Johnson Controls SABROE HeatPAC Manuel utilisateur

HeatPAC

with reciprocating compressor

Operating manual EN

Operating manual - HeatPAC with reciprocating compressor

009332 en 2021.07 3/62

Manual for HeatPAC

Unit type HeatPAC with reciprocating compressor

Compressor type

Designation

Compressor no.

Refrigerant R717

Oil type PAO 100 Other _____________

Approval PED (2014/68/EU) Other _____________

Supply voltage Motor 3 x _________ V/ _________ Hz

Control 1 x _________ V / _________ Hz

Motor IP23 IP55 Δ / D VSD

Power _________ kw Size IEC _________

Ex-execution (ATEX) Both compressor and unit are safeguarded

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Safety valve:

Data for calculation of down-

stream line according to EN

13136

Vessel data

Type External surface

[m2]

Design pressure

[bar]

Condenser

Float housing

Evaporator

Liquid separator

Oil separator

Oil cooler

Receiver

Economiser

Desuperheater

Subcooler

Other

Pressure loss, if any, from safety valve to customer connection (based on

design pressure) [bar] _____________

Safety valve type:

Back-pressure dependent

Back-pressure independent

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Contents

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

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

1.2 Definition of safety precautions used in this manual ......................10

1.3 Requirements for competent persons .......................................... 10

2. Safety .................................................................................................. 11

2.1 Areas of application.................................................................... 11

2.1.1 Application of the heat pump................................................ 11

2.1.2 Application of combustion engines ....................................... 11

2.2 Identification .............................................................................. 12

2.2.1 Identification of equipment...................................................12

2.2.2 Compressor name plates .................................................... 13

2.2.3 Vessel name plate ..............................................................15

2.2.4 Unit/pipe system name plate................................................ 16

2.2.5 Signs ................................................................................18

2.3 Safety precautions .....................................................................19

2.3.1 General precautions............................................................ 19

2.3.2 During operation .................................................................19

2.3.3 Water system .....................................................................20

2.3.4 Brine.................................................................................. 20

2.3.5 Safety during maintenance and service ................................ 20

2.3.6 Power supply...................................................................... 20

2.3.7 Lubricating oils ................................................................... 21

2.3.8 Refrigerants ....................................................................... 21

2.3.9 Purging of heat pump ..........................................................21

2.3.10 First aid for accidents with ammonia..................................... 23

2.3.11 Protecting the operator as well as the environment ................ 24

2.3.12 Emergency stop.................................................................. 25

3. Design and function ............................................................................26

3.1 Unit design ................................................................................26

3.1.1 General HeatPAC information.............................................. 26

3.1.2 HeatPAC description ........................................................... 27

3.2 Main components ...................................................................... 28

3.2.1 Compressor ....................................................................... 28

3.2.2 Control system ................................................................... 28

3.2.3 Evaporator .........................................................................28

3.2.4 Cascade evaporator............................................................ 28

3.2.5 Condenser .........................................................................28

3.2.6 Receiver ............................................................................28

3.2.7 Air purge valve ................................................................... 29

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

3.2.9 Automatic oil recovery system from evaporator ..................... 30

3.2.10 Automatic oil return from oil separator .................................. 32

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

3.2.12 WHC circulation system ......................................................33

4. Installation information ....................................................................... 35

4.1 Installation................................................................................. 35

4.1.1 General information ............................................................ 35

4.1.2 First start-up procedure .......................................................35

4.2 Sound and vibrations .................................................................36

4.2.1 General information ............................................................ 36

4.2.2 Sound and noise data ......................................................... 36

4.2.3 Foundation.........................................................................36

4.2.4 Vibration dampers............................................................... 36

4.2.5 HeatPAC with variable speed drive....................................... 37

4.3 Secondary system .....................................................................37

4.3.1 General information ............................................................ 37

4.3.2 Cleaning in place ................................................................ 38

4.3.3 Temperature and flow control...............................................38

4.3.4 Water and brine treatment ...................................................38

4.3.5 R717 detector.....................................................................38

5. Operating instructions ........................................................................39

5.1 Personnel qualification requirements ...........................................39

5.2 Pre-start check .......................................................................... 39

5.3 Starting ..................................................................................... 39

5.3.1 Starting procedures............................................................. 39

5.3.2 Normal start-up procedure...................................................40

5.3.3 Valve positions during operation...........................................41

5.3.4 Restarting the heat pump after power interruption ................. 42

5.3.5 Restarting the heat pump after alarm stop (shutdown) ...........42

5.4 During operation ........................................................................42

5.4.1 Checks to be performed during operation .............................42

5.4.2 Monitoring and logging of operation...................................... 42

5.5 Stopping procedures .................................................................. 42

5.5.1 Stopping for a brief period.................................................... 42

5.5.2 Shutting down for a long standstill period .............................. 43

5.6 Shutdown and alarms.................................................................43

5.6.1 Operating state................................................................... 43

5.6.2 Troubleshooting.................................................................. 43

5.6.3 Testing of HeatPAC units ..................................................... 45

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6. Maintenance instructions .................................................................... 46

6.1 Maintenance of heat pump units.................................................. 46

6.2 Selecting lubricating oil for heat pump units.................................. 47

6.3 R717 charge.............................................................................. 47

7. Final disposal...................................................................................... 48

7.1 Safety precautions .....................................................................48

7.2 Waste disposal .......................................................................... 48

8. Appendices ......................................................................................... 49

8.1 Monitoring of operation............................................................... 49

8.2 Spare parts list for CVUA 1201 oil recovery pot ............................ 50

8.3 High-pressure float valve for cascade evaporator .........................51

8.4 Declaration of conformity ............................................................ 52

8.5 Set-up guide — AKS 4100 280 mm

for ammonia heat pump application ............................................. 53

Index ................................................................................................... 61

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Introduction

1. Introduction

This manual describes operating conditions for the unit, including:

• Dangers resulting from failure to comply with safety precautions when operating the equipment

and performing maintenance tasks.

• How to start, operate and stop the equipment safely.

• How to act when problems occur during operation.

• Scheduled maintenance tasks for the equipment and when/how to carry them out safely.

This manual is primarily intended for operators and engineers.

To prevent accidents, assembly and disassembly of components should be carried out by competent

personnel only.

• It is important that the operating personnel familiarise themselves with the contents of this man-

ual in order to ensure a proper and efficient operation. Johnson Controls Denmark is not liable

for damage occurring during the warranty period where this is attributable to incorrect operation.

• All compressor intervention within the warranty period must be performed by competent person-

nel only. If not, the warranty no longer applies.

1.1 Amendments to the manual

2021.07 Version 6

• Copy of declaration of conformity removed from the manual. It is now only contained in the

printed manual delivered with the unit and the pdf version uploaded with the order specific

documentation.

• Various minor changes and new coverpage design.

2019.04 Version 5

• Updated designs/drawings of receivers, high-pressure regulation, by-pass function during

start-up and WHC circulation system.

• Set-up guide for AKS 4100 - 280 mm level sensor included.

• Various corrections/changes.

2018.12 Version 4

• Updated version of declaration of conformity for unit.

2017.12 Version 3

• Name plates with EurAsian Conformity mark (EAC) have been added.

• ‘Requirements for competent persons’ section has been added.

• Updated version of declaration of conformity for unit.

• And more.

Operating manual - HeatPAC with reciprocating compressor

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Introduction

For further information, see www.sabroe.com

This manual is produced by:

Johnson Controls Denmark ApS

Christian X's Vej 201

8270 Højbjerg, Denmark

Phone +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 purposes. Contravention

will be prosecuted.

The original version of this manual is the English language version. If there are any discrepancies or

conflicts between the English and any other version that has been translated into another language, the

English version will prevail.

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Introduction

1.2 Definition of safety precautions used in this manual

Danger!

Indicates an imminently hazardous situation which, if not avoided, will result in death or serious injury.

Warning!

Indicates a potentially hazardous situation or practice which, if not avoided, will result in death or serious

injury.

Caution!

Indicates a potentially hazardous situation or practice which, if not avoided, will result in damage to

equipment and/or minor injury.

Note: Indicates an operating procedure, practice, etc., or portion thereof, which is essential to highlight.

1.3 Requirements for competent persons

• Personnel working on the unit must be competent in accordance with national safety rules and

regulations relating to flammable refrigerants or according to EN 13313.

• Maintenance work must be performed according to EN 378 or ISO 5149 supported by evidence

of appropriate training.

• Assign only competent personnel instructed in safety and all machine functions to operate or

service the compressor/unit according to EN 13313.

• Operators and maintenance personnel must carefully read, understand and fully comply with all

alarms and instructions.

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