Airwell AW-WHPMA18-H93 User manual

TECHNICAL MANUAL
WELLEA MONOBLOC DF
R32
21.AW.WELLEA.MONO.DF.R32.TM.EN.22.02
AW-WHPMA18-H93
AW-WHPMA22-H93
AW-WHPMA26-H93
AW-WHPMA30-H93

1
CONTENTS
CONTENTS
Part 1 General Information............................................................................ 3
Part 2 Engineering Data ............................................................................... 19
Part 3 Installation and Field Settings.......................................................... 39

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3
Part 1 - General Information
Part 1
General Information
1 Wellea Mono DF System............................................................................ 4
2 Unit Capacities ........................................................................................... 6
3System Design and Unit Selection .............................................................. 7
4Typical Applications ................................................................................... 9

4
1 Wellea Mono DF System
1.1 System Schematic
Figure 1-1.1: System schematic
Wellea Mono DF is an integrated air-to-water space heating, space cooling and domestic hot water heat pump system.
Wellea Mono DF Outdoor Unit
Distributor
The outdoor heat pump system extracts heat from the outdoor air and transfers this heat trought refrigerant piping
to the plate heat exchanger in the hydronic system. The heated water in the hydronic system circulates to low
temperature heat emitters (floor heating loops or low temperature radiators) to provide space heating, and to the
domestic hot water tank to provide domestic hot water. The 4-way valve in the outdoor unit can reverse the
refrigerant cycle so that the hydronic system can provide chilled water for cooling using fan coil units.
Wellea Mono DF is an integrated air to water heat pump system which is one-stop solution for space heating, space
cooling and domestic hot water. The outdoor heat pump system extracts heat from the outdoor air and transfers this
heat through refrigerant piping to the plate heat exchanger in the hydronic system. The heated water in the
hydronic system circulates to low temperature heat emitters (floor heating loops or low temperature
radiators) to provide space heating, and to the domestic hot water tank to provide domestic hot water. The 4-way
valve in the outdoor unit can reverse the refrigerant cycle so that the hydronic system can provide chilled water for
cooling using fan coil units.
The heating capacity of heat pumps decreases with ambient temperature dropping. Wellea Mono DF can be
equipped with a backup electric heater to provide additional heating capacity for use during extremely cold
weather when the heat pump capacity is insufficient. The backup electric heater also serves as a backup in case of
heat pump malfunction and for anti-freeze protection of the outside water piping in winter.

5
Part 1 - General Information
1.2 System Configurations
Wellea Mono DF can be configured to run with the electric heater either enabled or disabled and can also be used in
conjunction with an auxiliary heat source such as a boiler.
The chosen configuration affects the size of heat pump that is required. Three typical configurations are described below.
Refer to Figure 1-1.2.
Configuration 1: Heat pump only
The heat pump covers the required capacity and no extra heating capacity is necessary.
Requires selection of larger capacity heat pump and implies higher initial investment.
Ideal for new construction in projects where energy efficiency is paramount.
Configuration 2: Heat pump and backup electric heater
Heat pump covers the required capacity until the ambient temperature drops below the point at which the heat
pump is able to provide sufficient capacity. When the ambient temperature is below this equilibrium point (as shown
in Figure 1-1.2), the backup electric heater supplies the required additional heating capacity.
Best balance between initial investment and running costs, results in lowest lifecycle cost.
Ideal for new construction.
Configuration 3: Heat pump with auxiliary heat source
Heat pump covers the required capacity until the ambient temperature drops below the point at which the heat
pump is able to provide sufficient capacity. When the ambient temperature is below this equilibrium point (as shown
in Figure 1-1.2), depending on the system settings, either the auxiliary heat source supplies the required additional
heating capacity or the heat pump does not run and the auxiliary heat source covers the required capacity.
Enables selection of lower capacity heat pump.
Ideal for refurbishments and upgrades.
Figure 1-1.2: System configurations

6
2 Unit Capacities
Table 1-2.1: Unit capacities range and appearances
Capacity 18kW 22kW 26kW 30kW
Model
AW-WHPMA18-H93 AW-WHPMA22-H93 AW-WHPMA26-H93 AW-WHPMA30-H93
Appearance

7
Part 1 - General Information
3 System Design and Unit Selection
3.1 Selection Procedure
Step 1: Total heat load calculation
Calculate conditioned surface area
Select the heat emitters (type, quantity, water temperature and heat load)
Step 2: System configuration
Decide whether to include AHS and set AHS’s switching temperature
Decide whether backup electric heater is enabled or disabled
Step 3: Selection of outdoor units
Determine required total heat load on outdoor units
Set capacity safety factor
Select power supply
Provisionally select Wellea Mono DF unit capacity based on nominal
capacity
Correct capacity of the outdoor units for the following items:
Outdoor air temperature / Outdoor humidity / Water outlet temperature1/
Altitude / Anti-freeze fluid
Is corrected Wellea Mono DF unit capacity ≥Required total heat load
on outdoor units2
Yes
No
Wellea Mono DF system
selection is complete
Select a larger model or enable
backup electric heater operation
Notes:
1. If the required water temperatures of the heat emitters are not all the same, the Wellea Mono’s outlet water temperature setting should be set at the
highest of the heat emitter required water temperatures. If the water outlet design temperature falls between two temperatures listed in the
outdoor unit's capacity table, calculate the corrected capacity by interpolation.
2. Select Mono units which should satisfy both total heating and cooling load requirements.

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3.2 Wellea Leaving Water Temperature (LWT) Selection
The recommended design LTW ranges for different types of heat emitter are:
For floor heating: 30 to 35⁰C
For fan coil units: 30 to 45⁰C
For low temperature radiators: 40 to 50⁰C
3.3 Optimizing System Design
To get the most comfort with the lowest energy consumptionwith Wellea, it is important to take account of the
following considerations:
Choose heat emitters that allow the heat pump system to operate at as low a hot water temperature as possible
whilst still providing sufficient heating.
Make sure the correct weather dependency curve is selected to match the installation environment (building
structure, climate) as well as ender user’s demands.
Connecting room thermostats (field supplied) to the hydronic system helps prevent excessive space heating by
stopping the outdoor unit and circulator pump when the room temperature is above the thermostat set point.

9
Part 1 - General Information
4 Typical Applications
4.1 Space Heating
The room thermostat is used as a switch. When there is a heating request from the room thermostat, the Mono unit
operates to achieve the target water temperature set on the user interface. When the room temperature reaches the
thermostat’s set temperature, the unit stops.
Figure 1-5.1: Space heating
Table 1-5.1: Space heating
Legend
1
Outdoor unit
5
Room thermostat (field supplied)
1.1
Manometer
6
Drain valve (field supplied)
1.2
Pressure relief valve
7
Fill valve (field supplied)
1.3
Expansion vessel
8
Balance tank (field supplied)
1.4
Plate heat exchanger
8.1
Air purge valve
1.5
Air purge valve
8.2
Drain valve
1.6
Flow switch
9
Expansion vessel (field supplied)
1.7
P_i: Circulation pump inside the unit
10
P_o: Outside circulation pump (field supplied)
2
Y-shape filter
11
Collector / Distributor (field supplied)
3
Stop valve (field supplied)
FHL 1...n
Floor heating loop (field supplied)
4
Wired controller
Notes:
1. The example is just for application illustration; please confirm the exact installation method according to the installation manual.

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4.2 Space Heating and DHW with solar system
Space heating without room thermostat connected to the unit. Domestic hot water tank is connected to the unit, and the
tank is with solar heating system. Solar water pump is controlled by Tsolar temperature sensor. Balance tank temperature
sensor is used to control on/off of heat pump. Once the heat pump stops, internal pump stops to save energy and then
balance tank provides hot water for space heating. In addition, balance tank temperature control can meet both space
heating and domestic hot water needs at the same time.
Figure 1-5.2: Space heating and DHW with solar system
Table 1-5.2: Space heating and DHW with solar system
Legend
1
Outdoor unit
8.2
Drain valve
1.1
Manometer
9
Expansion vessel (field supplied)
1.2
Pressure relief valve
10
P_o: Outside circulation pump (field supplied)
1.3
Expansion vessel
11
Collector / Distributor (field supplied)
1.4
Plate heat exchanger
12
Domestic hot water tank (field supplied)
1.5
Air purge valve
12.1
Air purge valve
1.6
Flow switch
12.2
Heat exchanger coil
1.7
P_i: Circulation pump inside the unit
12.3
Booster heater
2
Y-shape filter
13
T5: Temperature sensor
3
Stop valve (field supplied)
14
Hot water tap(field supplied)
4
Wired controller
15
P_d: Cycle hot water pump (field supplied)
5
SV1: 3-way valve (field supplied)
16
One way valve(field supplied)
6
Drain valve (field supplied)
17
Bypass valve(field supplied)
7
Fill valve (field supplied)
18
Solar heater(field supplied)
8
Balance tank (field supplied)
19
P_s: Solar pump(field supplied)
8.1
Air purge valve
FHL 1...n
Floor heating loop (field supplied)
Notes:
1. The example is just for application illustration; please confirm the exact installation method according to the installation manual.

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Part 1 - General Information
4.3 Space Heating, Cooling and DHW with solar system
Space cooling and heating application with a room thermostat suitable for heating/cooling changeover when connected to
the unit. Heating is provided through floor heating loops and fan coil units. Cooling is provided through the fan coil units
only. Domestic hot water is provided through the domestic hot water tank which is connected to the unit.
Figure 1-5.3: Space heating, cooling and DHW with solar system
Table 1-5.3: Space heating, cooling and DHW with solar system
Legend
1
Outdoor unit
10
P_o: Outside circulation pump (field supplied)
1.1
Manometer
11
Collector / Distributor (field supplied)
1.2
Pressure relief valve
12
Domestic hot water tank (field supplied)
1.3
Expansion vessel
12.1
Air purge valve
1.4
Plate heat exchanger
12.2
Heat exchanger coil
1.5
Air purge valve
12.3
Booster heater
1.6
Flow switch
13
T5: Temperature sensor
1.7
P_i: Circulation pump inside the unit
14
Hot water tap(field supplied)
2
Y-shape filter
15
P_d: Cycle hot water pump(field supplied)
3
Stop valve (field supplied)
16
One way valve(field supplied)
4
Wired controller
17
Bypass valve(field supplied)
5
Room thermostat (field supplied)
18
SV1: 3-way valve(field supplied)
6
Drain valve (field supplied)
19
SV2: 3-way valve (field supplied)
7
Fill valve (field supplied)
20
Solar heater(field supplied)
8
Balance tank (field supplied)
21
P_s: Solar pump(field supplied)
8.1
Air purge valve
FHL 1...n
Floor heating loop (field supplied)
8.2
Drain valve
FCU 1…n
Fan coil units(field supplied)
9
Expansion vessel (field supplied)
Notes:
1. The example is just for application illustration; please confirm the exact installation method according to the installation manual.

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4.4 AHS provides heat for space heating
Space heating application by either the unit or by AHS connected in the system.
If AHS only provides heat for space heating, AHS must be integrated in the piping work.
Figure 1-5.4: AHS provides heat for space heating
Table 1-5.4: AHS provides heat for space heating
Legend
1
Outdoor unit
8.2
Drain valve
1.1
Manometer
9
Expansion vessel (field supplied)
1.2
Pressure relief valve
10
P_o: Outside circulation pump (field supplied)
1.3
Expansion vessel
11
Collector / Distributor (field supplied)
1.4
Plate heat exchanger
12
Domestic hot water tank (field supplied)
1.5
Air purge valve
12.1
Air purge valve
1.6
Flow switch
12.2
Heat exchanger coil
1.7
P_i: Circulation pump inside the unit
12.3
Booster heater
2
Y-shape filter
13
T5: Temperature sensor
3
Stop valve (field supplied)
14
Hot water tap(field supplied)
4
Wired controller
15
P_d: Cycle hot water pump(field supplied)
5
Stop valve (field supplied)
16
One way valve(field supplied)
6
Drain valve (field supplied)
17
T1: Outlet water temperature sensor(field supplied)
7
Fill valve (field supplied)
18
SV1: 3-way valve (field supplied)
8
Balance tank (field supplied)
FHL 1...n
Floor heating loop (field supplied)
8.1
Air purge valve
Notes:
1. The example is just for application illustration; please confirm the exact installation method according to the installation manual.

13
Part 1 - General Information
4.5 AHS provides heat for space heating and DHW
Space heating application by either the unit or by AHS connected in the system. Bivalent operation is possible for both
space heating operation and domestic water heating operation. If AHS is also providing heat for domestic hot water, AHS
can be integrated in the piping work. In this condition, the unit can sent ON/OFF signal to AHS in heating mode, but AHS
control itself in DHW mode.
Figure 1-5.5: AHS provides heat for space heating and DHW
Table 1-5.5: AHS provides heat for space heating and DHW
Legend
1
Outdoor unit
8.2
Drain valve
1.1
Manometer
9
Expansion vessel (field supplied)
1.2
Pressure relief valve
10
P_o: Outside circulation pump (field supplied)
1.3
Expansion vessel
11
Collector / Distributor (field supplied)
1.4
Plate heat exchanger
12
Domestic hot water tank (field supplied)
1.5
Air purge valve
12.1
Air purge valve
1.6
Flow switch
12.2
Heat exchanger coil
1.7
P_i: Circulation pump inside the unit
12.3
Booster heater
2
Y-shape filter
13
T5: Temperature sensor
3
Stop valve (field supplied)
14
Hot water tap(field supplied)
4
Wired controller
15
P_d: Cycle hot water pump(field supplied)
5
Stop valve (field supplied)
16
One way valve(field supplied)
6
Drain valve (field supplied)
17
Additional heat source(field supplied)
7
Fill valve (field supplied)
18
SV1: 3-way valve (field supplied)
8
Balance tank (field supplied)
19
T1: Outlet water temperature sensor(field supplied)
8.1
Air purge valve
FHL 1...n
Floor heating loop (field supplied)
Notes:
1. The example is just for application illustration; please confirm the exact installation method according to the installation manual.

14
4.6 AHS provides heat for DHW
Figure 1-5.6: AHS provides heat for DHW
Table 1-5.6: AHS provides heat for DHW
Legend
1
Outdoor unit
8.2
Drain valve
1.1
Manometer
9
Expansion vessel (field supplied)
1.2
Pressure relief valve
10
P_o: Outside circulation pump (field supplied)
1.3
Expansion vessel
11
Collector / Distributor (field supplied)
1.4
Plate heat exchanger
12
Domestic hot water tank (field supplied)
1.5
Air purge valve
12.1
Air purge valve
1.6
Flow switch
12.2
Heat exchanger coil
1.7
P_i: Circulation pump inside the unit
12.3
Booster heater
2
Y-shape filter
13
T5: Temperature sensor
3
Stop valve (field supplied)
14
Hot water tap(field supplied)
4
Wired controller
15
P_d: Cycle hot water pump(field supplied)
5
Stop valve (field supplied)
16
One way valve(field supplied)
6
Drain valve (field supplied)
17
Additional heat source(field supplied)
7
Fill valve (field supplied)
18
SV1: 3-way valve (field supplied)
8
Balance tank (field supplied)
FHL 1...n
Floor heating loop (field supplied)
8.1
Air purge valve
Notes:
1. The example is just for application illustration; please confirm the exact installation method according to the installation manual.

15
Part 1 - General Information
4.7 Dual setpoint function application with two room thermostats
Space heating with two room thermostats application is through floor heating loops and fan coil units. The floor heating
loops and fan coil units require different operating water temperature. The floor heating loops require a lower water
temperature in heating mode compared to fan coil units. To achieve these two set points, a mixing station is used to adapt
the water temperature according to requirements of the floor heating loops. The fan coil units are directly connected to
the unit water circuit and the floor heating loops are after the mixing station. The mixing station is controlled by the unit
(or field supply, controls by itself). With the help of hydronic adapter board(optional) which is connected between hydronic
box and thermostats, maximum 8 thermostats for 8 rooms are available to control heat pump, which greatly improves the
operation convenience.
Figure 1-5.7: Dual setpoint function application with two room thermostats
Table 1-5.7: Dual setpoint function application with two room thermostats
Legend
1
Outdoor unit
7
Fill valve (field supplied)
1.1
Manometer
8
Balance tank (field supplied)
1.2
Pressure relief valve
8.1
Air purge valve
1.3
Expansion vessel
8.2
Drain valve
1.4
Plate heat exchanger
9
Expansion vessel (field supplied)
1.5
Air purge valve
10
P_o: Outside circulation pump (field supplied)
1.6
Flow switch
11
Collector / Distributor (field supplied)
1.7
P_i: Circulation pump inside the unit
12
Bypass valve (field supplied)
2
Y-shape filter
13
Mixing station(field supplied)
3
Stop valve (field supplied)
13.1
P_c: zone 2 pump (field supplied)
4
Wired controller
13.2
SV3: 3-way valve (field supplied)
5A
Room thermostat for zone 1 (field supply)
14
Tw2: Zone 2 water flow temp.(field supplied)
5B
Room thermostat for zone 2 (field supply)
FHL 1...n
Floor heating loop (field supplied)
6
Drain valve(field supplied)
FCU 1...n
Fan coil units (field supplied)
Notes:
1. The example is just for application illustration; please confirm the exact installation method according to the installation manual.

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4.8 Dual setpoint function application without thermostats
Heating is provided through floor heating loops and fan coil units. The floor heating loops and fan coil units require
different operating water temperatures. The floor heating loops require alower water temperature in heating mode
compared to fan coil units. Toachieve these two set points, a mixing station is used to adapt the water temperature
according to requirements of the floor heating loops. The fan coil units are directly connected to the unit water circuit and
the floor heating loops are after the mixing station. The mixing station is controlled by the unit (or field supply, controls by
itself).
Figure 1-5.8: Dual setpoint function application without thermostats
Table 1-5.8: Dual setpoint function application without thermostats
Legend
1
Outdoor unit
8
Balance tank (field supplied)
1.1
Manometer
8.1
Air purge valve
1.2
Pressure relief valve
8.2
Drain valve
1.3
Expansion vessel
9
Expansion vessel (field supplied)
1.4
Plate heat exchanger
10
P_o: Outside circulation pump (field supplied)
1.5
Air purge valve
11
Collector / Distributor (field supplied)
1.6
Flow switch
12
Bypass valve (field supplied)
1.7
P_i: Circulation pump inside the unit
13
Mixing station(field supplied)
2
Y-shape filter
13.1
P_c: zone 2 pump (field supplied)
3
Stop valve (field supplied)
13.2
SV3: 3-way valve (field supplied)
4
Wired controller
14
Tw2: Zone 2 water flow temp.(field supplied)
5
Stop valve (field supplied)
FHL 1...n
Floor heating loop (field supplied)
6
Drain valve(field supplied)
FCU 1...n
Fan coil units (field supplied)
7
Fill valve (field supplied)
Notes:
1. The example is just for application illustration; please confirm the exact installation method according to the installation manual.

17
Part 1 - General Information
4.9 Group control function for cooling, heating and DHW
Modularity is perfect when an extension of capacity becomes required as the building cooling/heating demand evolves. 6
units can be controlled in group. The group control system can control and view the operation of the entire system only by
connecting the master to the wire controller. If the DHW function is required, the water tank can only be connected to the
master unit water circuit through athree-way valve, and controlled by the master unit.If AHS is needed, it can only be
connected to the master waterway and controlled by the master unit. The Tbt1 temperature sensor must be installed in
the parallel system (otherwise unit cannot be started). If the balance tank is too large, Tbt2 needs to be added in order to
improve the control accuracy. Tbt2 is set in the lower part of the balance tank. The water inlet and outlet pipe joints of
each unit of the parallel system should be connected with soft connections and one-way valves must be installed at the
water outlet pipe
Figure 1-5.9: Group control function for cooling, heating and DHW
Table 1-5.9: Group control function for cooling, heating and DHW
Legend
1-1
Outdoor unit: master
12.3
Booster heater
1-2...1-n
Outtdoor unit: slave
13
T5: DHW tank temp. sensor
2
Y-shape filter
14
Hot water tap (field supply)
3
Stop valve (field supply)
15
P_d: DHW pump (field supply)
4
Wired controller
16
One way valve (field supply)
5
Additional heating source(boiler) (field supply)
17
Bypass valve(field supply)
6
Drain valve (field supply)
18
SV1: 3-way valve (field supply)
7
Fill valve (field supply)
19
SV1: 3-way valve (field supply)
8
Balance tank (field supply)
20
Mixing station (field supply)
8.1
Air purge valve
20.1
P_c: zone 2 pump (field supply)
8.2
Drain valve
20.2
SV3: 3-way valve (field supply)
9
Expansion vessel (field supply)
21
Tw2: Zone 2 water flow temp. (individual purchase)
10
P_o: Outside circulation pump (field supply)
22
Tbt1: Balance tank temp. sensor (individual purchase)
11
Collector / distributor (field supply)
23
Tbt2: Balance tank temp. sensor (individual purchase)
12
Domestic hot water tank (field supply)
FHL 1...n
Floor heating loop (field supply)
12.1
Air purge valve
FCU 1...n
Fan coil units (field supply)
12.2
Heat exchanger coil
Notes:
1. The example is just for application illustration; please confirm the exact installation method according to the installation manual.

18

19
Part 2 - Engineering Data
Part 2
Engineering Data
1 Specifications ........................................................................................... 20
2 Dimensions and Center of Gravity ............................................................ 21
3 Piping Diagrams ....................................................................................... 22
4 Wiring Diagrams....................................................................................... 23
5 Capacity Tables......................................................................................... 26
6 Operating Limits....................................................................................... 32
7 Hydronic Performance.............................................................................. 33
8 Sound Levels ............................................................................................ 34
9 Accessories .............................................................................................. 37