Hewalex PCWU 2.5kW Mode d’emploi

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INSTRUCTIONS FOR USER

NAME PCWU 2.5kW

EQUIPMENT CHARACTERISTICS

Utility water heat pump - PCWU 2.5kW uses heat contained in outdoor or

ventilation air for high-efficiency hot utility water production.

The temperature of outlet air from heat pump is 5-10°C lower. It may be

used to cool rooms in summertime.

The PCWU 2,5kW heat pump is a complete device using RES, which offers the most extended package of possibilities for utility

water heating:

–possibility of work as the only source for utility water heating beyond heating season

–all-year-round operation with ventilation air, flow exceeding 350 m3/h

–setting operation priorities for various heating devices in HUW boiler-room, so as to ensure possibly lowest costs of the

system interaction

–time programmes

–circulation control

–intuitive and at the same time the most complex controller in the HUW heat pump market in Poland

–possibility to control and analyse operation statistics in EKONTROL.pL (a separate LAN module is needed)

–access to thoroughly metered thermodynamic system of the unit

–the system completeness - e.g. circulating pump, absorbing feet, all temperature sensors in the set

–complete connection accessories available in the offer (including: ducts, dampers, air guides and on-wall structures)

Table of Contents

Introduction

1. The system safety and comfort ................................................................. 2

2. Technical warranty terms and conditions................................................... 4

3. Recycling and utilisation............................................................................ 5

4. Environmental requirements...................................................................... 5

User’s part

1. Introduction ................................................................................................6

2. Savings..................................................................................................... 7

3. Heat pump design..................................................................................... 7

4. Controller description..................................................................................8

Controller map......................................................................................... 8

Heat pump start-up...................................................................................9

Operation parameters settings ...............................................................10

Controller settings ..................................................................................15

Measurement indications........................................................................16

Info.........................................................................................................16

5. Anti-Legionella..........................................................................................16

6. Equipment maintenance...........................................................................16

7. Remotely-controlled access to the unit.....................................................17

8. Frequently asked questions regarding operation ......................................18

Guarantee Certificate ................................................................................ 19

Checklist (for user)..................................................................................... 20

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Introduction

The system safety and comfort

NOTE:

HEWALEX bears no responsibility in cases, when installation safety rules haven’t been followed.

All specified safety rules shall be strictly followed in order to avoid hazard for health or life of users and fitters!

operation ADULT

fitting FITTER

The unit may be operated by grown up persons only,

without any mental and/or physical impairment, trained by

fitter and knowing the unit Manual well.

The heat pump should be installed by qualified fitter

possessing specialised knowledge and valid licence for

electrical works up to 1kV. In case if the unit location must

be changed, also use services of qualified fitters.

Secure the unit

COOLING-RELATED failures

Do not put your fingers inside the unit housing, if it is

connected to power supply. There is a hazard of burning,

electric shock or cutting your fingers. In particular, protect

the unit against access of children.

Heat pump is filled with cooling medium allowing its

correct operation. It is prohibited to allow people without

required experience and qualifications cooling cycle

opening. Any possible repairs should be also carried out

by qualified personnel.

Flammable gases or corrosive environment

CHECKLIST

Do not install the unit near storage areas used for

flammable gases or in environment, which may have

corrosive impact on the equipment.

Fitting and first start-up should be carried out by a person

commissioning the system according to the system start-

up checklist, accompanied by the Investor. Suitable report

should be made as well.

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Maintenance

Design

Evaporator should be cleaned at least 1 per year (before

season) in order to ensure its efficient operation. Cut off

power supply in case of cleaning or maintenance of the

unit subassemblies.

Make sure that the structure holding the unit is firmly fixed

to the wall. The machine should be adequately levelled in

order to ensure correct heat pump operation and proper

condensate discharge.

Power supply

In case of emergency...

Power supply line should be provided according to the

requirements specified in the Manual and laid so as to

prevent its flooding with water. If it is planned that heat

pump will not be used in winter season, it should be

switched off only through the controller. Do not cut off

power supply.

Earthing is an obligatory element of power supply.

If user observes any alarming symptoms (e.g. noise or

odour) indicating abnormal equipment operation, it is

required to cut off power supply and consult authorised

service centre.

Safety

The unit location

During installation keep to industrial safety requirements

according to current regulations concerning environmental

protection, safety of work, and making of installations and

safeguards.

Install the heat pump in a heated room. If you do not use

the unit in winter, cover air ducts in order to avoid

excessive cooling of room.

THE CE CERTIFICATE

The heat pump is CE marked.

The CE mark confirms the product compliance with regulations applicable in the European Union. The compliance has

been confirmed on the basis of obtained results of tests related to harmonised standards:

PN-EN 60335-1:2004:/A1:2005/A2:2008,

PN-EN 60335-2-40:2004+A1:2006+A2:2009+A11:2005+A12:2005

The tests were performed by an accredited Research Laboratory in Poland.

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Technical warranty terms and conditions

At the end of this Manual you will find Guarantee Certificate containing the following warranty terms and conditions. Correctly

filled card is the basis for making a complaint regarding incorrectly working equipment.

A) It is prohibited to repair the unit without contact with HEWALEX service. In case of incorrect equipment operation, report

failures by phone ((32) 214 17 10) or e-mail ([email protected]). Depending on failure type, service team will be sent to the

site, or guidelines concerning repair of minor defects will be provided.

B) It is allowed to connect the heat pump to correctly working electrical system only. Installation requirements:

–power cable to the mains socket: 3x2.5mm2300/500V, complying with the 227IEC53

–current protection: B16 or C16

–differential-current protection: 30mA

–correctly made earth installation (grounding resistance should not exceed 4Ω).

All the above power supply parameters are standard and do not go beyond applicable norms.

C) Water in the system must meet the requirements specified for potable water (O.J. (Poland) no. 203, item 1718). Important for

own water intakes:

–pH ranges between 6.5 and 9.5

–conductivity under 2500 [uS/cm at 20°C]

–ammonia under 0.5 [mg/l]

–nitrates under 50 [mg/l]

–chlorides content under 250 [mg/l]

–copper under 2 [mg/l, permissible value provided that it does not cause any change in water colour due to its

corrosive aggressiveness]

–sulphates under 250 [mg/l]

–hardness 60-500 [mg CaCO3]

D) Water, air and wiring systems for the unit should be made according to the guidelines and connection diagram.

E) Select proper location for the unit installation. Any damage caused by improper selection of the equipment location will not be

covered by the guarantee (that is caustic and polluted air drawn into the heat pump, unlevelled equipment, foundation tilting the

unit, installing in an unheated room).

H) It is prohibited to switch off the unit during break in operation (e.g. in wintertime). Otherwise, user will be solely responsible

for eliminating circulating pump protection against seizure and anti-freezing protection.

NOTE:

Guarantee is valid since equipment purchase date. Guarantee requires sending the checklist not later than 30 days after fitting date

(however not later than 90 days from purchase date) to the following address: HEWALEX Sp. z o.o. Sp. komandytowa, ul.Słowackiego 33,

43-502 Czechowice-Dziedzice, Poland, with a note: GWARANCJA PCWU [PCWU GUARANTEE] 2.5kW, or after registering at

hewalex.pl/gwarancja and filling the form.

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Recycling and utilisation

All machine components are made of materials, which are not harmful for environment. To a large extent they are recyclable.

Non-reusable materials can be utilised.

Environmental requirements

During maintenance and/or service works, one must satisfy important for environment requirements regarding recovery, reuse

and utilisation of materials. In particular, keep to the following standards concerning cooling medium contained in freon cycle:

DIN 8960 Cooling medium, requirements

DIN EN 378 Cooling systems and heat pumps - requirements concerning safety and environment protection

The R410a cooling medium is safe, non-flammable, freon-free and not harmful for ozone layer.

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User’s part

Introduction

Heat pump is a device, which allows efficient absorbing of heat from our environment. Drawing heat from area of lower

temperature with a compressor, it rises medium temperature. This allows using absorbed energy for heating purposes. Heat

pumps belong to the category of renewable energy sources, because on average 70-80% of energy for heating is taken from

environment.

HEAT PUMP PRINCIPLE OF OPERATION

Basic advantage of heat pump is that it is characterised by considerably lower electric energy consumption than thermal energy

generated by it. Compared to electric heater of the same power, electric energy consumption is few times lower. Therefore, the

main parameter characteristic for heat pump operation is the COP (coefficient of performance). Below you will find an

explanation how heat pump works and how different factors affect its operation efficiency.

The COP coefficient is calculated according to the following formula:

equipment heating power

COP = absorbed power of the drive

The COP coefficient depends primarily on the temperature of air delivered to heat pump and utility water temperature required

by us. The higher COP value, the better efficiency of our installation.

The COP coefficient drops with decreasing air temperature, and due to physical parameters of the medium in compressor

system it becomes impossible to receive heat for certain low temperature of the source. The same problem applies to the

temperature on heated water side. Raising required utility or heating water temperature will also lower the COP coefficient

value. Therefore, in order to maximise efficiency of heat pump use we should make efforts to provide optimal conditions of its

operation that is to ensure adequately warm air for its work, and to consider whether preset heating temperature of the heat

pump is not unnecessarily too high.

From point of view of the system economy, if utility water temperature ranging from 45 to 50°C is comfortable for us, then heat

pump should work up to the temperature of 50°C (its restart according to factory settings will take place as soon as temperature

in the tank drops to 45°C). In other heating sources, where cost of heating does not depend on the temperature of heated water,

a frequently applied solution involves vessel superheating and using a mixing valve - in case of heat pumps it is not an

economically justified solution.

Inlet air temperature grows

Air humidity is higher

Temperature of heated water is lower

COMPRESSOR

EXPANSION VALVE

AIR INLET

AIR INFLOW

TOTAL

THERMAL

ENERGY

ELECTRIC ENERGY

HUW OUTLET

GASEOUS COOLING MEDIUM

RENEWABLE

ENERGY

LIQUID COOLING MEDIUM

HUW INLET

CONDENSER

EVAPORATOR

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The essence of operation of such machine as heat pump is its work with heat transmitted during phase transitions. Therefore,

using special cooling media, we are able to receive heat at low air temperature values and transfer it to warmer water without

high energy expenditure. In some way, it is a system much like refrigerator - from its interior we carry heat out of cooling

chamber. In case of heat pumps the process is reverse, however analogical as regards its principle - heat is drawn from

environment and transferred inside utility water tank.

Savings

One of the main criteria for equipment purchase is to ensure savings during its operation. Especially, when we use electric

heaters or oil-fired boiler for HUW heating in summertime, we have economic grounds for switching to air heat pump. In case of

solid fuel fired boiler we speak less about economic profits compared to combusted fuel itself, because water heating costs are

comparable - here, decisive issues are: automatics of the system operation and possible costs, which have to be incurred for

chimney repair in case of boiler work at low parameters (flue gas condensation).

Below we show costs for 1kWh of heat in summertime for various automatic equipment:

1. For heat pump – average-season COP coefficient = 3.4; cost for

1kWh of electric energy 0.65 PLN

2. For natural gas assumed cost is 2.15 PLN/m3(fixed charges not

included), min. kWh content in 1 m3of gas (according to standard)

reaching 8.61 kWh/m3, actual efficiency of gas-fired boilers in

summertime (low-load work), near 70%

3. For oil heating, cost for 1l of oil 4.10 PLN, actual efficiency of oil-

fired boilers in summertime near 70%, kWh content in 1l of oil:

10 kWh/l

4. Cost of 1 kWh of electric energy, 0.65 PLN/kWh

In case of using heat pump for room cooling, return on investment will be even faster - cooling is a side-effect, and therefore it is

completely free and reduces return on investment period to 2-3 years.

Heat pump design

Main parameters of the compressor in heat pump system:

1) Increases cooling medium pressure and temperature to allow efficient

heat transfer in heat pump condenser

2) The compressor has considerable impact on the efficiency and

productivity of the whole process, because this heat pump section

consumes ca. 90% of electric energy.

Condenser. Shell-and-tube heat exchanger has been used as a device,

in which heat is transferred to utility water. Utility water flows through

copper tube with extended heat exchange area. Cooling medium flows in

jacket between housing and internal cylinder. During heat transfer it

condenses from gaseous form to liquid and returns process heat

previously drawn in the evaporator.

Due to the exchanger design, we can work

directly with utility water, considering both

hygiene and negligible exchanger

susceptibility to scaling.

Rotary compressor has been used in the

PCWU 2.5kW heat pumps.

Medium state changes from liquid to

gaseous inside the evaporator. During

evaporation, the medium draws a lot of heat

from air (this heat will be returned to utility

water during condensation). Due to low

specific heat of air, we have to force air flow

through evaporator using the fan.

Electronic, automatically controlled

precision expansion valve. Expansion valve

is expected to ensure that cooling medium

in evaporator draws heat from air washing

the evaporator. Heat transfer is generated

through medium evaporation. Depending

on medium temperature difference before

and after the evaporator, expansion valve

either opens (at the moment when high

volume of heat may be drawn in evaporator

- larger amount of the medium can be

evaporated) or closes (if too much medium

is being sent to the evaporator and all of it

cannot be evaporated because of

insufficient amount of heat in air). Expansion valve opening or closing

changes medium pressure before evaporator - and thus modifies medium

evaporation temperature (lower pressure - the medium boils at lower

temperatures, and for higher pressure - at higher temperatures).

Remember that soiled evaporator (e.g. with greasy air, pollens or leaves)

will draw heat from air in a considerably less efficient way.

electricity

heat pump

natural gas

fuel oil

Cost

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Controller description

Controller map

MENU Login [default 0000]

Parameter settings

Heat pump operation parameters

Heat pump activation [YES/NO, factory setting YES]

HUW temperature for heat pump [10-60°C, factory setting 50°C]

Minimum ambient temperature (T1) [-5-10°C]

Parameters of accessory equipment

Heater E [shown in diagrams no. 3,4,5,6,7,8,9]

Heater activation [YES/NO, factory setting YES]

HUW temperature for heater - heat pump on [30-60°C, factory setting 45°C]

HUW temperature for heater - heat pump off [30-60°C, factory setting 55°C]

Heater stoppage during heat pump operation [YES/NO, factory setting YES]

Heater stoppage during gas-fired boiler operation [YES/NO, factory setting YES -

shown in diagrams no. 4,7,9]

Heater P [shown in diagrams no. 4,5,6,7,8,9]

Heater activation [YES/NO, factory setting YES]

HUW temperature for heater - heat pump on [30-60°C, factory setting 45°C]

HUW temperature for heater - heat pump off [30-60°C, factory setting 55°C]

Heater stoppage during heat pump operation [YES/NO, factory setting YES]

Heater stoppage during gas-fired boiler operation [YES/NO, factory setting YES -

shown in diagrams no. 4,7,9]

Circulating pump [shown in diagrams no. 2,3,4,6,7,8,9]

Minimum circulating pump activation temperature [20-60°C, factory setting 35°C]

Circulating pump operation mode [INTERMITTENT/CONTINUOUS, factory

setting INTERM.]

Solid fuel fired boiler B [shown in diagrams no. 5,7,9]

Max. boiler pump deactivation temperature [10-85°C, factory setting 65°C]

Min. boiler pump activation temperature [30-60°C, factory setting 45°C]

Temperature difference for boiler pump activation [5-15°C, factory setting 8°C]

Solid fuel fired boiler heating priority [YES/NO, factory setting YES]

Gas-fired boiler D [shown in diagrams no. 6,7,8]

Max. boiler pump deactivation temperature [10-85°C, factory setting 65°C]

Boiler stoppage during heat pump operation [YES/NO, factory setting YES]

Time programmes

Heat pump

Heater E

Circulating pump [shown in diagrams no. 2,3,4,6,7,8,9]

Gas-fired boiler D [shown in diagrams no. 6,7,8]

Anti-Legionella [shown in diagrams no. 3-9]

Anti-Legionella function activation [YES/NO, factory setting YES]

Protection carried out by heater E [YES/NO, factory setting YES]

Protection carried out by heater P [YES/NO, factory setting YES]

Protection carried out by gas-fired boiler [YES/NO, factory setting YES, shown in diagrams

no. 6,7,8]

Passwords

User

Controller settings

Date and time

Display Backlight brightness [1-10, fab.10]

Inactivity time until backlight switching off [1-10min., factory setting 10min.]

Sounds Sound of keys [YES/NO, factory setting YES]

Sound of alarms [YES/NO, factory setting YES]

Port RS485

Transmission rate [by default 115200]

Physical address [by default 255]

Logic address [by default 65535]

Language

Polish

English

German

Manual control

Measured indications

Info

Software replacement [only for manufacturer]

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Heat pump start-up

The following messages will be displayed for few seconds after switching on power supply of the machine. Please, do not touch

keyboard then.

Main screen of the controller will appear then. It contains the following:

Start with studying basic pushbuttons to freely move though the controller.

Approval key. Press it to approve settings or enter

required controller level.

Arrow up. You will move to higher items in the list,

or return to the main screen from the screen

showing internal diagram of heat pump.

Return key. Press it to return to previous controller

level without saving setting changes.

Arrow down. You will move to higher items in the

list, or go from the main screen to the screen

showing internal diagram of heat pump.

Press arrow down to move to internal diagram of heat pump. Press arrow up or wait few seconds to return to the main screen.

Press this button to enter individual settings menu. A list of settings or information to browse or change will appear.

Press arrow down to see the whole list. Press arrow up to return to previous items.

The unit on/off pushbutton. Confirmation screen will appear after pressing this button (below, on the left side. Press

OK to switch off the controller.

Device operated from heat pump controller

(marked with letter)

Operation or alarm status message

Pulsating items indicate devices

currently at work

Indications of temperature sensors

Date and hour

Digits indicate position of

temperature sensors

to be operated by the controller

Number of selected boiler-room diagram

High pressure pick-up

Condenser (heat exchanger)

Expansion valve

Evaporator (heat exchanger)

Low pressure pick-up

Compressor

Circulating pump - WILO ZRS 15 / 6

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NOTE:

It is prohibited to cut off power if the unit is filled with water. This will deactivate tank protection and circulating pump safeguards.

Login is the first item in Menu (below, on the left side). Press OK. Access screen appears where password should be entered

(photo below, to the right). By default, for the user it has been set to 0000 (press OK 4 times). After the next 5 minutes from

return to the main screen the password will be saved and there is no need to enter it again throughout the controller. Fitter’s

password is provided in installation and service instructions in the controller map.

Operation parameters settings

After approval we may enter parameter settings (screen view below on the left side). Scrolling arrow down, we may also see

second part of the list (below, to the right).

Heat pump parameters

3 items will appear when we enter heat pump parameters (OK pushbutton). Press OK, the value in grey field will start to pulsate.

Then, set the required value using arrows and confirm with OK.

YES - heat pump will work until the required water

temperature in the tank is reached. If the heat pump is

set to YES, its operation may be stopped only by an

alarm or settings of other equipment priorities.

NO - heat pump will not switch off

It is possible to change heated water setting within 10 to

60°C.

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