Trane Exergy S 180 User manual

EXES01 2150EN
13 January 2022
RF-SVX005A-GB
Installation and operation manual
Exergy S 180 - S 2000
Read these instructions carefully before installation, use, or maintenance

Contents
1 Introduction
1.1 Safety precautions...................................................................................... 3
1.2 Transportation and storage.........................................................................7
1.3 Delivery content, optional equipment and accessories.............................11
1.4 Decommissioning...................................................................................... 11
2 Technical data
2.1 Heat pump technical data.........................................................................13
3 Installation
3.1 Installation site requirements.................................................................... 15
3.2 Main parts................................................................................................. 17
3.3 System design and sizing the heat pump................................................ 18
3.4 Connections and dimensions....................................................................18
3.5 S380 HC+, S490 HC, S490 HC+ and S580 HC evaporator inlet
temperature sensor...................................................................................19
3.6 Installing flow switch................................................................................. 20
3.7 Flow diagrams...........................................................................................21
3.8 Electrical connections............................................................................... 28
4 Commissioning
4.1 Prerequisites for commissioning...............................................................29
4.2 Checking hot circuit.................................................................................. 30
4.3 Checking cold circuit.................................................................................30
4.4 Checking safety valve blow-off pipe.........................................................31
4.5 Checking refrigerant circuit....................................................................... 31
4.6 Checking electrical connections and the control cabinet..........................31
4.7 First start-up..............................................................................................32
4.8 Commissioning the system.......................................................................34
4.9 Network and internet connections............................................................ 36
4.10 Master–Slave operation: setting up parallel units..................................... 37
4.11 Setting up distribution condenser/subcooler.............................................39
5 Operation
5.1 Main features............................................................................................ 40
5.2 Operating principle....................................................................................41
5.3 Heating and cooling..................................................................................42
5.4 Coefficient of performance........................................................................44
5.5 Control system.......................................................................................... 44
5.6 Control panel.............................................................................................44
5.7 Control settings......................................................................................... 48
5.8 Cold side settings and warm side settings...............................................51
5.9 Language, Date and Time, and Ethernet settings....................................53
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5.10 Changing user level..................................................................................55
5.11 Viewing motor status................................................................................ 55
5.12 Controlling actuators................................................................................. 58
5.13 Viewing PID controller values...................................................................59
5.14 Trends view...............................................................................................60
6 Maintenance
6.1 Regular check and maintenance.............................................................. 63
6.2 Troubleshooting.........................................................................................64
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1 Introduction
1.1 Safety precautions
Read these instructions carefully before installation, commissioning, operation or
maintenance of the device. The given instructions must be followed. Throughout this
manual, the following three symbols are used to point out very important information:
Be careful. The DANGER symbol indicates a possible danger of bodily
harm or lethal injury.
Pay attention. The CAUTION sign indicates a possible danger of
damage to the device, components or surroundings.
Note indicates tips, hints, and other essential information.
Keep these instructions as well as the electrical 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:
Installation, commissioning, or service of the appliance is to be carried
out by an authorized service provider, adhering to all local regulations
and requirements.
IN CASE OF FIRE OR OTHER EMERGENCY
● Turn off power from the main switch.
● Follow safety instructions.
● Contact the safety supervisor.
Connectors in control box are under voltage. Only authorized users may
open safety cover.
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This device is not intended for use by children under 9 years of age or
persons whose physical, perceptual or mental qualities are lowered, or
those who have no experience or knowledge in the device‘s use, unless
they do so under supervision or after receiving appropriate training
from the person responsible for device-related safety. Children may not
clean the device or perform any maintenance tasks without supervision.
Children should be supervised to make sure that they do not play with
the device.
Wear proper hearing protection and personal protective equipment,
such as protective footwear, 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 people or property.
Do not mix the refrigerant with air above atmospheric pressure for leak
testing or any other purpose.
To avoid slipping, keep floor surfaces dry, and seal off or report any
leaks that you detect.
The heat pump can be loud when in operation. Wear hearing protection
in the vicinity of the heat pump.
The heat pump contains lubricating oil that may cause irritation.
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Refrigerant safety notice
The refrigerants used in Oilon heat pumps are in normal working conditions non-toxic
and non-flammable. Read the following information always before starting any work
on the appliance. Follow the instructions and take care of preventive safety measures.
For more detailed information, see the Material Safety Data Sheet of the refrigerant
manufacturer.
Data Description
Product name R134A
R410A
R450A
R513A
R1234ze
Composition, R-134A
Composition, R-410A
Tetrafluoroethane
Difluoromethane
Pentafluoroethane
Appearance Clear, colorless liquid and vapor
Physical 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 faint sweetish odor. Non-
flammable material. Overexposure may cause dizziness and loss
of concentration. At higher levels, CNS depression and cardiac
arrhythmia may result from exposure. Vapors displace air and can
cause asphyxiation in confined spaces. At higher temperatures, (>
250°C, 482°F), decomposition products may include Hydrofluoric
Acid (HF) and carbonyl halides.
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Potential health hazards First aid measures
SKIN
Irritation would result from a defatting action on
tissue. Liquid contact could cause frostbite.
Promptly flush skin with water until all chemical is
removed. If there is evidence of frostbite, bathe with
lukewarm water. Do not use hot water, and do not
rub. If water is not available, cover with a clean,
soft cloth or similar covering. Get medical attention
if symptoms persist. Treatment of overexposure
should be directed at the control of symptoms and
the clinical conditions.
EYES
Liquid contact can cause severe irritation and
frostbite. Mist may cause irritation.
Immediately flush eyes with large amounts of
water for at least 15 minutes. In case of frostbite,
water should be lukewarm, not hot. Lift eyelids
occasionally to facilitate irrigation. Get medical
attention if symptoms persist.
INHALATION
The refrigerant is low in acute toxicity in animals.
When oxygen levels in air are reduced to 12–
14% by displacement, symptoms of asphyxiation,
loss of coordination, increased pulse rate and
deeper respiration will occur. At high levels, cardiac
arrhythmia may occur.
Immediately remove to fresh air. If breathing has
stopped, give artificial respiration. Use oxygen as
required, provided a qualified operator 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 because of the physical
properties and is not expected to be hazardous. DO
NOT induce vomiting unless instructed to do so by a
physician.
DELAYED EFFECTS
None known
Not applicable
Flammable properties Fire fighting measures
Material itself is not flammable. Its autoignition
temperature is 750°C, 1,382°F.

UNUSUAL FIRE AND EXPLOSION HAZARDS
The refrigerant is not flammable at ambient
temperatures and atmospheric pressure. However,
this material will become combustible when mixed
with air under pressure and exposed to strong
ignition sources. Contact with certain reactive
metals may result in formation of explosive or
exothermic reactions under specific conditions (for
example very high temperatures and/or appropriate
pressures).
SPECIAL FIRE FIGHTING PRECAUTIONS AND
INSTRUCTIONS: Firefighters should wear self-
contained, NIOSH-approved breathing apparatus
for protection against possible toxic decomposition
products. Proper eye and skin protection should
be provided. Use water spray to keep fire-exposed
containers cool.
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Exposure controls, personal protection, and accidental release measures
Type Preventive measures
GENERAL Always wear recommended personal protective equipment. Where
contact with liquid is likely, such as in a spill or leak, impervious boots
and clothing should be worn.
ENGINEERING CONTROLS Provide local ventilation at filling zones and areas where leakage is
probable. Mechanical (general) ventilation may be adequate for other
operating and storage areas. Equip the installation site with any gas
alarms and/or gas protection required by local rules and regulations.
SKIN PROTECTION: General work clothing and gloves (leather)
should provide adequate protection. If prolonged contact with liquid
or gas is anticipated, insulated gloves constructed of PVA, neoprene
or butyl rubber should be used. Any contaminated clothing should be
promptly removed and washed before reuse.
PERSONAL PROTECTIVE
EQUIPMENT
EYE PROTECTION: or normal conditions, wear safety glasses.
Where there is reasonable 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.
IN CASE OF A SPILL OR OTHER RELEASE
● Always wear recommended personal protective equipment.
● Evacuate unprotected personnel.
● Protected personnel should remove ignition sources and shut off leak, if without
risk, and provide ventilation.
● Unprotected personnel should not return until air has been tested and determined
safe, including low-lying areas.
● Spills and releases may have to be reported to federal and/or local authorities.
● Regarding reporting requirements refer to the Material Safety Data Sheet of the
refrigerant manufacturer.
1.2 Transportation and storage
The heat pump is top-heavy and may tip over if not handled properly.
Transport and store the heat pump in a vertical position.
Be careful when lifting the heat pump. Use appropriate lifting tools.
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Preparations for storage, transfer, and lifting
1. Check that the way is free from obstacles.
2. Use appropriate vehicle for transport.
3. At installation site check that you have proper means and resources for lifting and
placing the pump.
Storage
Before transporting to the final installation site and commissioning phase, the 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 the pump.
Lifting
S 180 - S 580:
There are welded lifting supports in the pump frame, see illustration.
Lifting brackets ver. 1
A and B, lifting supports
Use a forklift or a pallet jack to lift the heat pump as indicated by the labels and
markings on the device.
Do not transfer or lift the heat pump without any housing covers.
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S 600 - S 2000:
Transferring the unit
Be careful not to damage the valves and pipes under the heat
exchanger, see the figure above.
Lift the heat pump from the beams running along the length of the heat pump (marked
in green in the figure below). Use a forklift or two pallet jacks to lift the heat pump as
indicated by the labels and markings on the device.
Lifting S 600 - S 2000 ver. 1
Lifting the unit for transport
When lifting the unit onto a vehicle for transport, use the lifting lugs attached to the
support frame under the unit, see the figure.
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Hoisting S 600 - S 2000 ver. 2
Use a cruciform (cross-shaped) lifting beam for lifting the unit, see the figure below.
This way the lifting straps or chains can be placed so that they cannot damage the
equipment.
Crufiform lifting beam ver. 1
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In some heat pumps, the bottom support frame is not wide enough for the lifting
lugs to extend far enough from the sides of the unit. If this is the case, the unit will
be delivered with an additional lifting support (beam) bolted onto the frame. This will
provide sufficient clearance for lifting the unit without harming the equipment. The
support can be removed after use.
If the delivery includes an additional lifting support, hoisting the unit
without the support is not allowed. Doing so will cause damage to the
equipment during lifting.
The lifting support is not intended for use in any other lifting applications
or in continuous use.
1.3 Delivery content, optional equipment and accessories
Standard delivery content
A standard heat pump delivery includes the following:
● heat pump
● 1 flow switch with cable
● installation and operation manual, electrical drawings
● installation, commissioning and warranty records
● maintenance sheets
● PI-diagram or flow diagram for the pipe connections
● preliminary work form for commissioning.
1.4 Decommissioning
Heat pump systems must be decommissioned in accordance with applicable laws and
regulations. Heat pumps include materials and substances that require special care,
including:
● Refrigerant
● Oil
● Electrical components
● Batteries
● Other materials
The specific considerations for each substance or material are described in the
following sub-sections.
Refrigerant
Depending on the model, the heat pump includes one of the refrigerants listed in table
below.
Refrigerant Details
R134a Norfluorane / 1,1,1,2-Tetrafluoroethane
R1234ze(E) trans-1,3,3,3-tetrafluoropropene
R513A mix of R1234yf and R134a
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Refrigerant Details
R450A mix of R1234ze and R134a
R410a mix of difluoromethane and pentafluoroethane
R1233zd Trans-1-chloro-3,3,3-trifluoropropene
Refrigerants should be recycled, or disposed if recycling is not possible, by a service
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. Use appropriate precautions to
prevent the oil for leaking or ending up in the environment.
Electrical components
Heat pumps include a wide range of electrical components, such as digital devices,
electric circuits, sensors, and a variable frequency drive. Any such items should be
handled and disposed of as indicated in the instructions given by their manufacturer or
in accordance with local laws and regulations.
Batteries
Batteries can be hazardous for the environment. Consequently, if the heat pump
includes an electronic device with an internal battery, the battery must be appropriately
disposed of.
Other materials
In addition to the above, 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.
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2 Technical data
2.1 Heat pump technical data
Dimensions and weight
Measurements without
cover and extra feet
S 180 S 280 S 380 S 490 S 580 S 600
Height (mm) 2091 2091 2091 2091 2091 1900
Width (mm) 2876 2876 2876 2876 2876 4700
Depth (mm) 911 911 911 911 911 1000
Weight (kg) 2300 2900 3600 4000 4500 3200
Measurements without
cover and extra feet
S 800 S 1000 S 1200 S 1500 S 2000
Height (mm) 1900 2100 2100 2190 2190
Width (mm) 4700 4700 4700 5500 5500
Depth (mm) 1000 1100 1100 1600 1600
Weight (kg) 4000 4500 5300 6500 7500
Connections
For information on pipe connections, see connection diagrams delivered with the heat
pump.
S 180 S 280 S 380 S 490 S 580 S 600
Electrical connections 3 L / PE / 400 VAC 50 Hz, ask for other alternatives
Fuse size (A) 250 355 400 500 630 2x3x400
Protection degree, control cabinet IP44
S 800 S 1000 S 1200 S 1500 S 2000
Electrical connections 3 L / PE / 400 VAC 50 Hz, ask for other alternatives
Fuse size (A) 2x3x400 2x3x630 2x3x630 2x3x800 2x3x1000
Protection degree, control cabinet IP44
Refrigerant circuit
The refrigerant charge values presented here are baseline values. The
actual refrigerant charge depends on the heat pump exchanger option,
other accessories, and the local conditions.
Always check the exact refrigerant charge from the heat pump’s type
plate.
S 180 S 280 S 380 S 490 S 580 S 600
Refrigerant R134A R134A R134A R134A R134A R134A
Refrigerant charge (kg) 34 55 77 90 96 2 x 75
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S 800 S 1000 S 1200 S 1500 S 2000
Refrigerant R134A R134A R134A R134A R134A
Refrigerant charge (kg) 2 x 100 2 x 135 2 x 170 2 x 240 2 x 350
Water or brine circuits: Minimum water/brine outlet temperature from the evaporator: –
15 °C. Maximum water/brine inlet temperature to the evaporator: +50 °C.
Process water quality requirements for shell and tube heat exchangers
For quality requirements concerning process water as well as general instructions
for shell and tube heat exchangers, refer to technical bulletin 0006 (TB-00006-
External_ENG).
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3 Installation
3.1 Installation site requirements
Installation, commissioning, or service of the appliance is to be carried
out by an authorized service provider, adhering to all local regulations
and requirements.
Do not install the heat pump in an explosive environment.
Install the heat pump in a location that is not accessible to the general
public.
The heat pump housing must be kept closed at all times. Only under
maintenance and service occasions, to access the internal components,
the heat pump housing can be opened.
The heat pump must not be installed on flammable material.
Follow local construction rules and regulations 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 with variable frequency drives, the maximum ambient
operating temperature is +30 °C. If the temperature is higher, separate ventilation
must be arranged for the VFD units.
● The minimum ambient operating temperature is +10 °C.
● The heat pump must be installed on an completely level and even surface.
● Each of the heat pump's feet must be firmly placed on the floor, and the load must
be evenly distributed on the feet.
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● The heat pump must be properly protected from the rain and direct sunlight.
● The machine room needs to be properly lit and ventilated. Escape and access
routes must be unobstructed and the site must have working emergency lighting.
● The maximum altitude for the installation site is 5,000 m.
Refrigerant circuit site requirements
Refrigerant circuits are equipped with pressure relief valves. In fault situations they will
discharge any excess pressure in the circuits.
Make sure that potential pressurized discharge from refrigerant circuit’s
pressure relief valves does not cause danger to people or property.
Refrigerant circuit safety valves
It is recommended to 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-
off pipe according to standard EN 13136.
Space requirements
For installation, operating and maintenance purposes, leave enough space on each
side of the heat pump. The minimum space requirements are listed in the following.
By default, the control cabinet is attached to the right side of the heat pump. On
request, the control cabinet can be moved to the left side of the heat pump.
Space requirements ver. 1
Legend mm
a
(left)
800
b
(back)
400
c
(right)
800
d
(front)
800
e
(top)
400
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3.2 Main parts
S 180 – S 580 main parts
d068643 ver. 1
The assembly may vary depending on the scope of delivery.
Pos. Part Pos. Part
1 Control panel 7 Double safety relief valve with
changeover valve
2 Control cabin 9 Filter drier
3 Condenser 10 Expansion valve
4 Evaporator 11 Main switch and either variable frequency
drive, star-delta starter or soft starter
5 Subcooler  
6 Compressor  
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S 600 – S 2000 main parts
D080678 ver. 1
The assembly may vary depending on the scope of delivery.
Pos. Part Pos. Part
1 Control panel 7 Double safety relief valve with
changeover valve
2 Control cabin 9 Filter drier
3 Condenser 10 Expansion valve
4 Evaporator 11 Main switch and either variable frequency
drive, star-delta starter or soft starter
5 Subcooler  
6 Compressor  
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 and need to be checked.
3.4 Connections and dimensions
For information on connection positions and sizes, refer to the diagrams delivered with
the unit.
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