Johnson Controls SABROE ComPAC User manual

ComPAC

Chiller unit with screw compressor

Installation guide EN

Installation guide - ComPAC

2/7 011829 en 2022.08

ComPAC Installation guide

ComPAC units

Please note that this installation guide only describes the main issues to con-

sider during installation.

Installation guidance is available in the operating manual, which must be read

carefully before operating the equipment.

Make sure to observe all local and national installation and safety

precautions.

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ComPAC Installation guide

Lifting instructions

Lifting eyes are welded on the base frame of the ComPAC. They are clearly marked with red

paint. The ComPAC must be lifted in these lifting eyes only, see Fig. 1 and Fig. 2.

Note: Lifting eyes are mounted on the compressor unit but these lifting eyes must NOT be

used to lift the ComPAC chiller unit.

Always use lifting yokes when handling the chiller to avoid damaging pipes, valves, insulation

and other components. Check that the crane, lifting yokes and steel wire are approved lifting

devices and have the necessary strength to lift the ComPAC.

To avoid damaging the chiller unit, some of the steel wires must be angled while lifting the unit

as shown in Fig. 1 and Fig. 2.

The exact weight and centre of gravity of the ComPAC is shown in the GA drawing.

Fig. 1

Fig. 2

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ComPAC Installation guide

Planning the machine room

When planning the machine room, it is important to make sure that there is enough space

around the plant to allow repairs and maintenance tasks to be carried out without problems.

Fig. 3 shows the minimum spacing in millimetre.

Fig. 3

A) For operation and opening of the electrical panel 1000 mm

B) For removal of the Vi slide 550 mm

C) For maintenance 600 mm

D) For operating Unisab III 600 mm

The foundation must have the necessary bearing strength and be as plane as possible.

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ComPAC Installation guide

Vibration dampers

ComPACs are designed for either 4 or 6 vibration dampers. For installation on solid concrete

floor, anti-vibration machine feet are sufficient. Such machine feet are designed for minimum

70% vertical isolation (100% capacity).

For installation on decks, special dampers are often required. Please consult a vibration expert

or a Johnson Controls Denmark representative for further information.

To ensure optimum effect of each individual anti-vibration machine foot, the load on the feet

must result in roughly the same deflection of all machine feet, see Fig. 4. Deflection of a ma-

chine foot can be adjusted by increasing or reducing the load compared to the other supports

by turning the adjusting rod.

Fig. 4: Anti-vibration machine foot

Other damper types can be adjusted by using liner plates.

Lo a d e d s t a te

L o ck n u t

U n loa d e d s t a te

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ComPAC Installation guide

Connection of pipes

Connect all piping and mount all hoses and valves for compressor cooling.

The piping design must include considerations regarding function, suspension, vibrations, ther-

mal expansion and pre-stress after welding in order to avoid high load on the unit connections.

The safety valves are fitted on the unit from factory. The pipe connection to the valve discharge

branch must be made in accordance with valid rules/standards. External piping and condens-

ers are not protected by the safety valves fitted on the unit.

Leak and pressure test

Leak and pressure test according to the applied/local codes and rules. Isolate the compressor

unit from the test pressure or disconnect pressure transducers and safety valves. Never ex-

ceed the test pressure of the unit stated on the unit name plate. All ComPAC units are pressure

and performance tested from factory.

Electrical connection

Connect power supply wiring according to electrical diagrams.

Final check

Check all relevant components, connections, electrical connections, safety valves, safety high

pressure cut-out and machine room safety.

Evacuation

Evacuate the system using a vacuum pump for 5 mm Hg and perform a vacuum test.

Note: The unit is pressurised with approximately 0.5 bar (g) nitrogen from factory. The nitrogen

will often be mixed with a minor amount of R717 vapour left from the factory test (absorbed in

oil). This should be taken into account when positioning the discharge from the vacuum pump.

Charge oil

Charge oil, if not charged from factory. The oil level should be visible in the middle of the upper

sight glass.

Note: ComPAC units can be charged with either S68 or PAO oils.

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ComPAC Installation guide

Charge refrigerant

The P&I diagram states the charge for each specific chiller. Start out by charging 75% of the

specified R717 charge.

After start-up carefully charge more R717 until the suction superheat is between 0.5 and 3°K.

Check the liquid level in the evaporator. Droplets should come out of the top of the plates.

The plates should not be completely covered by liquid.

Note: The liquid level must never be visible in the inspection glass.

Power supply

Turn on power.

Control system

Check the UniSAB III control system settings including calibration according to the UniSAB III

manual.

Motor

Check the direction of rotation of the compressor motor.

Coupling

Check alignment of coupling.

ComPACs are equipped with flange motors, and alignment is normally notnecessary.

Johnson Controls Denmark ApS

Sabroe Factory

Christian X's Vej 201 ∙ 8270 Højbjerg

Denmark

Phone +45 87 36 70 00

www.sabroe.com

Version 2

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