Sabroe DualPAC Operating instructions

NS-HPAC/DualPAC

with reciprocating compressors

Operating manual EN

Operating manual – DualPAC with reciprocating compressors

0012201 en 2022.11 3/71

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

4/71 0012201 en 2022.11

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 2022.11 5/71

Contents

1. Introduction...........................................................................................8

1.1 Amendments to the manual ..........................................................8

1.2 Definition of safety precautions used in this manual ........................9

1.3 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...................................................................... 20

2.3.7 Lubricating oils ................................................................... 20

2.3.8 Refrigerants ....................................................................... 20

2.3.9 Purging of DualPAC ............................................................ 21

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 Motor ................................................................................. 27

3.2.3 Control system ................................................................... 27

3.2.4 Evaporator .........................................................................27

3.2.5 GHUR intermediate cooler...................................................27

3.2.6 Condenser .........................................................................27

3.2.7 Receiver ............................................................................ 28

Operating manual – DualPAC with reciprocating compressors

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3.2.8 Air purge valve ................................................................... 28

3.2.9 Pressure regulation system (electrical) .................................29

3.2.10 LP regulating system ..........................................................29

3.2.11 High-pressure regulation system (electrical).......................... 30

3.2.12 Automatic oil recovery system from evaporator ..................... 31

3.2.13 Automatic oil return from oil separator .................................. 33

3.2.14 By-pass function during start-up...........................................33

3.2.15 WHC circulation system ...................................................... 33

3.2.16 Discharge check valve ........................................................ 35

3.2.17 Function of CVP valves ....................................................... 36

4. Installation information ....................................................................... 37

4.1 General information ................................................................... 37

4.2 First start-up procedure ..............................................................37

4.3 Noise and vibrations................................................................... 38

4.3.1 General information ............................................................ 38

4.3.2 Sound and noise data ......................................................... 38

4.3.3 Foundation.........................................................................39

4.3.4 Vibration dampers............................................................... 39

4.3.5 Variable speed drive............................................................ 39

4.4 Primary system.......................................................................... 40

4.4.1 R717 detector..................................................................... 40

4.4.2 Tightness of Sabroe equipment............................................40

4.5 Secondary system .....................................................................41

4.5.1 General information ............................................................ 41

4.5.2 Guideline for control of secondary sides ............................... 41

4.5.3 Cleaning in place ................................................................ 41

4.5.4 Temperature and flow control............................................... 42

4.5.5 Water and brine treatment ...................................................42

5. Operating instructions ........................................................................43

5.1 Personnel qualification requirements ...........................................43

5.2 Pre-start check .......................................................................... 43

5.3 Starting ..................................................................................... 43

5.3.1 Starting procedures............................................................. 43

5.3.2 Normal start-up procedure................................................... 44

5.3.3 Valve positions during operation...........................................45

5.3.4 Restarting DualPAC after power interruption ......................... 46

5.3.5 Restarting DualPAC after alarm stop (shutdown) ................... 46

5.3.6 Stopping for a brief period.................................................... 47

5.4 During operation ........................................................................47

5.4.1 Checks to be performed during operation .............................47

5.4.2 Monitoring and logging of operation...................................... 47

Operating manual – DualPAC with reciprocating compressors

0012201 en 2022.11 7/71

5.5 Stopping procedures .................................................................. 47

5.5.1 Stopping for a brief period.................................................... 47

5.5.2 Shutting down for a long standstill period .............................. 48

5.6 Shutdown and alarms.................................................................49

5.6.1 Operating state................................................................... 49

5.6.2 Troubleshooting.................................................................. 49

5.6.3 Testing of DualPAC units ..................................................... 50

6. Maintenance instructions .................................................................... 51

6.1 Maintenance of DualPAC units.................................................... 51

6.2 Selecting lubricating oil for DualPAC units....................................52

6.3 R717 charge.............................................................................. 52

7. Final disposal...................................................................................... 53

7.1 Safety precautions .....................................................................53

7.2 Waste disposal .......................................................................... 53

8. Appendices ......................................................................................... 54

8.1 Monitoring of operation............................................................... 54

8.2 Control description - DualPAC..................................................... 55

8.3 Spare parts list for CVUA 1201 oil recovery pot ............................ 56

8.4 Declaration of conformity ............................................................ 57

8.5 Set-up guide - AKS 4100

for ammonia heat pump application ............................................. 58

8.6 Motor installation and alignment instructions ................................ 68

Index ................................................................................................... 70

Operating manual – DualPAC with reciprocating compressors

8/71 0012201 en 2022.11

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 com-

petent 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 +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.

1.1 Amendments to the manual

2022.11 Version 3

• The compressor, vessel and unit pipe system name plates have been updated.

• New section: 4.5.2 Guideline for control of secondary sides.

• New section: 8.6 Motor installation and alignment instructions.

• Section 8.5 Set-up guide - AKS 4100 for ammonia heat pump application has been

updated.

• Various other updates.

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.

Operating manual – DualPAC with reciprocating compressors

0012201 en 2022.11 9/71

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 dam-

age 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 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.

Operating manual – DualPAC with reciprocating compressors

10/71 0012201 en 2022.11

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

following must be observed:

• The unit must only be used as a DualPAC intended for heating and cooling of water or

condensing 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 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 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 speci-

fied 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 ma-

chine room. Some refrigerant types may, to a certain extent, be absorbed by the fuel in a com-

bustion 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 re-

sulting from using the equipment for other purposes than the ones stated above.

Operating manual – DualPAC with reciprocating compressors

0012201 en 2022.11 11/71

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 drawings:

Fig. 1: Positioning of name plates on DualPAC

Pos. no. Designation

1Compressor name plate

2Vessel name plate

3Unit / Pipe system name plate

Operating manual – DualPAC with reciprocating compressors

12/71 0012201 en 2022.11

Safety

2.2.2 Compressor name plates

Test pressure

Allowable pressure

Pressure system

LP side

HP side

Year

Refrigerant

Compressor

Swept volume

Speed

bar

g

bar

g

rpm

m /h

3

1000010131

Max

Type

No

Johnson Controls Denmark ApS

Christian X's Vej 201

8270 Højbjerg, Denmark

www.sabroe.com

MADE IN DENMARK

Fig. 2: Name plate for standard compressor

Test pressure

Allowable pressure

Pressure system

LP side

HP side

Year

Refrigerant

Compressor

Swept volume

Speed

bar

g

bar

g

rpm

m /h

3

1000010132

Max.

Serial

Type

No

Johnson Controls Denmark ApS

Christian X's Vej 201

8270 Højbjerg, Denmark

www.sabroe.com

MADE IN DENMARK

Fig. 3: Name plate for ATEX compressor

Сторона

НД

1000010134

Сторона ВД

Хладагент

бар

Тип

Допустимое давление

макс

K

о

M

п

pe

сc

о

p

o

б

/

мин

м

³

/

ч

P

аб

o

чий

o

бь

e

м

Г

ep

м

e

тичная

сист

e

ма

C

ко

p

и

спытательное

давление

Серийный

СДЕЛАНО В ДАНИИ

№

Johnson Controls Denmark ApS

Christian X's Vej 201

8270 Højbjerg, Denmark

www.sabroe.com

ммгг

Fig. 4: Name plate for compressor with EurAsian Conformity

mark (EAC)

Test pressure

Allowable pressure

Pressure system

LP side

HP side

Year

Refrigerant

Compressor

Swept volume

Speed

psig

rpm

cfm

1000010133

Max.

Serial

Type

No

MADE IN DENMARK

Johnson Controls Denmark ApS

Christian X's Vej 201

8270 Højbjerg, Denmark

www.sabroe.com

Fig. 5: Name plate for compressor to the USA

Operating manual – DualPAC with reciprocating compressors

0012201 en 2022.11 13/71

Safety

The compressor name plate is positioned on the compressor and contains this information:

Serial no. Unique identification 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

calculating 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

maximum allowable pressure, depending on the operating con-

ditions 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 com-

pressor is in compliance with all relevant technical regulations of

the Eurasian Customs Union.

Operating manual – DualPAC with reciprocating compressors

14/71 0012201 en 2022.11

Safety

2.2.3 Vessel name plate

F

E

D

C

B

A

F

E

D

C

B

A

8765

4

32

1

8765

4

32

1

2

6

1

6

1

6646

1

6

1

6

1

6

1

6 18 3

6

1

10

12

21,6

1

422

20

20,5

52

1

13

2

6

R5

R4

105

93

105

93

6

R4

4

18,9

3

1

2

{

- -

Ø3,5

17

Logo, frame, text and square boxes

should be blank on blue (Pantone nr. 661)

Lacquer plate transparent

Material: 0,5 mm AISI 304 plate

Anvendte fonte/Used fonts

#

Hvor

where

Font Eksempel

Example

1Tekst i isbjørn logo

Text in polar bear logo

Arial

2Øvrig tekst

Remaining text

Arial Narrow

Side/Side/Seite

SABROE

WeldingProductionEngineering

Date

Master drw:

Date

Sheet No.

ApplicationSize:

Drawing No.

Scale:

Design std.

Checked by

Modified by

Drawn by

Type of project

Order No.

Designed by

Revision No.

ECN

Title

Rev. Revision description

www.sabroe.com

Christian X's Vej 201

DK-8270 Højbjerg, Denmark

Johnson Controls Denmark ApS

Quality

PED Nameplate for vessel

Danish, English, German

ABR 5-1-2009

ABR 2-6-2022

2516-340

AutoCAD1:1 A3

2516-350

91/1

9 Delete material. equal with rev.6

ABR/24-5-22

Rør/Tube/Rohr

Svøb/Shell/Mantel

bar

L

PS

V

/CAT.

Volumen/Volume

Type/Typ

Beregningsnorm/Design code/

Berechnungsnorm

Godkendelsesnr./

Approval No /Abnahmenummer

Side/Seite

Tilladeligt tryk

Allowable pressure

Zulässiger Druck

2516-350

Medie/Fluid/Medium

Max./Min.

°C

TS

Tilladelig temperatur

Allowable temperature

Zulässige Temperatur Max./Min.

PT

Test tryk

Test pressure

Probedruck bar

kg

Tom vægt/

Empty weight

Leergewicht

År

Year

Jahr

Test date

Probedatum

dd/mm

Nr.

No

Serie/Serien/

Serial

Rør/Tube/Rohr

Svøb/Shell/Mantel

bar

PS

/CAT.

Volumen/Volume

Type/Typ

Beregningsnorm/Design code/

Berechnungsnorm

Tilladeligt tryk

Allowable pressure

Zulässiger Druck

Medie/Fluid/Medium

Max./Min.

Tilladelig temperatur

Allowable temperature

Zulässige Temperatur Max./Min.

Test tryk

Test pressure

Probedruck bar

kg

Nr.

No

Serie/Serien/

Serial

V

Side/Seite

°C

2516-350

PT

L

Godkendelsesnr./

Approval No /Abnahmenummer

TS

Tom vægt/

Empty weight

Leergewicht

6

25,6

/

8

År

Year

Jahr

Test date

Probedatum

dd/mm

Fig. 6: Vessel name plate - CE mark

1 2 3 4 5 6 7 8

A

B

C

D

E

F

A

B

C

D

E

F

1

2

{

ABR

16-4-2004

MKM

9-7-04

QualityProductionEngineering

Date

Master drw:

Date

Sheet No.

ApplicationSize:

Drawing No.

Scale:

Design std.

Checked by

Modified by

Drawn by

Type of project

Order No.

Designed by

Revision No.

ECN

Title

Rev.

Revision description.

www.sabroe.com

DK-8270 Højbjerg, Denmark

Christian X's Vej 201, P.O. Box 1810

PED skilt for beholder Rusisk

Nameplate for vessel Russian- language PED

ABR 7-6-2022

AutoCAD1:1 A3

2516-331

14 1/1

14 Delete material; equal to rev.12

ABR/24-5-22

Logo, frame, text and square boxes

should be blank on blue (Pantone nr. 661)

Lacquer plate transparent

Material: 0,5 mm AISI 304 plate

Anvendte fonte/Used fonts

#

Hvor

where

Font

Eksempel

Example

1

Tekst i isbjørn logo

Text in polar bear logo

Arial

2

Øvrig tekst

Remaining text

Arial Narrow

SABROE

Mасса пустого cocyдa

2

6

1

6

1

66 4 6

1

6

1

6

1

6

1

6

18

3

6

1

10

12

21,6

1

422

22,5

17

52

1

13

2

6

R5

R4

105

93

105

93

6

4

18,9

3

∅3,5

17

Tpyбок

/ Tube

Oбeчaйки / Shell

л

l

PS

V

Oбъeм/Volume

Тип/Type

Пpoeкт пo cтaндapтy

Design code

Утвepждeн пoд N°

Approval No

Cтopoнa

/ Side

Paбoчee двпeниe Макс./Мин.

Allowable pressure Max./Min.

2516-331

Cpeдa/Fluid

°C

TS

Допустимая температура Макс./Мин.

Allowable temperature Мax./Min.

PT

Давление испытания

Test pressure

Mасса пустого

cocyдa

Empty weight

Дата

Test date

Cерийный №

Serial No

.

6

25,6

/

кг

Kg

год

Year

/ Кат.

/Cat.

/

Tpyбок

/ Tube

Oбeчaйки / Shell

MПа

MPa

л

l

V

Oбъeм/Volume

Тип/Type

Пpoeкт пo cтaндapтy

Design code

Утвepждeн пoд N°

Approval No

Cтopoнa

/ Side

2516-331

°C

Mасса пустого

cocyдa

Empty weight

Дата

Test date

Cерийный №

Serial No

.

/

кг

Kg

год

Year

/ Кат.

/Cat.

MПа

MPa

PS

TS

PT

MПа

MPa

MПа

MPa

Oбъeм/Volume

Paбoчee двпeниe Макс./Мин.

Allowable pressure Max./Min.

Допустимая температура Макс./Мин.

Allowable temperature Мax./Min.

Давление испытания

Test pressure

Fig. 7: Vessel name plate - EurAsian Conformity mark (EAC)

The name plate is positioned on the shell of the vessel and contains this information:

Serial no. Vessel identification no.

Empty weight The empty weight of the vessel in kg.

Test date The date of the pressure test.

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 and 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

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

Eurasian Customs Union.

Note: Depending on the supplier of the pressure vessel/heat exchanger, the layout and con-

tent of the vessel name plate may differ from the Sabroe name plate above.

Operating manual – DualPAC with reciprocating compressors

0012201 en 2022.11 15/71

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.

Serial

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

1000010126

MADE IN DENMARK

No

Fig. 8: Name plate for standard unit, with CE mark

Scope

Design code

Approval No

Refrigerant

Supply voltage

Test pressure

Allowable pressure

Category

Pressure system

Refrigerant charge

Max.

Allowable temp.

Min./Max.

Year

Fluid

Group

Control

V/Hz

kg

bar

g

bar

g

°C

LP side

HP side

1000010127

Main

Serial

Type

No

Johnson Controls Denmark ApS

Christian X's Vej 201

8270 Højbjerg, Denmark

www.sabroe.com

MADE IN DENMARK

Fig. 9: Name plate for ATEX unit

Scope

Design code

Approval No

Refrigerant

Supply voltage

Test pressure

Allowable pressure

Category

Pressure system

Refrigerant charge

Max.

Allowable temp.

Min./Max.

Year

Fluid

Group

Control

V/Hz

kg

bar

g

bar

g

°C

LP side

HP side

1000010128

Main

MADE IN DENMARK

Serial

Type

No

Johnson Controls Denmark ApS

Christian X's Vej 201

8270 Højbjerg, Denmark

www.sabroe.com

Fig. 10: Name plate for standard unit, without CE mark

Назначение

Код стандарта

№

сертификата

Хладагент

Группа

Напряжение питания

Управ

ление

В/Гц

Заправка хладагентом

Кг

Давление

бар

Допустимое давление

Давление ислытания

макс

Категория

°

С

Допустимая темп

мин/макс

1000010129

Жидкость

Сеть

Сторона НД

Сторона ВД

ммгг

Тип

Johnson Controls Denmark ApS

Christian X´s Vej 201

8270 Højbjerg, Denmark

www.sabroe.com

СДЕЛАНО В ДАНИИ

Серийный

№

Fig. 11: 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:

Serial No. Unique identification number.

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 sys-

tem.

’Piping’ means that the CE/EAC mark applies to the piping sys-

tem only, and it is the sole responsibility of the owner to ensure

and declare that the complete unit is in conformity with the provi-

sions 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/noti-

fied 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 condi-

tions 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 allow-

able 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 Eura-

sian 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, 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 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 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).

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.

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Safety

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.

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 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 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 approved 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 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 compo-

nents on the compressor/unit before starting the dismantling/servicing process. It is rec-

ommended 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 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.

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Safety

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 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 haz-

ards both during normal operation or in the event of equipment malfunctioning.

•When the cause of the shutdown has been removed, the motor may restart. This can

be dangerous for machines and installations, and it is therefore important that the user

takes adequate precautions against restarting if the motor makes an unscheduled stop.

•System maintenance must always be carried out by personnel who have the necessary

training and experience.

2.3.7 Lubricating oils

Compressor oils include the following oil types:

Code design Oil types

M Mineral oil, naphtenic base

ASynthetic oils based on alkylated aromatics (alkyl-benzene)

AP Synthetic oils blended from alkyl-benzene and poly-alfa-olefin base stocks

S Semi synthetic oils (hydro-treated mineral oil on paraffinic base)

PAO Synthetic oils based on poly-alfa-olefin

POE Synthetic oils based on polyol esters

PAG Synthetic oils based on polyalkylene glycols

See the Sabroe oil recommendation for the recommended type of oil.

Warning!

When charging oil, follow the safety instructions given by the oil supplier (MSDS: Material

Safety Data Sheet). Always avoid direct contact with the oil as this may cause skin allergies.

Always use protective equipment, goggles and gloves, when charging oil.

When changing oil on the compressor or draining oil from the vessel of the refrigeration plant,

always collect the used oil in containers marked “waste oil,” and send them to an approved

hazardous waste disposal site. It is not recommended to reuse oil.

2.3.8 Refrigerants

Be very careful when dealing with refrigerants. For safe handling, please refer to the safety/da-

ta sheets delivered by the refrigerant supplier.

Warning!

Be aware that large amounts of leaking (or released) refrigerant entail a risk of asphyxiation. If

in direct contact with leaking liquid refrigerant, there is a high risk of injuries caused by

frostbite.

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Sabroe DualPAC Operating instructions

Sabroe DualPAC Operating instructions

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