Airwell WELLEA MONOBLOC AW-WHPM05-H91 User manual

S ERV I CE MANUAL
WELLEA MONOBLOC R32
AW-WHPM05-H91
AW-WHPM07-H91
AW-WHPM09-H91
AW-WHPM12-H91
AW-WHPM14-H91
AW-WHPM16-H91
AW-WHPM12-H93
AW-WHPM14-H93
AW-WHPM16-H93
20AW-SER V ICE MANUAL WELLEA MONOBLOC R32-2020020 7 -R ev 01

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CONTENTS
CONTENTS
Part 1 General Information ............................................................................ 3
Part 2 Component Layout and Refrigerant Circuits ..................................... 5
Part 3 Control ............................................................................................... 13
Part 4 Diagnosis and Troubleshooting ......................................................... 27

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Part 1 - General Information
Part 1
General Information
1 Unit Capacities and External Appearance .............................................. 4

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1 Unit Capacities and External Appearance
1.1 Unit Capacities
Table 1-1.1: Capacity range
Capacity 5kW 7kW 9kW 12kW 14kW 16kW
Mono
Capacity 12kW 14kW 16kW
Tri
1.2 External Appearance
Table 1-1.2: Unit appearance
5/7/9kW 12/14/16kW
X
XX
XXXX X X

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Part 2 - Component Layout and Refrigerant Circuits
Part 2
Component Layout and
Refrigerant Circuits
1 Layout of Functional Components .............................................................. 6
2 Piping Diagrams ....................................................................................... 10
3 Refrigerant Flow Diagrams ....................................................................... 12

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1 Layout of Functional Components
AW-WHPM05-H91 / AW-WHPM07-H91 / AW-WHPM09-H91
Figure 2-1.1: top view
Figure 2-1.2: front view

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Part 2 - Component Layout and Refrigerant Circuits
Figure 2-1.3: oblique view

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AW-WHPM12-H91 / AW-WHPM14-H91 / AW-WHPM16-H91
AW-WHPM12-H93 / AW-WHPM14-H93 / AW-WHPM16-H93
Figure 2-1.4: top view
Figure 2-1.5: front view

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Part 2 - Component Layout and Refrigerant Circuits
Figure 2-1.6: oblique view

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2 Piping Diagrams
AW-WHPM05-H91 / AW-WHPM07-H91 / AW-WHPM09-H91
AW-WHPM12-H91 / AW-WHPM14-H91 / AW-WHPM16-H91
AW-WHPM12-H93 / AW-WHPM14-H93 / AW-WHPM16-H93
Figure 2-2.1: piping diagram
Legend
1
Compressor
16
Refrigerant outlet (gas pipe) temp. sensor
2
4-Way Valve
17
Water outlet temp. sensor
3
Gas-liquid separator
18
Water Inlet temp. sensor
4
Air side heat exchanger
19
Air purge valve
5 Electronic expansion valve 20 Expansion vessel
6 Single-way electromagnetic valve 21 Circulating pump
7 Liquid Tank 22 Manometer
8
Strainer
23
Safety valve
9 Water Side Heat Exchanger(Plate Heat Exchange) 24 Y-shape filter
10 Backup heater (optional for 5/7/9kW) 25 High Pressure Switch
11
Flow switch
26
Low Pressure Switch
12 Discharge gas sensor 27 Pressure valve
13 Outdoor temperature sensor 28 Capillary
14 Evaporation sensor in heating(Condenser sensor in cooling) 29 Suction gas sensor
15
Refrigerant inlet (liquid pipe) temp. sensor
Pressure sensor
Filter
Electronic expansion valve
Filter
High pressure
switch
Low pressure
switch
Compressor
Accumulator
Air side heat exchanger
Distributor
Water side heat exchanger
Accumulator
4-way
valve
LW
EW
1
2
3
4
5
6
7
8
8
10
11
12
13
14
15
16 17
18
19
20
21
22
23
24
25
26
27
28
29
F
T1
Electronic expansion valve capiiiary

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Part 2 - Component Layout and Refrigerant Circuits
Key components:
1. Accumulator:
Stores liquid refrigerant and oil to protect compressor from liquid hammering.
2. Electronic expansion valve (EXV):
Controls refrigerant flow and reduces refrigerant pressure.
3. Four-way valve:
Controls refrigerant flow direction. Closed in cooling mode and open in heating mode. When closed, the air side heat
exchanger functions as a condenser and water side heat exchanger functions as an evaporator; when open, the air
side heat exchanger functions as an evaporator and water side heat exchanger function as a condenser.
4. High and low pressure switches:
Regulate refrigerant system pressure. When refrigerant system pressure rises above the upper limit or falls below the
lower limit, the high or low pressure switches turn off, stopping the compressor.
5. Air purge valve:
Automatically removes air from the water circuit.
6. Safety valve:
Prevents excessive water pressure by opening at 43.5 psi (3 bar) and discharging water from the water circuit.
7. Expansion vessel:
Balances water system pressure. (Expansion vessel volume: 2L in 5/7/9kW units and 3.2L in 12-16kW units.)
8. Water flow switch:
Detects water flow rate to protect compressor and water pump in the event of insufficient water flow.
9. Backup heater:
Provides additional heating capacity when the heating capacity of the heat pump is insufficient due to very low
outdoor temperature. Also protects the external water piping from freezing.
10. Manometer:
Provides water circuit pressure readout.
11. Water pump:
Circulates water in the water circuit.

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3 Refrigerant Flow Diagrams
Heating and domestic hot water operation
Figure 2-3.1: Refrigerant flow during heating or domestic hot water operation
Cooling and defrosting operation
Figure 2-3.2: Refrigerant flow during cooling and defrosting operations

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Part 3 - Control
Part 3
Control
1 Stop Operation ........................................................................................ 14
2 Standby Control ....................................................................................... 14
3 Startup Control ........................................................................................ 15
4 Normal Operation Control ....................................................................... 17
5 Protection Control ................................................................................... 19
6 Special Control ......................................................................................... 23
7 Role of Temperature Sensors in Control Functions ................................... 25

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1 Stop Operation
The stop operation occurs for one of the following reasons:
1. Abnormal shutdown: in order to protect the compressors, if an abnormal state occurs the system makes a 'stop with
thermo off’ operation and an error code is displayed on the outdoor unit PCB digital displays and on the user
interface.
2. The system stops when the set temperature has been reached.
2 Standby Control
2.1 Crankcase Heater Control
The crankcase heater is used to prevent refrigerant from mixing with compressor oil when the compressors are stopped.
The crankcase heater is controlled according to outdoor ambient temperature and the compressor on/off state. When the
outdoor ambient temperature is above 8°C or the compressor is running, the crankcase heater is off; when the outdoor
ambient temperature is at or below 8°C and either the compressor has been stopped for more than 3 hours or the unit has
just been powered-on (either manually or when the power has returned following a power outage), the crankcase heater
turns on.
2.2 Water Pump Control
When the outdoor unit is in standby, the internal and external circulator pumps run continuously.

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Part 3 - Control
3 Startup Control
3.1 Compressor Startup Delay Control
In initial startup control and in restart control (except in oil return operation and defrosting operation), compressor startup
is delayed such that a minimum of the set re-start delay time has elapsed since the compressor stopped, in order to
prevent frequent compressor on/off and to equalize the pressure within the refrigerant system. The compressor re-
start delays for cooling and heating modes are set on the user interface. Refer to the Wellea Mono Engineering Data Book
Part 3, 7.5 “COOL MODE SETTING Menu” and Part 3, 7.6 “HEAT MODE SETTING Menu”.
3.2 Compressor Startup Program
In initial startup control and in re-start control, compressor startup is controlled according to outdoor ambient
temperature. Compressor startup follows one of two startup programs until the target rotation speed is reached. Refer to
Figures 3-4.1, 3-4.2 and 3-4.3.
Figure 3-4.1: Compressor startup program1,2 when ambient temperature is above 4°C
38rps
Target rotation speed
Compressor rotation
speed (rps)
Time (s)
0
32rps 42rps 56rps
66rps 86rps
40s 60s 40s 40s 40s
40s
Notes:
1. Once the first, 40-second stage of the program is complete, the program proceeds to the subsequent stages in
a step-by-step fashion and exits when the target rotation speed has been reached.
2. This program is used on all Wellea Mono models: 5kW to 16kW, single phase and three phase.
Figure 3-4.2: For 5/7/9kW compressor startup program1 when ambient temperature is at or below 4°C
Target rotation speed
Compressor rotation
speed (rps)
40s
38rps
90s
32rps
60s
42rps
40s
56rps
40s
66rps
40s
82rps
Time (s)
0
90s
36rps
Notes:
1. Once the first, 40-second stage of the program is complete, the program proceeds to the subsequent stages in a
step-by-step fashion and exits when the target rotation speed has been reached.

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Figure 3-4.3: For 12/14/16kW compressor startup program1 when ambient temperature is at or below 4°C
38rps
0
Target rotation speed
Compressor rotation
speed (rps)
Time (s)
24rps 33rps 42rps
56rps 66rps
82rps
40s
90s 90s 60s
40s
40s
40s
Notes:
1. Once the first, 40-second stage of the program is complete, the program proceeds to the subsequent stages in a
step-by-step fashion and exits when the target rotation speed has been reached.
3.3 Startup Control for Heating and Domestic Hot Water Operation
Table 3-4.1: Component control during startup in heating and domestic hot water modes
Component Wiring diagram
label 5/7/9kW
12/14/16
kW Control functions and states
Inverter compressor COMP ● ●
Compressor startup program selected according to
ambient temperature1
DC fan motor / Upper DC fan motor FAN1 / FAN_UP
● ●
Fan runs at maximum speed2
Lower DC fan motor FAN_DOWN ●
Electronic expansion valve EXV ● ●
Position (steps) from 0 (fully closed) to 480 (fully
open), controlled according to outdoor ambient
temperature, discharge temperature and suction
superheat
Four-way valve ST ● ● On
Notes:
1. Refer to Figure 3-4.1, Figure 3-4.2 and Figure 3-4.3 in Part 3, 4.2 “Compressor Startup Program”.
2. Refer to Table 3-5.3 in Part 3, 5.6 “Outdoor Fan Control”.
3.4 Startup Control for Cooling Operation
Table 3-4.2: Component control during startup in cooling mode
Component Wiring diagram
label 5/7/9kW
12/14/16
kW Control functions and states
Inverter compressor COMP ● ●
Compressor startup program selected according to
ambient temperature1
DC fan motor / Upper DC fan motor FAN1 / FAN_UP
● ●
Fan run at maximum speed2
Lower DC fan motor FAN_DOWN ●
Electronic expansion valve EXV ● ●
Position (steps) from 0 (fully closed) to 480 (fully
open), controlled according to outdoor ambient
temperature, discharge temperature and suction
superheat
Four-way valve ST ● ● Off
Notes:
1. Refer to Figure 3-4.1, Figure 3-4.2 and Figure 3-4.3 in Part 3, 4.2 “Compressor Startup Program”.
2. Refer to Table 3-5.3 in Part 3, 5.6 “Outdoor Fan Control”.

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Part 3 - Control
4 Normal Operation Control
4.1 Component Control during Normal Operation
Table 3-5.1: Component control during heating and domestic hot water operations
Component Wiring diagram
label 5/7/9kW
12/14/16kW
Control functions and states
Inverter compressor COMP ● ●
Controlled according to load requirement from
hydronic system
DC fan motor / Upper DC fan motor FAN1 / FAN_UP
● ● Controlled according to outdoor heat exchanger
pipe temperature
Lower DC fan motor FAN_DOWN ●
Electronic expansion valve EXV ● ●
Position (steps) from 0 (fully closed) to 480 (fully
open), controlled according to discharge
temperature, suction superheat and compressor
speed
Four-way valve ST ● ● On
Table 3-5.2: Component control during cooling operation
Component Wiring diagram
label 5/7/9kW
12/14/16kW
Control functions and states
Inverter compressor COMP ● ●
Controlled according to load requirement from
hydronic system
DC fan motor / Upper DC fan motor FAN1 / FAN_UP
● ● Controlled according to outdoor heat exchanger
pipe temperature
Lower DC fan motor FAN_DOWN ●
Electronic expansion valve EXV ● ●
Position (steps) from 0 (fully closed) to 480 (fully
open), controlled according to discharge
temperature, suction superheat and compressor
speed
Four-way valve ST ● ● Off
4.2 Compressor Output Control
The compressor rotation speed is controlled according to the load requirement. Before compressor startup,
the Wellea Mono outdoor unit determines the compressor target speed according to outdoor ambient
temperature, leaving water set temperature and actual leaving water temperature and then runs the appropriate
compressor startup program. Refer to Part 3, 4.2 “Compressor Startup Program”. Once the startup program is complete,
the compressor runs at the target rotation speed.
During operation the compressor speed is controlled according to the rate of change in water temperature, the refrigerant
system pressure and the refrigerant temperature.
4.3 Compressor Step Control
The running speed of six-pole compressors (used on all models) in rotations per second (rps) is one third of the frequency
(in Hz) of the electrical input to the compressor motor. The frequency of the electrical input to the compressor motors can
be altered at a rate of 1Hz per second.

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4.4 Four-way Valve Control
The four-way valve is used to change the direction of refrigerant flow through the water side heat exchanger in order to
switch between cooling and heating/DHW operations. Refer to Figures 2-3.1 and 2-3.2 in Part 2, 3 “Refrigerant Flow
Diagrams”.
During heating and DHW operations, the four-way valve is on; during cooling and defrosting operations, the four-way
valve is off.
4.5 Electronic Expansion Valve Control
The position of the electronic expansion valve (EXV) is controlled in steps from 0 (fully closed) to 480 (fully open).
At power-on:
 The EXV first closes fully, then moves to the standby position (304 (steps)). After 30 seconds the EXV moves to an
initial running position, which is determined according to operating mode and outdoor ambient temperature.
After a further 150 seconds, the EXV is controlled according to suction superheat and discharge temperature.
Once a further 6 minutes have elapsed, the EXV is then controlled according to suction superheat, discharge
temperature and compressor speed.
When the outdoor unit is in standby:
 The EXV is at position 304 (steps).
When the outdoor unit stops:
 The EXV first closes fully, then moves to the standby position (304 (steps)).
4.6 Outdoor Fan Control
The speed of the outdoor unit fan(s) is adjusted in steps, as shown in Table 3-5.3.
Table 3-5.3: Outdoor fan speed steps
Fan speed index
Fan speed (rpm)
5kW 7kW
10-16kW (1Ph) 12-16kW (3Ph)
Upper fan1 Lower fan2 Upper fan1 Lower fan2
0 0 0 0 0 0 0
1 300 300 300 - 300 -
2 340 340 330 300 330 300
3 400 400 400 380 400 380
4 450 450 460 440 460 440
5 520 520 520 500 520 500
6 600 600 630 610 630 610
7 680 680 780 760 780 760
8 730 730 - - - -
9 800 800 - - - -
Notes:
1. The upper fan is labelled FAN_UP in the wiring diagram. Refer to the Wellea Mono
Engineering Data Book Part 2, 4 “Wiring diagram”.
2. The lower fan is labelled FAN_DOWN in the wiring diagram. Refer to the Wellea Mono
Engineering Data Book Part 2, 4 “Wiring diagram”.

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Part 3 - Control
4.7 Spray liquid cooling control
When the discharge temperature of compressor exceeds 105℃, the solenoid valve opens and the frequency of
compressor drops in order to reduce the discharge temperature. When the discharge temperature is below 90℃, the
solenoid valve closes.
If the discharge temperature exceeds 108℃ while the spray liquid cooling control is in progress, which is judged every 20s,
the frequency of compressor drops 4Hz until the minimum frequency which differs from every model. When the discharge
temperature is below 95℃, the compressor runs at the current frequency.
5 Protection Control
5.1 High Pressure Protection Control
This control protects the refrigerant system from abnormally high pressure and protects the compressor from transient
spikes in pressure.
Figure 3-6.1: High pressure protection control
Notes:
1. Pc: Discharge pressure
When the discharge pressure rises above 4.2MPa the system displays P1 protection and the unit stops running. When the
discharge pressure drops below 3.2MPa, the compressor enters re-start control.
5.2 Low Pressure Protection Control
This control protects the refrigerant system from abnormally low pressure and protects the compressor from transient
drops in pressure.
Figure 3-6.2: Low pressure protection control
Notes:
1. Pe: Suction pressure
When the suction pressure drops below 0.14MPa the system displays P0 protection and the unit stops running. When the
suction pressure rises above 0.3MPa, the compressor enters re-start control.
When P0 protection occurs 3 times
in 60 minutes, the HP error is
displayed. When an HP error occurs,
a manual system restart is required
before the system can resume
operation.
Pe < 0.14MPa Pe > 0.30MPa
Normal operation
Low pressure protection, error code P0 is displayed