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In addition to the above, heat pumps have several components that are made of metals

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EXEP01 2150EN

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Summary of Contents for Exergy P100

Page 1: ...EXEP01 2150EN 13 January 2022 RF SVX006A GB Installation and operation manual Exergy P 30 P 450 Read these instructions carefully before installation use or maintenance ...

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Page 3: ...oning 27 4 2 Checking hot circuit 28 4 3 Checking cold circuit 28 4 4 Checking safety valve blow off pipe 29 4 5 Checking refrigerant circuit 29 4 6 Checking electrical connections and the control cabinet 29 4 7 First start up 30 4 8 Commissioning the system 32 4 9 Network and internet connections 34 4 10 Master Slave operation setting up parallel units 35 4 11 Setting up distribution condenser su...

Page 4: ... Viewing motor status 53 5 12 Controlling actuators 56 5 13 Viewing PID controller values 57 5 14 Trends view 58 6 Maintenance 6 1 Regular check and maintenance 61 6 2 Troubleshooting 62 2 64 EXEP01 2150EN ...

Page 5: ...rical diagrams available near the device Oilon products are manufactured according to general product standards and directives and based on our best knowledge about product design and technologies Operation safety is one of the leading principles in our product development However it is wise to be prepared and think about safety Read the following principal safety warnings and instructions Install...

Page 6: ... gloves and safety goggles when necessary Installation may involve hot work such as welding Hot work may only be performed by authorized and trained personnel adhering to all local regulations and requirements Do not touch hot pipes or surfaces during operation or maintenance Make sure that potential pressurized discharge from refrigerant circuit s pressure relief valves does not cause danger to p...

Page 7: ...sical state Gas at typical ambient temperatures Classifications ANSI ASHRAE 34 Safety Group R 1234ze A2L HMIS Classification Health 1 Flammability 1 Reactivity 0 NFPA Classification Health 2 Flammability 1 Reactivity 0 US DOT HAZARD CLASS 2 2 Canada Listed on DSL R 134A EU EINECS 2065578 HFC 125 R 410A EU EINECS 223770 R 1234ze A2L Emergency overview Colorless volatile liquid with ethereal and fai...

Page 8: ...perator is available Get medical attention immediately DO NOT give epinephrine adrenaline INGESTION Ingestion is unlikely because of the low boiling point of the material Should it occur discomfort in the gastrointestinal tract from rapid evaporation of the material and consequent evolution of gas would result Some effects of inhalation and skin exposure would be expected Ingestion is unlikely bec...

Page 9: ...le probability of liquid contact wear chemical safety goggles DISPOSAL CONSIDERATIONS Not a hazardous waste WARNING DO NOT vent to the atmosphere To comply with provisions of the U S Clean Air Act any residual must be recovered Contains greenhouse gas which may contribute to global warming The refrigerant should not be mixed with air above atmospheric pressure for leak testing or any other purpose...

Page 10: ...he heat pump must not be stored longer than needed If the heat pump must be stored longer than one month the manufacturer must be informed The heat pump must be stored in a dry place where the temperature is at least 5 C Transfer models S RE P 220 450 Move the heat pump with a forklift or two pallet jacks Keep the heat pump in a vertical position When using pallet jacks place one on each side of t...

Page 11: ...oup A2L EN 378 2016 ASHRAE Standard 2010 It is in the lower segment of the mildly flammable refrigerants A unique characteristic of this refrigerant is the absence of flammable mixture with air below 30 C of ambient temperature That s why it is nonflammable for handling and storage When utilized in a system R1234ze E could become flammable with air in case of a leakage If a flame occurs with R1234...

Page 12: ... provider duly authorized to do so pursuant to local laws and regulations Depending on the refrigerant type refrigerants can be flammable toxic or both In addition certain refrigerants have a high global warming potential GWP if released into the atmosphere Oil Waste oil should be delivered to a service provider with the means for processing such materials in accordance with laws and regulations U...

Page 13: ...ove heat pumps have several components that are made of metals and plastics If possible any such components should be recycled and if recycling is not an option disposed of in accordance with local laws and regulations EXEP01 2150EN 11 64 ...

Page 14: ...at pump start up current A 102 136 230 356 445 534 623 712 Compressor maximum operating current A 34 68 115 178 267 356 445 534 Fuse size A 50 125 160 200 315 400 500 630 Protection degree control cabinet IP44 Electrical data North America P 30 P 60 P 100 P 150 P 220 P 300 P 380 P 450 Electrical connections 3 L PE 460 VAC 60 Hz Heat pump start up current A 102 136 230 356 445 534 623 712 Compresso...

Page 15: ...ne circuits Minimum water brine outlet temperature from the evaporator 15 C Maximum water brine inlet temperature to the evaporator 50 C Minimum water brine inlet temperature to the condenser 0 C Maximum water outlet temperature from the condenser 80 C R134a 90 C R450A or 100 C R1234ze EXEP01 2150EN 13 64 ...

Page 16: ...ions when installing the heat pump General site requirements The installation site must have a sufficient structural capacity The installation site must have a floor drain Select the installation site so that noise and vibration from the apparatus causes no danger or discomfort to building users For models with ON OFF control the maximum ambient operating temperature is 40 C For models equipped wi...

Page 17: ...draw the safety valves blow off pipes to outside the building in a location where a refrigerant discharge does not pose a risk Also check the requirements of local standards laws and other regulations concerning blow off pipe locations The blow off pipe must be approximately 5 meters long measured from the valve s blow off port If the pipe length exceeds 5 meters calculate the diameter of the blow...

Page 18: ...rts P 30 main parts The assembly may vary depending on the scope of delivery Pos Part Pos Part 1 Control cabin 5 Compressor 2 Evaporator 6 Dryer filter 3 Condenser 7 Expansion valve 4 Subcooler 16 64 EXEP01 2150EN ...

Page 19: ...filter 4 Condenser 11 Expansion valve 6 Subcooler 12 Frequency converter 3 3 System design and sizing the heat pump Heat pump or pumps must be selected and configured based on the actual capacity required and the operating conditions specific to the site These parameters are specified by the customer If there is a change in operating conditions the original heat pump settings are no longer valid a...

Page 20: ...r Place the switch on the side of the pipe not on the bottom due to dirt nor on the top due to air Install the flow switch in a G1 2 sleeve max length 29 mm For electrical connections refer to the heat pump s wiring diagrams Water flow adjustment range 1 150 cm s adjust according to the minimum flow of the site With normal flow rates all green LEDs should be active Alarm delay adjustment range 1 4...

Page 21: ... the system is depressurized The following flow diagrams are only examples of various connection principles Always check the final connections from the diagrams delivered with the heat pump Legend A Safety valve P60 P450 blow off pipe to outside the building Customer delivery scope Supplier delivery scope Recommended to use a filter Balancing valve in customer delivery scope EXEP01 2150EN 19 64 ...

Page 22: ...gerant circuit Flow diagram example 1xHP 1xref circuits ver 2 Position Description 1 Customer LV switchgear 2 Control cabinet 3 Desuperheater 4 Evaporator 5 Subcooler 6 Condenser 7 Compressor 1FS11 Flow switch 20 64 EXEP01 2150EN ...

Page 23: ...gerant circuits Flow diagram example 1xHP 2xref circuits ver 1 Position Description 1 Customer LV switchgear 2 Control cabinet 3 Desuperheater 4 Evaporator 5 Subcooler 6 Condenser 7 Compressor 1FS11 Flow switch EXEP01 2150EN 21 64 ...

Page 24: ... and condensers in parallel Flow diagram example 2xHP con_p eva_p ver 2 Position Description 1 Customer LV switchgear 2 Control cabinet 3 Desuperheater 4 Evaporator 5 Subcooler 6 Condenser 7 Compressor 1FS11 Flow switch 22 64 EXEP01 2150EN ...

Page 25: ... and evaporators in series Flow diagram example 2xHP con_p eva_s ver 2 Position Description 1 Customer LV switchgear 2 Control cabinet 3 Desuperheater 4 Evaporator 5 Subcooler 6 Condenser 7 Compressor 1FS11 Flow switch EXEP01 2150EN 23 64 ...

Page 26: ... and evaporators in parallel Flow diagram for 2xHP con_s eva_p ver 2 Position Description 1 Customer LV switchgear 2 Control cabinet 3 Desuperheater 4 Evaporator 5 Subcooler 6 Condenser 7 Compressor 1FS11 Flow switch 24 64 EXEP01 2150EN ...

Page 27: ...2 Position Description 1 Customer LV switchgear 2 Control cabinet 3 Desuperheater 4 Evaporator 5 Subcooler 6 Condenser 7 Compressor 1FS11 Flow switch The customer determines final pipe sizes The fllow switch is included in the delivery but the customer takes care of installation EXEP01 2150EN 25 64 ...

Page 28: ...t devices that draw over 2 A of current directly to the controller Use a contactor instead Recommended cable sizes Europe Model Cable size Model Cable size P30 3 x 10Cu 10Cu P220 2 x 3 x 95Cu 50Cu 1 x 3 x 185Cu 70Cu P60 3 x 70Cu 35Cu P300 2 x 3 x 120Cu 70Cu 1 x 3 x 240Cu 95Cu P100 3 x 95Cu 50Cu P380 2 x 3 x 150Cu 70Cu P150 2 x 3 x 50Cu 25Cu 1 x 3 x 120Cu 70Cu P450 2 x 3 x 240Cu 120Cu Recommended c...

Page 29: ...ion and competence for installing high pressure devices have expert knowledge about heating and cooling systems be familiar with the heat pump control system Loosen the nut of the compressor vibration damper until the slotted washer can be removed Remove the slotted washer It is recommended that an authorized and certified expert performs commissioning Tasks to be completed before commissioning Co...

Page 30: ... is heated 5 Check that all valves and other components displayed in the PI diagram have been correctly installed Make sure that the valves can be operated at 0 100 6 Check and note selected filter mesh size The recommended mesh size is 0 8 mm in closed circuits and 0 08 mm in open circuits 7 Check that all threaded flange and or welded connections to the heat pump are properly made and tightened ...

Page 31: ...ke sure that condensate cannot enter the safety valves It is recommended to place a drain valve in the lowest section of the pipe below the pipe s connection at the heat pump 5 Make sure that the blow off pipe is properly supported No stress must be transferred to the heat pump connections 4 5 Checking refrigerant circuit 1 Make sure that nothing was damaged or loosened during transport 2 Check sc...

Page 32: ...ply voltage 10 Check the cooling fans and filters in the control cabinet Check the variable frequency drives fans and filters if present Start the cooling fans by lowering the cabinet s internal temperature setpoint Note down the original setting and reset after testing 11 Check that the communication interface is connected and correctly set up Refer to the instructions and settings in the Modbus ...

Page 33: ...Control settings Set the power control options Green in use white not in use Cold side settings Set the options for the cooling side of the heat pump Green in use white not in use EXEP01 2150EN 31 64 ...

Page 34: ...on the Start button turns green the heat pump is permitted to start 4 8 Commissioning the system Carry out commissioning tasks according to this check list Pay special attention to the leakage test Measure compressor current Control superheating temperature Check and trim expansion valve functionality Define overcurrent protection device settings Perform thermal protection device functional test 3...

Page 35: ... the Heat pump leakage check list of the Commissioning report Verifying certificates documents and approvals Make sure that the pre commissioning certificate is completely filled and signed by the person responsible for the installation All required control documents regarding the installation are in order including leak and pressure test of water piping and electrical supply certificate Electrica...

Page 36: ... Wi Fi establish a Wi Fi connection as you would with any other device The network ID is Chillheat and the password 0il0nm0bile Open a web browser In the address bar enter http 10 20 30 1 Connecting with a LAN cable Connect a LAN cable to your device and plug the cable into the Tosibox unit s service port Open a web browser In the address bar enter http 172 17 17 17 Sign in using the Admin passwor...

Page 37: ...pported 4 10 Master Slave operation setting up parallel units Physical configuration 1 Start the circulation and open up all throttling valves to the fully open position a If the circuit is capacity controlled make sure the system is running at the maximum flow 2 Measure the individual flows and compare to the specified flows a If the flow notably deviates from the specified flow search for the re...

Page 38: ...he slave heat pumps must be set under remote control Open the slave heat pump s Control settings view see section Control settings Press the remote setpoint button see the figure below Master Slave operation In a Master Slave configuration a number of slave heat pumps are controlled by a master heat pump s controller The heat pumps are started and stopped one at a time each after a start or stop d...

Page 39: ...tem is running at the maximum flow 2 Measure the individual flows and compare to the specified flows Measured total flow m3 h or kg s If the flow notably deviates from the specified flow search for the reason for this deviation Possible reasons can be pump filter valves pipe length air gas or dirt in the system 3 If the system has several condensers in parallel follow the steps in section Master S...

Page 40: ...single machine both for cooling and heating Our heat pumps are well suited for heating and cooling applications either as dedicated cooling or heating solutions or as a combined solution It is possible to connect several heat pumps in series for an even higher capacity heating or cooling solution Automation is a key component in the system as it allows the unit to produce chill and heat with high ...

Page 41: ...it it collects heat energy which causes the temperature in the fluid to rise The fluid completes its circuit by returning to the evaporator and releasing the heat energy into the refrigerant which circulates between the evaporator and the condenser When the refrigerant is in the evaporator it is colder than the fluid in the cooling circuit allowing he heat energy to transfer from the fluid into th...

Page 42: ...at pump to cool down one part of a process heat is generated as a by product The generated heat can be used effectively in another process which requires heat The typical coefficient of performance COP in these applications can vary between 5 and 8 Example of a combined solution An example of a combined solution is a data center A data center usually consists of an office area and a large server r...

Page 43: ...le be channelled into the district heating network improving the efficiency of the plant and increasing the total heat output The free heat sources can be put to use for heating spaces and producing hot water among other things The heat pumps can utilize these heat sources and produce valuable heating energy for industrial processes or to be sold out Under the operation period the heat source circ...

Page 44: ...em has the following features Clear easy to use graphical user interface and reliable programmable industrial controller with support for controlling multiple units Modbus and Profibus protocols available Remote monitoring and programming Control system user interface The user interface has a number of different views for operating the system and changing its settings The views can be browsed thro...

Page 45: ...nsumption 5 Switch to the Process view 12 Heated water out 6 Heating COP 13 Heated water in 7 Power 0 100 14 Heat energy produced Process view The Process view allows you to view key process values and access different views and settings To view detailed information about a specific device such as a pump or a valve and to change its settings tap on the device s icon To change a setpoint or limit v...

Page 46: ...easurements will also be displayed Note that these buffer tanks must be enabled in the Warm settings or the Cold settings view see section Cold side and warm side settings before they are displayed Start delay stop delay and oil heating delay The start delay and stop delay are shown in the top left corner as degree minutes These values can be changed For example if the stop delay value is 30Cmin a...

Page 47: ...rocess values Process screen center ver 3 A number of key process values are shown in the center of the process view A Cold side values B Warm side values Pres Suction pressure Pres Discharge pressure Evap Evaporating pressure Cond Condensating temperature Temp Suction temperature Temp Discharge temperature SH Suction superheat SH Discharge superheat ExV Expansion valve opening Accessing setting v...

Page 48: ...e Pos Item Description 1 Start difference and stop difference These values specify how much the temperature must exceed or fall below the setpoint before the unit will be started or stopped for example when heating is no longer required The unit will be stopped with a delay 2 Primary control mode selection Switch between two modes Chill snowflake button or Heat sun button 3 Setpoint control method...

Page 49: ... The setpoint can be specified either in the Home view or by tapping on the setpoint values in the Control settings view B Dynamic The setpoint will calculated based on current outdoor temperature and a temperature curve A temperature curve can be set up in the Dynamic setpoint view C Remote A remote setpoint through a bus connection will be used Slaves The Slaves view is discussed in section Mast...

Page 50: ...tlet temperature values for each outdoor temperature Tap to adjust each value The values along the X axis each indicate a specific outdoor temperature point To specify an outlet flow temperature for a given outdoor or process temperature point tap on the white box above the temperature point Pos 6 in the figure The applicable temperature range can be changed by changing the temperature values alon...

Page 51: ...kly schedule select the days on which the timed setpoint should apply Then specify the hours between which the temporary setpoint will be active In the figure above the setpoint will be used on Mondays and Tuesdays between 8 AM and 4 PM 5 8 Cold side settings and warm side settings The Cold side settings and the Warm side settings view are nearly identical These views will be used to specify the c...

Page 52: ...mperature will be used as the setpoint and the pump will run even if the heat pump is off Temperature difference always on temperature difference will be used as the setpoint and the pump will run even if the heat pump is off Constant speed always on the pump will run at constant speed and the pump will run even if the heat pump is off Valve Used there is a valve in the circuit on the cold or warm...

Page 53: ...let temperature Buffer tank ver 1 Energy meter To edit the kilowatt hours per pulse value tap the value field Settings present only in the Cold side view Flow switch Deactivating the flow switch can result in damage to the heat pump or the system The flow switch is delivered as standard in all heat pumps and shown active in the Cold side view This setting should not be changed 5 9 Language Date an...

Page 54: ... The flag button will change to match the selected language Set the current date and time Set the time zone Adjust Ethernet settings Setting language In the Other settings view tap on the flag button The language selection pop up window appears Language screen ver 3 52 64 EXEP01 2150EN ...

Page 55: ...5 10 Changing user level Some functions require logging in as an Expert user When trying to access such functions you will be asked to log in The Login dialog box appears Login screen ver 4 1 From the User drop down list select Expert 2 Enter password in the Password field and press OK You will be automatically logged out from the Expert level after 30 minutes of inactivity 5 11 Viewing motor stat...

Page 56: ...or s or pump s icon in the Process view Viewing on off controlled motor ver 4 Pos Item Description 1 Motor status pop up window Pop up window for on off controlled motors Displays the current motor status 2 Run time value Displays the running hours for the motor 3 Auto manual toggle button Toggle the motor between automatic and manual mode Green automatic White manual 4 Stop Stop the pump when und...

Page 57: ...tap the relevant compressor s or pump s icon in the Process view Speed controlled motors often have additional PID related settings Viewing speed controlled motor ver 5 Pos Item Description 1 Motor status pop up window Pop up window for speed controlled motors Displays the current motor status 2 Run time value Displays the running hours for the motor 3 Control value Displays the control value 4 Me...

Page 58: ...er 2 Pos Item Description 1 Actuator popup window Pop up window for actuators Allows the valve actuator to be controlled manually if required 2 Close button Closes the pop up window 3 Auto Manual toggle button Toggle between automatic and manual mode Green automatic White manual 4 Closed button Close the valve run the actuator to the closed position when under manual control 5 Open button Open the...

Page 59: ...5 Pos Item Description 1 PID pop up window PID proportional integral derivative pop up window 2 Close button Closes the popup 3 PV value A bar display of the process variable value 4 SP value A bar display of the setpoint value 5 More options Expand the view to display advanced options 6 Manual Manual control 7 Automatic Automatic control 8 PV value Displays the process variable value 9 SP value D...

Page 60: ...age distance P gain 5 Deadbandwidth The area around the setpoint where control does not move 6 P out Difference P gain 7 I out I out difference P gain I Time Example I out at the start 0 difference constant After 1 I time I out will be equal to P out After 2 I time I out will be 2 P out 8 D out Change in the difference within D time P gain Example if D time is 10 s the past difference from 10 s ag...

Page 61: ...en real time and history mode Play view the trends in real time Pause view the trends as a static screen 4 Open trend legend Display the trend legend see below 5 Trend selection Open the Trend Selection dialog box 6 Trend legend Show and hide individual trend curves see below 7 Mode Displays the trend mode History shown only when in History mode Trend selection To open the Trend selection dialog b...

Page 62: ...d dialog box tap on the Open trend legend button see above The trend legend allows you to display and hide individual trend curves Trend view legend ver 5 Position Item Description 1 Trend legend The trend legend dialog box 2 Current value Real time value of the measurement 3 Show hide trend trend shown 4 Show hide trend trend hidden Hides or shows the selected measurement or value curve 60 64 EXE...

Page 63: ... the panels Heat pumps check and maintenance must comply with the European Union s Regulation No 517 2014 and follow the attached table CO2 equivalent of refrigerant can be calculated by multiplying the refrigerant charge by the refrigerant GWP value The amount of refrigerant in the device Normal maintenance interval Maintenance interval with the leak detector 5 50 ton CO2 equiv 12 months 24 month...

Page 64: ...mperatures 10 min after stop Check operating conditions If not near freezing point contact Customer Service Discharge pressure high Heating water too hot or too low flow in condenser or too high refrigerant charge level If refrigerant charge is correct condensing temperature should be within 5 C of temperature of water out when running unless very low or very high flow Check warm water flow check ...

Page 65: ...the heat pump does not stop or the motor s OFF signal does not reach the controller Electrical problem either contactor or wiring Check wiring contact Customer Service The oil alarm device is mounted on the lower right side of the compressor right at the front To reset the alarm press and hold the white button on the device for approximately 2 seconds The unit s alarm indicator should start blinki...

Page 66: ... the text Off For example in the image the alarm On Protection device alarm 2comp1 is active whereas the alarm Off Protection device alarm 1comp2 has been reset Certain alarms will be automatically reset once the system recovers from alarm state while others will remain active and need to be acknowledged manually To acknowledge all alarms tap the Ack all alarms button In case of increased pressure...

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