Airwell WELLEA MONOBLOC AW-WHPM05-H91 Service Manual Download Page 104

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SER

VICE MANUAL

WELLEA MONOBLOC

R32

WARNING:

The design and specifications are subject to change without prior notice

for product improvement. Consult with the sales agency or manufacturer

for details.

20AW-

ICE MANUAL WELLEA MONOBLOC R32-20200020

-R

Summary of Contents for WELLEA MONOBLOC AW-WHPM05-H91

Page 1: ...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 SERVICE MANUAL WELLEA MONOBLOC R32 2020020...

Page 2: ...Wellea Monobloc 1 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...

Page 3: ...Wellea Monobloc 2...

Page 4: ...Wellea Monobloc 3 Part 1 General Information Part 1 General Information 1 Unit Capacities and External Appearance 4...

Page 5: ...ies 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...

Page 6: ...llea monobloc 5 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 1...

Page 7: ...Wellea monobloc 6 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...

Page 8: ...Wellea Monobloc 7 Part 2 Component Layout and Refrigerant Circuits Figure 2 1 3 oblique view...

Page 9: ...Wellea Monobloc 8 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...

Page 10: ...Wellea Monobloc 9 Part 2 Component Layout and Refrigerant Circuits Figure 2 1 6 oblique view...

Page 11: ...er 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 ga...

Page 12: ...igerant 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 t...

Page 13: ...low 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...

Page 14: ...art 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 C...

Page 15: ...t 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 outd...

Page 16: ...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 program 1 2 when ambient temperature is above 4 C 38rps Target...

Page 17: ...xpansion 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 Ref...

Page 18: ...ature 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 spe...

Page 19: ...perheat 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...

Page 20: ...ikes 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...

Page 21: ...r Current Protection Control This control protects the compressor from abnormally high currents Figure 3 6 5 Compressor current protection control Table 3 6 1 Current limitation for compressors Model...

Page 22: ...d is less than 150rpm for more than 20 seconds When DC fan motor protection control occurs the system displays the H6 error code and the unit stops running After 3 minutes the unit restarts automatica...

Page 23: ...3 Module Temperature Protection Control When the module temperature rises at or above 72 C the system displays C7 protection and the unit stops running When the module temperature drops at or below 6...

Page 24: ...nger pipe temperature Lower DC fan motor FAN_DOWN Electronic expansion valve EXV 304 steps Four way valve ST Off Tables 3 7 2 show component control during oil return operation in heating and DHW mode...

Page 25: ...ser interface Refer to the Wellea Mono Engineering Data Book Part 3 7 4 DHW MODE SETTING Menu Domestic hot water demand priority can be ended by changing the switch on controller from on to off Table...

Page 26: ...le of Temperature Sensors in Control Functions Figure 3 7 1 Location of the temperature sensors on 5 16KW unit systems Notes 1 The names and functions of the temperature sensors labelled 1 to 12 in th...

Page 27: ...exchanger water outlet temperature sensor Tw_out Heating Compressor output5 and on off control6 Freeze prevention control10 Cooling DHW 9 Backup electric heater water outlet temperature sensor T1 Hea...

Page 28: ...Wellea Monobloc 27 Part 4 Diagnosis and Troubleshooting 1 Outdoor Unit Electric Control Box Layout 28 2 Outdoor Unit PCBs 31 3 Error Code Table 46 4 Troubleshooting 48 5 Appendix to Part 4 100...

Page 29: ...M05 H91 AW WHPM07 H91 AW WHPM09 H91 Figure 4 1 1 Electric control box front view Transformers Main PCB for hydronic system Main PCB for refrigerant system Power supply terminals Communication terminal...

Page 30: ...l reset thermal cutout Auto reset thermal cutout Backup electric heater contactors Backup electric heater power supply terminals Outdoor unit power supply terminals Transformer Communication terminal...

Page 31: ...ic heater contactors Transformer Outdoor unit power supply terminals Communication terminal blocks Backup electric heater power supply terminals Notes 1 The components marked with asterisk are applied...

Page 32: ...se models In addition to the two main PCBs all models also have an inverter module and the three phase models also have a filter board The locations of each PCB in the outdoor unit electric control bo...

Page 33: ...h 13 S1 S2 DIP switch 14 CN34 Output port for deforst 15 CN40 Port for anti freeze electric heating tape internal 16 CN41 Port for anti freeze electric heating tape internal 17 CN25 Output port for ex...

Page 34: ...Modules and Filter Boards AW WHPM05 H91 AW WHPM07 H91 AW WHPM09 H91 Figure 4 2 2 5 7 9kW outdoor unit main PCB for refrigerant system 1 1 2 3 4 5 6 29 28 27 7 8 9 10 11 12 13 14 15 26 25 24 23 21 20...

Page 35: ...11 CN8 Port for Tp temp sensor 12 CN9 Port for outdoor ambient temp sensor and condenser temp sensor 13 CN1 Port for Th temp sensor 14 CN14 Port for TF temp sensor 15 CN4 Port for pressure sensor 16 C...

Page 36: ...l in Figure 4 2 3 Code Content 1 U Compressor connection port U 2 V Compressor connection port V 3 W Compressor connection port W 4 CN20 Output port for 12V 5V CN20 5 CN19 Port for fan 6 CN302 Reserve...

Page 37: ...H91 AW WHPM14 H91 AW WHPM16 H91 Figure 4 2 4 MHC V12 14 16 W D2N8 outdoor unit main PCB for refrigerant system 1 1 2 3 4 5 6 7 8 9 10 28 27 26 25 24 23 22 21 20 11 12 13 19 17 16 15 14 Notes 1 Label d...

Page 38: ...rical expansion value 9 CN1 Input port for live wire 10 CN2 Input port for neutral wire 11 CN11 Ground wire 12 CN4 Output port for live wire 13 CN3 Output port for neutral wire 14 CN16 Power supply po...

Page 39: ...for high pressure switch 3 CN6 Output port for 15V 4 CN1 Port for communication with PCB for refrigerant system 5 CN2 Reserved 6 N Input port N for IPM module 7 W Compressor connection port W 8 V Comp...

Page 40: ...2 H93 AW WHPM14 H93 AW WHPM16 H93 Figure 4 2 6 12 14 16kW H93 outdoor unit main PCB for refrigerant system 1 1 2 3 4 5 6 7 26 8 9 10 11 12 25 24 23 22 21 19 18 17 16 15 14 13 Notes 1 Label description...

Page 41: ...detection 8 CN10 Port for communication with hydro box control board 9 CN11 Reserved 10 SW7 SW8 DIP switch 11 DIS1 Digital display 12 CN22 Port for electrical expansion value 13 CN41 Port for power su...

Page 42: ...Figure 4 2 7 Code Content 1 CN4 Output port for 15V 2 CN1 Port for communication with PCB for refrigerant system 3 W Compressor connection port W 4 V Compressor connection port V 5 U Compressor connec...

Page 43: ...r board Label in Figure 4 2 8 Code Content 1 L3 Power supply L3 2 L2 Power supply L2 3 L1 Power supply L1 4 N Power supply N 5 GND_1 Ground wire 6 CN18 Power supply port for load 7 CN19 Power supply p...

Page 44: ...ling mode Water side heat exchanger refrigerant outlet temperature C Actual value value displayed 10 Heating mode Water side heat exchanger refrigerant outlet temperature C Cooling mode Water side hea...

Page 45: ...splayed Temperature is 9 C Actual value value displayed When decimal point is displayed between the two digits Temperature is 10 C Actual value value displayed x 10 Example 1 2 indicates 12 C 7 Discha...

Page 46: ...or or protection code Error or protection code System check Refer to Table 4 2 9 Refer to Table 4 2 10 2 5 DIP Switch Settings The rotating coded switch S3 0 F on the main control board of hydraulic m...

Page 47: ...in PCB Sensor Th EA 11 Discharge pipe temperature sensor error User interface and refrigerant system main PCB Sensor Tp Ed 14 Water side heat exchanger water inlet temperature sensor error User interf...

Page 48: ...erter module protection Refrigerant system main PCB L1 DC bus low voltage protection Refrigerant system main PCB L2 DC bus high voltage protection Refrigerant system main PCB L4 MCE error Refrigerant...

Page 49: ...accordance with all applicable legislation all national local and other laws standards codes rules regulations and other legislation that apply in a given situation Power off the outdoor units before...

Page 50: ...isplayed 3 times When an E0 error occurs a manual system restart is required before the system can resume operation Wellea Mono stops running Error code is displayed on hydronic system main PCB and us...

Page 51: ...is damaged Yes Replace the water flow switch No Internal circulator pump fuse backup electric heater fuse or hydronic system main PCB fuse has blown3 Yes Replace the blown fuse No Replace hydronic sys...

Page 52: ...se sequence error Only applies to 3 phase models Wellea Mono stops running Error code is displayed on refrigerant system main PCB and user interface Possible causes 4 3 3 Power supply phases not conne...

Page 53: ...f the phase sequence is inverted the compressor will operate inversely If the wiring connection of each outdoor unit is in A B C phase sequence and multiple units are connected the current difference...

Page 54: ...on hydronic system main PCB and user interface Possible causes 4 4 3 Communication wires between outdoor unit and user interface not connected properly Communication wiring X Y E terminals misconnecte...

Page 55: ...Ensure the communication wires and high voltage wires are separated No Communication wires are close to a source of electromagnetic radiation such as transformer or strong fluorescent lamp Yes Remove...

Page 56: ...r side heat exchanger refrigerant inlet gas pipe temperature sensor error Ed indicates a water side heat exchanger water inlet temperature sensor error HA indicates a water side heat exchanger water o...

Page 57: ...tem main PCB labeled 8 in Figure 4 2 1 in Part 4 2 2 Main PCB for Hydronic System Domestic hot water tank temperature sensor connection is port CN13 on the hydronic system main PCB labeled 9 in Figure...

Page 58: ...E6 indicates an outdoor ambient temperature sensor error E9 indicates a suction pipe temperature sensor error EA indicates a discharge temperature sensor error Wellea Mono stops running Error code is...

Page 59: ...Modules and Filter Boards labeled 4 in Figures 4 2 4 in Prat 4 2 3 Main PCBs for Refrigerant System Inverter Modules and Filter Boards and labelled 5 in Figure 4 2 6 in Part 4 2 3 Main PCBs for Refri...

Page 60: ...ible causes 4 7 3 Hydronic system main PCB EEPROM is not connected properly Hydronic system main PCB damaged Procedure 4 7 4 EE Hydronic system EEPROM1 is not connected properly Yes Ensure the EEPROM...

Page 61: ...ydronic system main PCB and user interface Possible causes 4 8 3 The DC generatrix voltage is too low Procedure 4 8 4 F1 Power supply is abnormal Yes Provide normal power No LED light is OK Yes Voltag...

Page 62: ...y Yes Ensure the EEPROM is connected properly No Replace refrigerant system main PCB Notes 1 Refrigerant system main PCB EEPROM is designated IC23 on the refrigerant system main PCBs labeled 29 in Fig...

Page 63: ...er s is abnormal1 Yes Provide normal power supply No A transformer has malfunctioned2 Yes Replace the transformer No There is a source of electromagnetic radiation near the unit such as high frequency...

Page 64: ...mal1 Yes Provide normal power supply No The transformer has malfunctioned2 Yes Replace the transformer No There is a source of electromagnetic radiation near the unit such as high frequency transmitte...

Page 65: ...is required before the system can resume operation The cause of an HH error should be addressed promptly in order to avoid system damage Wellea Mono stops running Error code is displayed on refrigeran...

Page 66: ...ce refrigerant system main PCB Notes 1 Refer to Figures 4 1 1 to 4 1 7 in Part 4 1 Outdoor Unit Electric Control Box Layout and to the Wellea Mono Engineering Data Book Part 2 5 Wiring Diagrams 2 Only...

Page 67: ...stops running Error code is displayed on refrigerant system main PCB and user interface Possible causes 4 13 3 Power supply voltage not within 10 of rated voltage or a phase is missing Outdoor unit p...

Page 68: ...rol box power supply terminals are loose Yes Ensure the wires are connected properly No Outdoor unit powered on immediately after being powered off Yes Power off the unit and wait for at least 3 minut...

Page 69: ...m main PCB is loose Yes Ensure the sensor is connected properly No High pressure sensor has short circuited or failed1 Yes Replace the sensor No Replace refrigerant system main PCB Notes 1 Measure the...

Page 70: ...ormal operation resumes HP indicates P0 protection has occurred 3 times in 60 minutes When an HP error occurs a manual system restart is required before the system can resume operation Error code is d...

Page 71: ...To check for insufficient refrigerant An insufficiency of refrigerant causes compressor discharge temperature to be higher than normal discharge and suction pressures to be lower than normal and comp...

Page 72: ...n and Wellea Mono stops running When the discharge pressure falls below 3 2MPa P1 is removed and normal operation resumes Error code is displayed on refrigerant system main PCB and user interface Poss...

Page 73: ...igerant System Inverter Modules and Filter Boards Pressure sensor connection is port CN14 on the MHC V5 7 9 W D2N8 refrigerant system main PCB labeled 15 in Figure 4 2 2 in Part 4 2 3 Main PCBs for Re...

Page 74: ...to 16kW models 31A three phase models 15A the system displays P3 protection and Wellea Mono stops running When the current returns to the normal range P3 is removed and normal operation resumes Error...

Page 75: ...exchanger water piping circulator pumps and water flow switch for dirt blockages In cooling mode check air side heat exchanger fan s and air outlets for dirt blockages 2 High pressure side blockage ca...

Page 76: ...rises above 115 C the system displays P4 protection and Wellea Mono stops running When the discharge temperature falls below 90 C P4 is removed and normal operation resumes Error code is displayed on...

Page 77: ...o Temperature sensor has short circuited or failed3 Yes Replace the sensor No High pressure switch connection or pressure sensor connection on refrigerant system main PCB is loose4 Yes Ensure the pres...

Page 78: ...4 2 2 in Part 4 2 3 Main PCBs for Refrigerant System Inverter Modules and Filter Boards port CN9 on the MHC V12 14 16 W D2N8 outdoor unit invert module PCB labeled 2 in Figure 4 2 5 in Part 4 2 3 Mai...

Page 79: ...de heat exchanger water inlet and water outlet temperatures protection Wellea Mono stops running Error code is displayed on hydronic system main PCB and user interface Possible causes 4 19 3 Temperatu...

Page 80: ...side heat exchanger water inlet temperature sensor and water side heat exchanger water outlet temperature sensor connections are port CN6 on the hydronic system main PCB labeled 8 in Figure 4 2 1 in P...

Page 81: ...P6 error code is displayed on the user interface one of the following specific error codes is displayed on the refrigerant system main PCB L0 L1 L2 L4 L5 L7 L8 L9 Refer to Table 4 4 1 Table 4 4 1 Spe...

Page 82: ...pen the current across the PTC to charge capacitor after 5 seconds the contactor closed The capacitor output steady power supply for inverter module P N terminals In standby the voltage between P and...

Page 83: ...e to the correct compressor terminals as indicated by the labels on the compressor 2 Measure the resistance between each of U V and W and each of P and N on the inverter module All the resistances sho...

Page 84: ...Replace the inverter module3 Notes 1 Refer to Figure 4 4 1 2 Use clip on ammeter to measure the compressor current if the current is normal indicates the inverter module is failed if the current is a...

Page 85: ...rectifier terminals If any of the resistances is close to zero the bridge rectifier has failed Method 2 dial a multimeter to the diode setting Put the red probe on the DC power output negative termin...

Page 86: ...damaged1 Yes Replace the inverter module2 Notes 1 If the fan motor is running and the DC voltage between terminals P and N on inverter module is not 380V the PFC is damaged 2 When replacing an invert...

Page 87: ...mpressor frequency differs from target frequency Specific error codes for P6 inverter module protection 4 21 4 If a P6 error code is displayed on the user interface one of the following specific error...

Page 88: ...13 times and stops for 1 second then repeats L5 Zero speed protection Flashes 15 times and stops for 1 second then repeats L7 Phase sequence error Flashes 16 times and stops for 1 second then repeats...

Page 89: ...between refrigerant system main PCB and inverter module is port CN6 on refrigerant system main PCB and port CN1 on inverter module For MHC V12 14 16 W D2RN8 the communication port between refrigerant...

Page 90: ...e N terminal on the inverter module through the current sensor in the direction indicated by the arrow on the current sensor and end at the N terminal of capacitor Refer to Figure 4 4 5 Figure 4 4 5 D...

Page 91: ...s 1 Connect the U V W wire from the inverter module to the correct compressor terminals as indicated by the labels on the compressor 2 Measure the voltage between each of W W V V U U and GND when the...

Page 92: ...lace the compressor No Replace the inverter module2 Notes 1 When replacing an inverter module a layer of thermally conductive silica gel should be painted on the IPM module on the reverse side of the...

Page 93: ...powered on L1 L2 P N 15V wire on refrigerant system main PCB is not connected properly1 Yes Ensure P N 15V wire is connected properly No Voltage between N and 15 is abnormal2 Yes Check 15V circuit3 N...

Page 94: ...h of terminals 1 2 and 3 should be around 0 378V If the voltage is 0 the bridge rectifier has failed Put the red probe on the DC power output positive terminal terminal 4 then put black probe onto eac...

Page 95: ...between the two wires which connect the contactor with the refrigerant system main PCB If the voltage is 220V AC and the contactor is open the contactor has failed Condition 3 L4 error appears after...

Page 96: ...rly No Water side heat exchanger water outlet temperature sensor water inlet temperature sensor or backup electric heater outlet water temperature sensor has short circuited or failed3 Yes Replace the...

Page 97: ...han 3 seconds the system displays Pd protection and Wellea Mono stops running When the air side heat exchanger refrigerant outlet temperature returns drops below 52 C Pd is removed and normal operatio...

Page 98: ...erature sensor connections are port CN9 on the refrigerant system main PCB labeled 12 in Figure 4 2 2 in Part 4 2 3 Main PCBs for Refrigerant System Inverter Modules and Filter Boards labeled 5 in Fig...

Page 99: ...inlet temperature is higher than outlet temperature in heating mode Wellea Mono stops running Error code is displayed on hydronic system main PCB and user interface Possible causes 4 24 3 Temperature...

Page 100: ...water side heat exchanger water outlet temperature sensor connections are port CN6 on the hydronic system main PCB labeled 8 in Figure 4 2 1 in Part 4 2 2 Min PCB for Hydronic System 2 Measure sensor...

Page 101: ...769 22 11 496 62 2 181 102 0 574 17 89 353 23 10 971 63 2 102 103 0 558 16 84 278 24 10 473 64 2 026 104 0 542 15 79 521 25 10 65 1 953 105 0 527 14 75 059 26 9 551 66 1 883 13 70 873 27 9 125 67 1 81...

Page 102: ...7 261 4 33 38 89 73 8 643 113 2 559 6 247 8 34 37 30 74 8 358 114 2 489 5 234 9 35 35 78 75 8 084 115 2 422 4 222 8 36 34 32 76 7 820 116 2 357 3 211 4 37 32 94 77 7 566 117 2 294 2 200 7 38 31 62 78...

Page 103: ...535 60 12 144 100 3 2734 19 450 81 21 58 804 61 11 715 101 3 1777 18 425 59 22 56 209 62 11 302 102 3 0853 17 401 91 23 53 742 63 10 906 103 2 9960 16 379 69 24 51 396 64 10 526 104 2 9096 15 358 83 2...

Page 104: ...LOC R32 WARNING The design and specifications are subject to change without prior notice for product improvement Consult with the sales agency or manufacturer for details 20AW SERVICE MANUAL WELLEA MO...

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