

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4. Installation information ....................................................................... 21

4.1 General information ................................................................... 21

4.2 First start-up procedure ..............................................................21

4.3 Noise and vibrations................................................................... 21

4.4 Secondary system .....................................................................22

5. Operating instructions ........................................................................23

5.1 General information ................................................................... 23

5.2 Pre-start check .......................................................................... 23

5.3 Valve positions during operation.................................................. 24

5.4 Starting ..................................................................................... 31

5.4.1 Starting procedures............................................................. 31

5.4.2 Normal start-up procedure...................................................31

5.5 During operation ........................................................................31

5.6 Stopping procedures .................................................................. 31

5.7 Shutdowns and alarms ............................................................... 32

5.8 Troubleshooting.........................................................................32

6. Maintenance instructions .................................................................... 33

6.1 Maintenance of the chiller unit..................................................... 33

6.2 Selecting lubricating oil for ChillPAC Air units ............................... 33

6.3 R717 charge.............................................................................. 33

7. Final disposal...................................................................................... 34

7.1 Safety precautions .....................................................................34

7.2 Waste disposal .......................................................................... 34

8. Appendices ......................................................................................... 35

8.1 Spare parts list for ChillPAC Air ................................................... 35

8.2 Declaration of conformity ............................................................ 35

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Introduction

1. Introduction

1.1 Introduction to 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 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.

1.1.1 Models covered

The ChillPAC Air manual covers three types of air-cooled chillers:

• ChillPAC Air standard:

Normal operation condition, with adjusted refrigerant charge.

• ChillPAC Air winter 1:

Winterization below 0°C down to -10°C ambient temperature, with valves and adjusted

refrigerant charge.

• ChillPAC Air winter 2:

Winterization below -10°C ambient temperature, with valves and receiver with addition-

al refrigerant charge.

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 +45 87 36 70 00

CVR No 19 05 61 71

www.sabroe.com

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.

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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

following 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 com-

pressor unit and plant parts caused by torsional oscillation or the like which is attribut-

able to built-in VSD solutions initiated by the customer after delivery.

• The secondary side on the evaporator is only intended for water or brine as cooling me-

dium. The secondary medium is stated on the P&I diagram. Deviations are only permit-

ted 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 oper-

ating limits specified in the manual or in a written agreement with Johnson Controls

Denmark.

• The compressor must only be used with the rpm shown on the compressor name plate.

• The unit is designed for outdoor installation on a roof or at ground level. (Follow EN

378-1, ISO 5149-1 or EN 60079-10.)

• The secondary side on the condenser is only intended for air as cooling medium.

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.

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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

1 Compressor (see the ChillPAC manual)

2 Evaporator (see the ChillPAC manual)

3 Oil separator (see the ChillPAC manual)

4Receiver (see the ChillPAC manual)

5Unit/pipe system (see the ChillPAC manual)

6 Enclosure (see the enclosure manual) - not shown

7Air-cooled condenser (see the condenser manual) - not shown

2.2.2 Unit/pipe system name plate

See the ChillPAC manual.

Depending on the type of declaration of conformity, the unit can be identified as follows:

• Complete unit with one declaration of conformity and one overall name plate, (see sec-

tion 8.2).

• Separate units with partial declaration of conformity and separated name plates for

each unit, (see section 8.2).

2.2.3 Compressor name plate

See the ChillPAC manual.

2.2.4 Vessel name plate

See the ChillPAC manual.

2.2.5 Condenser name plate

See air-cooled condenser manual.

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Safety

2.2.6 Signs

All signs which may be found on your equipment are shown below. The number of signs, how-

ever, 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 refrig-

erant R290

Gas under pressure Corrosive Toxic Dangerous to the

environment

No unauthorised

access

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

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 af-

fect 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 medi-

cal 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/perform-

ing 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 be-

fore 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

inside the ventilated enclosure).

For further information, see the ChillPAC Mk 3 manual.

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Design and function

3. Design and function

3.1 Unit design

3.1.1 General information about ChillPAC Air

The ChillPAC Air unit is a complete, factory-manufactured chiller unit intended for water or

brine cooling and equipped with an air-cooled condenser.

ChillPAC Air only uses ammonia (R717) as refrigerant. Once the unit is charged with R717,

connected to electricity, and pipe connections to water/brine have been established, it is ready

for operation.

The unit is provided with adjustable anti-vibration machine feet for installation on a solid con-

crete floor. For installation on decks, special vibration dampers are often required.

ChillPAC Air is delivered as a split unit. The chiller section is pressure and function tested from

the factory without condenser, according to existing EU directives (CE marked).

For specific dimensions and size of connections, see the P&I diagram and GA drawing.

Area of operation

The chiller is available in three different designs made for operation in different outdoor tem-

perature ranges.

ChillPAC Air standard - The standard unit is designed for ambient conditions down to 0° C

with adjusted refrigerant charge and without receiver.

ChillPAC Air winter 1 - The winter 1 unit is designed for ambient conditions below 0°C down

to -10°C, with adjusted refrigerant charge and without receiver. An electrical motor valve in the

discharge line and a stop/check valve in the liquid line ensures that refrigerant from the evapo-

rator does not flow to the condenser when the condenser is located colder than the evaporator

in periods when the compressor is not operating.

ChillPAC Air winter 2 - The winter 2 unit is designed for ambient conditions below -10°C, with

a receiver and additional refrigerant charge. Electrical motor valves in the discharge line, liquid

line and equalization line secure that refrigerant from the evaporator and receiver does not flow

to the condenser when the condenser is located colder than the evaporator in periods when

the compressor is not operating.

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Design and function

3.1.2 Components on a ChillPAC Air (standard unit)

Fig. 2: ChillPAC Air with position numbers (standard unit)

Pos. no. Component

1 Evaporator/Liquid separator

2 Oil separator

4 Inlet evaporator

5Outlet evaporator

6 Expansion valve with built-in stop/check valve

7 Liquid level column and level sensor

8 Compressor

9 UniSAB lll controller and emergency stop (built into electrical panel)

10 Motor

11 Oil recovery system (from evaporator)

12 Liquid inlet (from condenser)

14 Oil return system (from oil separator)

15 R717 charge valve

16.a Drain valve (from liquid line)

17 Electrical panel

18 High level alarm

19 Discharge outlet (to condenser)

22 Sight glass (liquid line)

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Design and function

3.1.3 Components on a ChillPAC Air (winter 1 unit)

Fig. 3: ChillPAC Air with position numbers (winter 1 unit)

Pos. no. Component

1 Evaporator/Liquid separator

2 Oil separator

4 Inlet evaporator

5Outlet evaporator

6 Expansion valve (with built-in stop/check valve)

7 Liquid level column and level sensor

8 Compressor

9 UniSAB lll controller and emergency stop (built into electrical panel)

10 Motor

11 Oil recovery system (from evaporator)

12 Liquid inlet (from condenser)

14 Oil return system (from oil separator)

15 R717 charge valve

16.a Drain valve (from liquid line)

17 Electrical panel

18 High level alarm

19 Discharge outlet (to condenser)

20 Electrical motor valve (discharge line)

22 Sight glass (liquid line)

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Design and function

3.1.4 Components on a ChillPAC Air (winter 2 unit)

Fig. 4: ChillPAC Air with position numbers (winter 2 unit)

Pos. no. Component

1 Evaporator/Liquid separator

2 Oil separator

3 Receiver

4 Inlet evaporator

5Outlet evaporator

6 Expansion valve

7 Liquid level column and level sensor

8 Compressor

9 UniSAB lll controller and emergency stop (built into electrical panel)

10 Motor

11 Oil recovery system (from evaporator)

12 Liquid inlet (from condenser)

13 Equalizing receiver (from condenser)

14 Oil return system (from oil separator)

15 R717 charge valve

16 Drain valve (from receiver)

16.a Drain valve (from liquid line)

17 Electrical panel

18 High level alarm

19 Discharge outlet (to condenser)

20 Electrical motor valve (discharge line)

21 Electrical motor valve (liquid line)

22 Sight glass (liquid line)

23 Solenoid valve (equalizing line)

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Design and function

3.2 Main components

The ChillPAC Air consists of a unit with cooling circuit, water supplies, electrical panel and con-

trol system built into a sound damping enclosure on a steel frame. It is supplied with an air-

cooled condenser with pipe connections - or without pipe connections for customer manufac-

ture of piping connections.

The ChillPAC Air chiller unit and condenser must be level, and it is therefore recommended to

install the units on machine feet.

For further information, see the ChillPAC Mk 3 manual.

3.2.1 Enclosure

The enclosure is made of aluminium profiles, mounted with perforated galvanised steel plates

inside and aluzinc plates outside. The base frame is hot-dip galvanised in weather-resistant

design. Isolation thickness is 50 mm in panels and 40 mm in doors.

The enclosure is equipped with mechanical ventilation to ensure sufficient air change inside

the enclosure to avoid accumulation of refrigerant gases.

3.2.2 Compressor and oil separator

The ChillPAC Air is equipped with a Sabroe SMC reciprocating compressor, complete with stop

valves, motor, etc. and a standard separate oil separator built into the enclosure. For more in-

formation, see the compressor operating manual.

3.2.3 Control system

The ChillPAC Air is delivered with UniSAB III monitoring, safety and capacity regulating system

and supplemented with an independent condenser controller to control fan speed.

3.2.4 Evaporator

The ChillPAC Air is equipped with a standard evaporator, fully welded plate heat exchanger as

described in the ChillPAC Mk 3 operating manual.

The R717 droplets are separated from the vapour in the separator room above the plates. The

evaporator has one or two sets of brine connections depending on size and operating condi-

tions. A sight glass is mounted at the end cover.

3.2.5 Condenser

The ChillPAC Air is equipped with an air-cooled V-coil condenser. The heat exchanger is made

of stainless steel pipes with aluminium fins, and it is built into an enclosure of galvanised steel

plate (painted).

The condenser is equipped with speed-regulated axial fans with EC motors, protection class

IP54.

Fig. 5: V-coil condenser with two refrigerant circuits

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Design and function

Condenser with two refrigerant circuits in parallel (standard and winter 1 unit)

To obtain maximum condenser efficiency under all operating conditions, follow these require-

ments when installing the remote condenser:

1. Place the condenser close to the unit with short piping to reflect the pressure drop be-

tween the condenser and unit as low as possible. Elevate the condenser to increase air

flow and to obtain sufficient height of the vertical liquid legs.

2. The height “H” of the vertical liquid legs from each coil outlet should be min. 1 m for am-

monia R717 to equalize any difference in coil outlet pressure. All reductions in liquid

drain lines must be made in vertical piping.

3. Liquid pipe connection between the condenser and the ChillPAC Air enclosure.

4. The discharge piping should be as symmetrical as possible in order to equalize the

pressure drop to each individual condenser circuits.

Note: If it is not possible to place the condenser close to the unit, and the discharge lines are

long and have a large pressure design drop, allowance must be made in either the compressor

or condenser selection.

Contact Johnson Controls Denmark for further information.

Fig. 6: Two condenser refrigerant circuits in parallel with vertical liquid legs.

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Design and function

Condenser with two refrigerant circuits in parallel connected to a receiver (winter 2 unit)

To obtain maximum condenser efficiency under all operating conditions, follow these require-

ments when installing the remote condenser:

1. Place the condenser close to the unit with short piping to reflect the pressure drop be-

tween the condenser and unit as low as possible. Elevate the condenser to increase air

flow and to obtain sufficient height of the vertical liquid legs.

2. To equalize difference in coil outlet pressures it is essential to use trapped vertical liquid

legs from each condenser outlet to the receiver. The height “H” of the vertical liquid legs

from each coil outlet should be min. 1 m for ammonia R717 to equalize any difference

in coil outlet pressure. All reductions in liquid drain lines must be made in vertical

piping.

3. Liquid pipe connection between the condenser and the ChillPAC Air enclosure.

4. The discharge piping should be as symmetrical as possible in order to equalize the

pressure drop to each individual condenser circuits.

5. The equalizing line equalizes the pressure between the receiver and both condenser

coil outlets to obtain a free flow of refrigerant liquid from the condenser outlet to the re-

ceiver. The pressure equalizing is connected in parallel without U-trap as close to both

coil outlets as possible after the flange connections at the top of the vertical legs. See

detail drawing below.

Fig. 7: Two condenser refrigerant circuits in parallel with vertical liquid legs and pressure equalising.

3.2.6 Receiver

The ChillPAC Air standard unit and winter 1 unit are equipped with adjusted refrigerant charge

without a receiver.

The ChillPAC Air winter 2 unit is equipped with a receiver to accumulate the refrigerant liquid

coming from the condenser.

Please see the ChillPAC manual for information about connections and sight glasses, which

are all located on the flat end cover.

3.2.7 Sight glass in the liquid line

The ChillPAC Air standard unit and winter 1 unit are equipped with a sight glass positioned in

the liquid line close to the LP regulating system for view of the liquid flow. If a gas/liquid mixture

(bubbles) is detected in the sight glass, it indicates that the subcooling is insufficient and can

be solved by charging more refrigerant.

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Design and function

Fig. 8: Sight glass

3.2.8 Air purge valve

If there is air in the refrigeration plant, it tends to accumulate in the receiver and the condenser.

On ChillPAC Air, the air purge valve is fitted either on top of the receiver and/or the condenser

at the highest point in the discharge line before the condenser inlets and at the condenser

outlets.

During air purging, the air purge valve should be connected to an open vessel containing water

via a refrigerant hose. The air will leave the water as bubbles, whereas the R717 gas will be

absorbed by the water.

See the ChillPAC manual for more information.

3.2.9 Low pressure (LP) regulating system

The ChillPAC Air is equipped with an LP regulating system.

The principal function of the LP regulating system is to keep a constant level of R717 in the

evaporator.

See the ChillPAC manual for further information.

3.2.10 Automatic oil recovery system from evaporator

See the ChillPAC manual for further information.

3.2.11 Automatic oil return from the oil separator

See the ChillPAC manual for further information.

3.2.12 Alarm for high level in the evaporator

The ChillPAC Air has a level switch.

See the ChillPAC manual for further information.

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Design and function

3.2.13 Safety valves

The safety valves are individually approved in accordance with existing standards under PED

from the manufacturer.

In each case, the customer must be asked if special rules apply in the user country for safety

valves with release into free air as this area is governed by national rules.

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Sabroe ChillPAC Air Operating instructions

Brand: Sabroe

Model: ChillPAC Air

Type: Operating instructions

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Sabroe ChillPAC Air Operating instructions

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