Airwell AW-WHPMA04-91 Handbuch

Airwell Typical Installation with Third

Party controls

Installation and Setup

Monobloc system

Rev 1.3 March 29th 2022

Draft for Comments

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This manual is designed to be a quick start guide for the most common type of installation, for the Airwell Monobloc

range.

This shows heating via Buffer Tank and domestic hot water via a cylinder, with a sensor pocket and immersion

heater installed, using 1x 3 port drive open valve to control space heating and Hot water heating demand using

the Airwell controller and third-party control for the end user control.

In the above system the monobloc unit functions are controlled by the unit’s own controller and this is for use

by the technician. End user control is via Third Party controls.

The end user controls the heating demand via the third-party controller.

The heat pump controls the domestic hot water temperature itself (including an optional sterilization cycle

assisted by the immersion heater) using a drive open 3 port valve in a W plan heating configuration.

The hot water temperature is managed through the Airwell Controller. Hot water takes priority over heating.

There is no electric heater installed inside the monobloc unit.

There is a Flow sensor, Pump, Auto Air Vent, Safe Relief valve and 8lt Expansion vessel located within the monobloc

unit.

There is a pump installed within the monobloc, however a second pump will be required on downstream of the buffer

to feed the heating circuits.

A strainer must be installed in the return pipework to the mono block this is included with the unit. It is strongly

recommended by Airwell in addition to this, a Magnetic filter and Flow setter should also be installed to the unit.

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Warranty

Please check the following before commencing start-up of the unit, as these are important conditions of the Airwell

Warranty*

•The manufacture supplied filter has been installed to the return to the monobloc.

•The system should be flushed, this is especially important if the system is an old gas or oil system. Flushing

should be completed in accordance to BS7593.

•Airwell recommends a suitable heat transfer fluid is used to give a minimum frost protection of -12. In

order to stop bacterial growth, it is also recommended to use a suitable Biocide, if not included in the heat

transfer solution.

•A 25lt buffer is Recommended for the 4-10kw units and a 40lt for the 12-16kw Airwell heat pumps, In order

to meet the minimum system water open volume at all times.

•The pipe work diameter should be sized in relation to the length of the pipework run, number of fittings

and components but should have an internal bore no less than 28mm copper pipework. Be aware that

plastic pipework tends to have a smaller internal bore and needs to be sized correctly.

•The external monobloc should be installed on a base suitable for withstanding the weight of the unit and

should be level. The steel plinth is Structural and MUST NOT be removed

•There shall be a proper means of disposal of the condensate, this should be via a drain or soak away.

•The external monobloc unit should be positioned so that there is good air flow around the unit. The

minimum clearances are 300mm to the left, 600mm to the right, 300mm behind the unit and 1000mm in

front on the 4-6kw and 1500mm on the 8-16kw units.

*The Terms and Condition should be referred to for further information.

As part of the commissioning process, it is important that the correct flow rates are achieved for the output of the unit.

Failure to do so, will result in poor performance and protentional faults. The flow rates required are specified below.

*Please be aware if the only the minimum flow rate is achieved through the unit the unit will not function to its full output.

Unit

Minimum Flow Rate

Maximum Flow Rate

AW-WHPMA04-91

6.64 Lpm*

14.16 Lpm

AW-WHPMA06-91

6.64 Lpm*

20.82 Lpm

AW-WHPMA08-91

6.64 Lpm*

27.48 Lpm

AW-WHPMA10-91

6.64 Lpm*

33.32 Lpm

AW-WHPMA12-91

11.62 Lpm*

41.65 Lpm

AW-WHPMA14-91

11.62 Lpm*

45.81 Lpm

AW-WHPMA16-91

11.62 Lpm*

49.98 Lpm

AW-WHPMA12-91 3ph

11.62 Lpm*

41.81 Lpm

AW-WHPMA14-91 3ph

11.62 Lpm*

45.81 Lpm

AW-WHPMA16-91 3ph

11.62Lpm*

49.98 Lpm

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Power Supplies

The Monobloc requires one Power supply, the details of the power supply are detailed below.

*The above sizing are for guidance only, correct cable sizing should be undertaken by a suitably qualified engineer.

All electrical connections should be completed by a NICEIC competent electrician

If an immersion heater is installed to the DHW tank this should have its own independent supply. DO NOT supply

directly from the PCB. This would require an additional 13amp supply and suitably sized cable.

All supplies should be via a double switched isolator and all cables should be sized in accordance with BS7671.

The Controller Requires a 5 core Screened cable. We would

recommend CAT 5e FTP cable, this cable is polarity sensitive,

so, it is important not to mix up the cores.

Unit

4kW

6kW

8kW

10kW

12kW

14kW

16kW

12kW 3-PH

14kW 3-PH

16kW 3-PH

Maximum

overcurrent

protector(MOP)(A)

Wiring size(mm2)

4.0*

8.0*

10.0*

4.0*

Unit Power Supply

1-Phase

Unit Power Supply

1-Phase

Unit Power Supply

3-Phase

Unit Power Supply

3-Phase

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Control Wiring

Below shows a basic wiring schematic for use with the previous hydralic schematic, for the Airwell monobloc Heat

pump. Using a Third party room stat for switching on and off the heating demand.

Each terminal supplies a maximum of 0.2amp if the item connected draws more than 0.2amp a relay and a external

power supply should be used.

The Domestic Hot water sensor is connected directly to the PCB on plug CN13. There is a flying lead with a plug on for

connecting this, this is located at the right-hand side of the unit. As in the

picture to the right-hand side.

The Domestic Hot water sensor is supplied with a 10m Cable, this cable

can be extended to a maximum of 20m. This should not be shortened.

Power Supply Via

Switched Fuse Spur

Power Supply Via Switched Fuse Spur*

*Pumps with a drawing less that 0.2A can be connected

directly to PCB

*Alternatively, the Immersion can be feed

Via a 3rd Party time Clock Local to the

heater

Post Buffer

Pump

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DIP Switch Settings

There are 3 sets of dip switch located on the unit’s main PCB, these are S1, S2, S3 these control certain function of the

unit, so must be set accordingly to allow correct operation.

S1 Dip Switch’s control the IBH if fitted in the unit.

S2 Dip Switch’s control the Internal Pump.

S4 Dip Switched are for multiple unit setups.

S1 Dip switch 1/2 should be set to OFF/OFF, this will deactivate the IBH (internal back up heater is not fitted to the

Airwell unit as standard)

S1 Dip switch 3/4 should be set to OFF/OFF, this will deactivate the IBH and AHS (additional heat Source) if fitted set to

OFF/ON

S2 Dip switch 1 should be OFF

S2 Dip switch 2 should be set to OFF if the immersion heater is connected to the unit. If the Immersion heater is

independent from the heat pump this must be set ON, failure to do so will lead to faults.

S2 Dip switch 3/4 should be set according to the pump installed in the unit.

S4 Dip switch 1/2/3/4 all off as Default.

off

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Pre-Commissioning Checks

Before starting the unit, a number of pre checks that must be carried out. These can be found listed below.

On the larger 12/14/16kw units there is a Transportation support bracket installed to the compressor within the unit,

this bracket must be removed prior to starting the unit. Failure to remove the support bracket will result in the

compressor becoming noisy and potentially being DAMAGED and would not be covered under the Warranty terms and

conditions. Please find further details below.

1. Make sure the water hydraulics are piped up in accordance with the manufacturer’s instructions.

2. Make sure the electrical connections are wired in accordance with the manufacturer’s instructions.

3. Make sure the system is fully flushed and an adequate filtration system is fitted.

4. Open any auto air vents and fill the system 1 bar minimum and make sure the system is vented fully.

5. Make sure the system is leak free.

6. Make sure an adequate level of anti freeze is added to the system to give protection to a -12֯c. Make sure the

anti freeze is fully mixed into the system prior to starting the unit.

7. Make sure the DIP switches are set as per this manual.

Controller Overview

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Starting Up the Unit for the First Time

When the monobloc is powered up for the first time, 1-100% will be displayed on the user interface during

initialisation, in this time the controller can’t be used.

The following setting must be entered into the controller these are detailed below, in order for the controller and Heat

pump to operate correctly.

Press and Hold the unlock button for 3 seconds.

Press the menu button to enter the menu

Scroll down the using the down arrow to SERVICEMAN and press OK

Enter the SERVICEMAN code 234.

Select DHW MODE SETTING

Set DHW Mode to YES

DISINFECT should be set YES if the

immersion is controlled by the

heat pump.

DHW PRIORITY should be set to Yes

1.18 t_DHWHP_MAX should be set

According to the tank size:

200L - 60min

300L - 90min

All changes to selections must be confirmed with OK

Press BACK

Select Cool Mode

Cool Mode 2.1 should be set to NON

All changes to selections must be confirmed with OK

Press BACK

Select Heat Mode

Set T1setH1, set to 55֯c for Rads and 45֯c

for UFH or to the Design flow temp.

Set T1SetH2, set to 30֯c

Set T4H1, set to the External design temp

We recommend -2֯c or -5֯c for Scotland

FOR SERVICEMAN

Please input the password:

OK ENTER ADJUST

3 4

NON

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c֯15, set to Set T4H2

This will give a weather compensated curve of 45 degrees flow temp

degrees 52 degrees outside and a Flow temp of 30 degrees at 1-at

ambient air temprture outside

OKwith ds to selections must be confirmeAll change

Press Back

lect Room ThermostatSe

tat toChange Room Thermos

1 Zone

OKss Pre

ss Back Twice to return to the home screenPre

To Activate the Weather Compensated Curve entered earlier, the next steps must be followed.

From the main screen press Menu button

Select Pre-set temperature and press OK

Go across to Weather Temp. Set

Scroll down to Zone1 H-Mode low temp,

Press the ON/OFF button to turn on.

Scroll right to the Number 9 and Confirm with OK

Press Back, until you return to the Home Screen.

Test Mode

The unit can be put into a Test mode, this is done through the SERVICEMAN menu accessed as above.

In the Test mode menu, there are a couple options that can be selected in this menu, these include testing of all Outputs.

This will allow the installer to check the unit has been wired correctly, there is also a handy air purge function within this menu.

We recommend that the air purge function is carried out before initially starting the unit. Please Find below the details

on carrying out this process.

Enter SERVICEMAN mode using the password as

Detailed in the previous section.

Scroll down and Select Test Run with OK

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Once in Test Run menu, scroll down and select

Air Purge with OK the unit will now run-in air purge

Mode until exited.

During this process any auto air vent within the

unit should be open and any external auto air vent,

the pressure should be observed throughout, the

venting process and topped up as required.

To return to the home screen press Back until the

home screen is displayed

If point check is selected.

A number of outputs can be tested manually. Scroll

down to the required Output and turn on/off using

the ON/OFF button

Press Back until back at the home screen once

Completed.

Factory Reset

If at any point all the setting requires changing back to default, this can be done via the factory reset option.

This can be selected in the SERVICEMAN menu, by selecting Restore Factory Settings.

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