Airwell AW-WHPMA04-91 Manual

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.
A
B

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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)
18
18
32
32
43
43
43
27
27
27
Wiring size(mm2)
4.0*
4.0*
8.0*
8.0*
10.0*
10.0*
10.0*
4.0*
4.0*
4.0*
L
L
L
N
N
N
N
N
L1
L1
L2
L2
L3
L3
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
on
S1
S2
S3

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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
2
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.