gledhill BMA 240 HP-PQFY, PUHZ-W90VHA, BMA 210 HP-DEM, BMA 240 HP-DEM, BMA 180 HP-PQFY Installation & Servicing Instructions Manual

...

Design, Installation & Servicing

Instructions

BoilerMate Model Numbers

BMA 180 HP-DEM BMA 210 HP-DEM BMA 240 HP-DEM

A complete package to provide hot water and heating in

domestic housing from an air source heat pump

Air Source Heat Pumps

Appliances

These instructions also include wiring/installation details for a special version of the BoilerMate HP

appliance designed to work with the Mitsubishi PQFY-VRF heat pump range:

BoilerMate Model Numbers

BMA 180 HP-PQFY BMA 210 HP-PQFY BMA 240 HP-PQFY

Ecodan Air Source Heat Pump Model Number

PUHZ-W90VHA

Page 2

CONTENTS

Section Page

Summary Checklist 3

BOILERMATE HP-DEM

DESIGN

Introduction 5 Technical Data 8 System Details 17

INSTALLATION

Site Requirements 25 Installation 26 Wiring Diagrams 28 Commissioning 31

SERVICING

Servicing/Maintenance 33 Changing Components 33 Short Parts List 34 Fault Finding 35

MITSUBISHI ELECTRIC ECODAN AIR SOURCE HEAT PUMP

Installation Manual 36

BOILERMATE HP-PQFY / MITSUBISHI PQFY HEAT PUMP DETAILS

Electrical / Hydraulic Connection Layouts 44 BoilerMate HP-PQFY Appliance Electrical Schematic 46

FERNOX BOILER BUDDY

Installation Manual 48

FERNOX ALPHI-11

Product Data 52

Gledhill Terms & Conditions 54

This product is manufactured under an ISO 9001:2000 Quality System audited by BSI.

Patents Pending.

The Gledhill Group’s ﬁrst priority is to give a high quality service to our customers.

Quality is built into every Gledhill product and we hope you get satisfactory service from Gledhill.

If not please let us know.

ISSUE 5: 12-07

The code of practice for the installation,

commissioning & servicing of central heating systems

Building Regulations and Benchmark Commissioning

The Building Regulations (England & Wales) require that the installation of a heating appliance be notiﬁed to the relevant Local Authority Building Control Department. From 1st April 2005 this can be achieved via a Competent Person Self Certiﬁcation Scheme as an option to notifying the Local Authority directly. Similar arrangements will follow for Scotland and will apply in Northern Ireland from 1st January 06.

CORGI operates a Self Certiﬁcation Scheme for gas heating appliances.

These arrangements represent a change from the situation whereby compliance with the Building Regulations was accepted if the Benchmark Logbook was completed and this was then left on site with the customer).

With the introduction of a self certiﬁcation scheme, the Benchmark Logbook is being replaced by a similar document in the form of a commissioning check list and a service interval record is included with all gas appliance manuals. However, the relevant Benchmark Logbook is still being included with all Thermal Storage products and unvented cylinders.

Gledhill fully supports the Benchmark aims to improve the standards of installation and commissioning of central heating systems in the UK and to encourage the regular servicing of all central heating systems to ensure safety and efﬁciency.

Building Regulations require that the heating installation should comply with the manufacturer’s instructions. It is therefore important that the commissioning check list is completed by the competent installer. This check list only applies to installations in dwellings or some related structures.

Page 3

SUMMARY CHECKLIST

This checklist has been created to help you understand the differences from other types of heating systems that you will have installed. We suggest you use this checklist as a helpful summary of the main differences from conventional heating systems, but you will also need to understand and comply with all of the technical details contained within this document to ensure a successful installation. For further assistance please contact Gledhill Technical Support Helpline on 08449 310000.

BoilerMate A-Class HP-DEM

• Is normally mounted in the airing cupboard internal to the property. As it is based on an unvented cylinder, suitable provision needs to be made for the P&T discharge pipework.

• A 32A electrical power supply with a local isolator is needed to allow the Switch emergency electrical back-up to operate.

Primary System Circuit

• It is very important that the primary system is cleansed using a suitable cleansing agent such as Fernox F3 to ensure that any ﬂux residues / installation debris is removed.

• The heat pump and external connecting pipework require

protection against freezing. For this reason a combined anti-freeze and inhibitor product such as Fernox Alpha-11 must be used in the correct quantity.

• The Fernox Boiler Buddy should be ﬁtted internally on the heat pump return to help protect the heat pump from any heating system contamination and provide an ongoing visual indication of the system water condition.

Interconnection Between Ecodan and BoilerMate A-Class HP

• An eight core signal cable is needed to be run between the internal BoilerMate and the external Ecodan. An 8 metre supply of this cable is provided with the BoilerMate – if additional length is needed details of how to order this are provided.

Summary Checklist for Mitsubishi Ecodan and Gledhill BoilerMate A-Class HP Installation

Externally Mounted Temperature Sensor

• A n e x t e r n a l ly m ou n t ed temperature sensor is provided as part of the equipment package. This should be mounted in a suitable location on a north facing wall external to the property.

Radiator System Circuit

• As the heat pump generates lower temperatures than a conventional boiler the radiators should have been designed to suit the lower mean temperature. Normally this will need an increase of about 20% compared to a conventional system.

Underﬂoor Heating Circuit

• The BoilerMate contains a prefitted pump for the heating ci rc ui t(s ) . Wh e n us i ng a n underfloor heating circuit, the manifolds should be of the nonpum ped type. The blending valve should be set at the design temperature of the underfloor circuit.

Room Thermostat

• A 2 channel digital programmer is ﬁtted to the front of the BoilerMate A-Class HP appliance. A separate external room thermostat will normally be required.

KEY DIFFERENCES FROM

CONVENTIONAL

HEATING

SYSTEMS

Page 4

SUMMARY CHECKLIST

Mitsubishi Ecodan Air Source Heat Pump

• Is to be mounted external to the property in a suitable location using the detail provided in the manual and with a minimum distance of 300mm from the nearest wall.

• Cold air is blown from the front of the unit - it should be positioned in a location where this will not cause a nuisance.

• It should be mounted on the anti-vibration mounts provided with the kit.

• The anti-vibration ﬂexible hoses should be ﬁtted to the ﬂow /return pipework.

• Under some operating conditions, condensate water may be produced which will drain away from the unit. If this is likely to cause a problem (eg. due to freezing on a pathway), we suggest incorporating a 150mm wide by 50mm deep gravel ﬁlled channel as a soakaway, or a similar arrangement to suit the location.

• The external ﬂow / return pipework needs to be insulated and waterproofed to prevent freezing.

• A 25A power supply is needed with a local external isolator ﬁtted in accordance with IEE wiring regulations.

Incoming Water Supply

• As the performance of hot and cold water systems is totally reliant on the incoming mains cold water supply, check that the pressure will be a minimum of 2 bar at times of maximum simultaneous use and that the ﬂow rate is a minimum of 30 litres/minute. (For optimum performance this will need to be 50 litres in larger properties.)

KEY DIFFERENCES FROM CONVENTIONAL HEATING SYSTEMS

Hard Water Considerations

• A factory fitted scale inhibitor can be provided and should be specified at the time of order for hardness levels above 200 and up to 300 ppm(mg/l). Where the water is very hard ie above 300 ppm (mg/l) an optional polyphosphate type inhibitor should be ordered and fitted separately by the installer.

Special Considerations In Retroﬁt Situations

• The heat exchanger in the heat pump must be protected from particulate contaminates in the water circu i t. When fitting in a retrofit situation the existing radiator circuit MUST be chemically cleaned and thoroughly flushed by a competent person before installation.

Page 5

Any water distribution and central heating installation must comply with the relevant recommendation of the current version of the Regulations and British Standards listed below:-

Building Regulations I.E.E. Requirements for Electrical Installations (BS7671) Water Regulations Manual Handling Operations Regulations

British Standards BS6798, BS5449, BS5546, BS5440:1, BS5440:2, CP331:3, BS6700, BS7593 and BS7671. Health and Safety Document No 635

A competent person as stated in the Building Regulations must install the BoilerMate heating system. The manufacturer’s notes must not be taken as overriding statutory obligations.

The BoilerMate A-Class HP-DEM model is based on an Accolade unvented hot water storage appliance and therefore is covered by section G3 of the Building Regulations. Unless the installer is part of an approved competent installer scheme the installation is notiﬁable to Building Control prior to commencement. An annual inspection is recommended to ensure safe, long term operation.

This appliance must only be used with suitable heat pumps and is not suitable for use with any uncontrolled energy source such as solid fuel/steam. It should not be installed where the annual inspection is likely to be neglected.

The information in this manual is provided to assist generally in the selection of equipment. The responsibility for the selection and speciﬁcation of the equipment must however remain that of the customer and any Designers or Consultants concerned with the design and installation.

Please note: We do not therefore accept any responsibility for matters of design, selection or speciﬁcation or for the effectiveness of an installation containing one of our products unless we have been speciﬁcally requested to do so.

All goods are sold subject to our Conditions of Sale, which are set out at the rear of this manual.

In the interest of continuously improving the BoilerMate range, Gledhill Water Storage Ltd reserve the right to modify the product without notice, and in these circumstances this document, which is accurate at the time of printing, should be disregarded. It will however be updated as soon as possible after the change has occurred.

Modiﬁcations must not be made to this appliance. If any components are replaced in the ﬁeld, they must be obtained from Gledhill Water Storage to ensure continued safe operation and must not be tampered with. This applies particularly to the immersion heaters which incorporate a pre-set overheat thermostat.

INTRODUCTION

DESIGN

BMA 180 HP-DEM

BMA 210/240 HP-DEM

Page 6

DESIGN

INTRODUCTION

Sealed primary system expansion/filling

components available as an optional extra

Figure 1.1

BoilerMate 180 HP-DEM

Zone 1 CH system (radiators or underfloor)

Automatic bypass valve (if required)

CH zone

valve

boost

3kW

HWS

boost

3kW

Secondary HWS return connection

HWS expansion vessel(s) supplied separately

with the appliance for fitting on site

HWS outlet

HW zone

valve

T&P relief valve

Primary

relief valve

Discharge

pipe

MAV

Manual air vent (MAV)

Heat

pump

Discharge

pipe

MCWS

inlet

Balanced

CWS outlet

Combination

valve

S1/2

HP (primary) circulator

System

circulator P2

Externally

mounted

temperature

compensation

sensor

Boiler

Buddy

A BoilerMate A-Class HP-DEM is a ﬂoor standing packaged mains pressure unvented hot water appliance designed for use with the Mitsubishi Electric Ecodan air source heat pump. All models are factory ﬁtted with all the necessary safety and control equipment for connecting to the domestic water systems, heat pump and the heating system as can be seen from ﬁgures 1.1, 1.2, 1.3 and 1.4.

The appliance has been speciﬁcally designed to maximise the efﬁciency of the heat pump and use the energy to provide improved space heating and mains pressure hot water performance.

The built in controls monitor the demands for heat ensuring that the low cost energy from the heat pump is used whenever possible and top up from the conventional heat source is only initiated when the ﬂow temperature from the heat pump is not sufﬁcient to meet the demands. The controls are set to provide hot water priority, ie. if there is a demand at S3, any heating demands will be suspended until the store temperature reaches the point where S3 is satisﬁed.

All models are designed to heat the domestic hot water indirectly up to the maximum temperature possible with the heat pump and then boost the temperature by means of a 3kW immersion heater up to the required set temperature. All models have connections for a zone 1 circuit where the central heating ﬂow temperature can be boosted by means of an inline electric heater to the preset design temperature. However, the 210 and 240 models also have connections for a zone 2 circuit where no temperature boost is provided. This enables separate radiator and underﬂoor heating circuits to be provided, operating at

different design temperatures if required.

The BoilerMate A-Class HP-DEM is supplied with an outside temperature compensation sensor which needs to be mounted externally and wired back to the connection terminals provided in the appliance (using the 10m of cable provided). This will then automatically adjust the operation of both zone 1 and zone 2 heating circuits to take account of the external temperature and reduce the running costs.

8 metres of 8 core signal cable is also provided for connection between the BoilerMate A-Class HP-DEM appliance and the heat pump (see page 30 for details).

The most economical way of designing the heating systems is to utilise the temperature available from the heat pump itself. For this reason, underﬂoor/low temperature radiator systems should be chosen where possible. In these situations, the electric boost heater can be disabled at the control panel if required.

Page 7

DESIGN

INTRODUCTION

Once installed and commissioned, the integration of all the heat pump, domestic hot water and central heating functions will be automatically controlled by the PCB built into the BoilerMate A-Class HP-DEM appliance. However, the temperature of the central heating will need to be controlled by remote room thermostat(s)/thermostatic radiator valves.

Details of how to enter this product in SAP are available. Please request a copy of the latest SAP Data Sheet which covers this and all other Gledhill Water Storage products.

In the event the heat pump fails, both the domestic hot water and central heating (partial only) can be heated using the built in electric heaters. This manual emergency heating mode can be selected by pressing the button labelled ‘switch’ on the appliance front panel for 5 seconds. Even in this mode the controls will give priority to the hot water. However, the appliance should only be operated in this mode for the short period of time required for the problem to be resolved.

The BoilerMate A-Class HP-DEM is designed to be sold as part of a package with the Mitsubishi Electric Ecodan air source heat pump. The combination of the BoilerMate A-Class HP-DEM and the Mitsubishi Electric Ecodan air source heat pump has been the subject of independent testing by BRE and a report is available on request. To allow a visual indication of system water quality and to protect the waterways of the heat pump from contamination a Fernox Boiler Buddy is provided as part of the package.

Scale Protection

The Building Regulations L1A: New dwellings/ L1B: Existing dwellings and the requirements set out in the Domestic Heating Compliance Guide specify that “where the mains water hardness exceeds 200ppm provision should be made to treat the feed water to water heaters and the hot water circuit of combination boilers to reduce the rate of accumulation of lime scale”.

To comply with this requirement the hardness of the mains water should be checked by the installer and if necessary the optional factory ﬁtted in-line scale inhibitor should be speciﬁed at the time of order for hardness levels between 200 and 300 ppm (mg/l).

Where the water is very hard ie 300ppm (mg/l) and above the optional polyphosphate type, inhibitor should be specified at the time of order. However, this will need to be ﬁtted by the installer at a suitable point in the cold water supply to the appliance.

Sealed primary system expansion/filling

components available as an optional extra

Figure 1.2

BoilerMate 210/240 HP-DEM

Zone 1 CH system (radiators or underfloor)

Zone 2 CH system (underfloor or other

low temperature heating system)

HP (primary) circulator

S5 S6

CH zone

valve

boost

3kW

HWS

boost

3kW

Secondary HWS return connection

HWS expansion vessel(s) supplied separately

with the appliance for fitting on site

HWS outlet

HW zone

valve

T&P relief valve

Primary

relief valve

Discharge

pipe

MAV

Manual air vent (MAV)

System

circulator P2

Zone 2 CH

circulator P3

Boiler

Buddy

Discharge

pipe

MCWS

inlet

Balanced

CWS outlet

Combination

valve

S1/2

Externally

mounted

temperature

compensation

sensor

Heat

pump

Automatic bypass valve (if required)

Page 8

DESIGN

TECHNICAL DATA

180 model

Factory Fitted/Supplied Components

1 Domestic mains cold water inlet

connection - see notes on page 12

2 Balanced pressure cold water outlet

connection

3 Combination inlet control valve -

unvented store

4 Pressure relief (safety) valve - primary

system

5 Expansion vessel connection - unvented

store

5a Expansion vessel - unvented store - see

notes on page 12 & Figure 1.8

6 Pressure and temperature relief valve

- unvented store 7 Tundish 8 S5 sensor - heat pump return 9 Expansion vessel connection - primary

system (Heat pump and heating circuit)

10 Expansion vessel/gauge - primary system

- see notes on page 12 11 Temporary ﬁlling loop - primary system

- see notes on page 12 12 Drain valve 13 Manual air vents - primary systems 14 Central heating (Zone 1)/hot water

systems circulator (P2) 15 D.H.W. zone valve (energy cut out) 16 Central heating zone valve (Zone 1) 17 Central heating ﬂow connection (Zone 1)

- Isolating valve 18 Central heating return connection (Zone 1) 19 Flow connection (from heat pump) 20 Heat pump system circulator (P1) 21 Return connection (to heat pump) 22 Discharge pipe connection 23 S6 sensor - heat pump ﬂow 24 S4 sensor - central heating ﬂow (+ boost) 25 Electrical temperature boost assembly

- central heating (Zone 1 only) 26 S3 sensor - hot water boost 27 Primary system manifold 28 Electrical temperature boost (hot water only) 29 Flow to hot water coil - unvented system 30 Return from hot water coil - unvented

store 31 Domestic hot water outlet connection 32 Secondary domestic hot water return

connection 33 Electrical control panel/printed circuit

boards and connection terminals 34 User control panel and 2 channel clock 35 100mm high installation base 36 8m 8 core signal cable to be site run/

connected to Mitsubishi HP by the installer 37 S7 external temperature compensation

sensor and 10m of cable to be site run/

ﬁtted by installer 38 Fernox ‘Boiler Buddy’ in-line ﬁlter -

see

notes on page 12

Figure 1.3BoilerMate A-Class HP-DEM 180 model

13 (front)

5 (mid)

2 3

31 7/22

26 14

7/22

18 19

9(10/11)

(rear)

Other Optional Equipment

• Hot and cold water manifolds for use with plastic pipework (Set 1 or 2).

• Electronic scale inhibitor for mains water services with hardness levels above 200ppm (mg/l) ﬁtted in the appliance.

• Polyphosphate scale and corrosion inhibitor for mains water services with hardness levels above 300ppm (mg/l) for ﬁtting on site by the installer.

Page 9

210/240 models

Factory Fitted/Supplied Components

1 Domestic mains cold water inlet

connection - see notes on page 12

2 Balanced pressure cold water outlet

connection

3 Combination inlet control valve -

unvented store 4 Pressure relief (safety) valve - primary system 5 Expansion vessel connection - unvented

store 5a Expansion vessel - unvented store - see

notes on page 12 & Figure 1.8

6 Pressure and temperature relief valve

- unvented store 7 Tundish 8 S5 sensor - heat pump return 9 Not used on this model 10 Central heating return (Zone 2)

connection - expansion vessel/gauge

- primary system - see notes on page 12 11 Temporary ﬁlling loop - primary system

- see notes on page 12 12 Drain valve 13 Manual air vents - primary systems 14 Central heating (Zone 1)/hot water

systems circulator (P2) 15 D.H.W. zone valve (energy cut out) 16 Central heating zone valve (Zone 1) 17 Central heating ﬂow connection (Zone 1)

connection

33 Electrical control panel/printed circuit

boards and connection terminals 34 User control panel and 2 channel clock 35 Central heating circulator (P3)(Zone 2) 36 Central heating ﬂow connection (Zone 2) 37 S7 external temperature compensation

sensor and 10m of cable to be site run/

ﬁtted by installer 38 Fernox ‘Boiler Buddy’ in-line ﬁlter - see

notes on page 12

39 100mm high installation base 40 8m 8 core signal cable to be site run/

connected to Mitsubishi HP by the installer

Figure 1.4BoilerMate A-Class HP-DEM 210 & 240 models

13 (front)

5 (mid)

2 3

7/22

26 14

7/22

10(11)

(rear)

18 19

Other Optional Equipment

• Hot and cold water manifolds for use with plastic pipework (Set 1 or 2).

• Electronic scale inhibitor for mains water services with hardness levels above 200ppm (mg/l) ﬁtted in the appliance.

• Polyphosphate scale and corrosion inhibitor for mains water services with hardness levels above 300ppm (mg/l) for ﬁtting on site by the installer.

DESIGN

TECHNICAL DATA

Page 10

DESIGN

TECHNICAL DATA

Figure 1.5

Either radiator or

underfloor heating circuit

Please note:

This is a diagramatic representation,

all pipework should enter through

base of appliance.

All connections are 22mm.

Primary System Pipework Connections for BoilerMate A-Class HP 180 Model Only

Zone 1

flow

Zone 1

return

Water in

(return)

Water out

(flow)

Ecodan

(rear)

Page 11

DESIGN

TECHNICAL DATA

Primary System Pipework Connections for BoilerMate A-Class HP 210 & 240 Models Only

Figure 1.6

Zone 1

Either radiator or

underfloor heating circuit

Zone 2

Underfloor or other low

temperature heating circuit

Zone 1

flow

Zone 2

flow

Zone 1

return

Zone 2

return

Please note:

This is a diagramatic representation,

all pipework should enter through

base of appliance.

All connections are 22mm.

Ecodan

(rear)

Water in

(return)

Water out

(flow)

Page 12

Notes:

Item 5a is supplied separately with the appliance (see Figure 1.8 and Table 1.1 below for details), complete with a ﬁxing bracket and pipework installation kit.

Items 10 and 11 are available as an optional Primary Sealed System Kit at extra cost. If required, this should be ordered at the same time as the appliance (see Figure 1.7 and Table 1.1 below for details). The expansion vessels are provided with a suitable ﬁxing bracket.

Item 38 is supplied separately with the appliance package for ﬁtting internally in the heat pump return as near as possible to the heat pump, fully in accordance with the manufacturers instructions included later in this manual.

The appliance is available with the option of a factory ﬁtted scale inhibitor, at extra cost. In this case the aerial is ﬁtted on the 22mm cold inlet and the scale inhibitor PCB is ﬁtted in the electrical panel/PCB area.

Figure 1.7 Figure 1.8

Primary system expansion vessel available as an optional extra at the time of order as part of the Primary

Sealed System kit

Unvented store expansion vessel

supplied separately with the appliance

Expansion Vessels

Model

Primary Expansion Vessel (Optional Extra) Unvented Store Expansion Vessel (Supplied)

Capacity (l) Size (mm) LxWxH Capacity (l) Size-each (mm) LxDiam

BMA 180 HP-DEM 12 500 x 200 x 160 12 270 x 270

BMA 210 HP-DEM 12 500 x 200 x 160 12 270 x 270

BMA 240 HP-DEM 2 x 12 500 x 200 x 160 18 400 x 270

Table 1.1

The size of the primary system expansion vessel has been calculated using typical design criteria for the maximum recommended heating load shown in Table 1.2. However, the

DESIGN

TECHNICAL DATA

size should be checked and conﬁrmed as being accurate by the system designer/installer.

Page 13

DESIGN

TECHNICAL DATA

Technical Data

Model BMA 180 HP-DEM BMA 210 HP-DEM BMA 240 HP-DEM

Nominal domestic hot water storage volume (litres) 145 171 215

Overall app. dimensions (mm) (Height x Width x Depth) 1370 x 595 x 595 1600 x 595 x 595 1950 x 595 x 595

Minimum recommended cupboard dimensions (mm)

(Height x Width x Depth) 1970 x 700 x 600

(1)

2200 x 700 x 600

(1)

2250 x 700 x 700

(1)

Weight (kg) (Empty / Full) 87 / 232 103 / 274 114 / 329

Unvented store expansion vessel

Type: Varem 1 Off

(2)

Total nominal volume (litres) 12 18

Charge pressure (bar) 1.5

Heat pump circuit circulating pump P1 Grundfos UPS 15-50

System circulating pump P2 (HW and Zone 1 CH) Grundfos UPS 15-50

Circulating pump P3 (Zone 2 CH) –––– Grundfos UPS 15-50

HW circuit zone valve - type Honeywell V4043 22mm

CH circuit zone valve - type Honeywell V4043 22mm

Electrical data

Supply: 230V AC, 50Hz rated at 6.5kW

Main supply circuit breaker 32A type B

Internal protection: Immersion heaters

2 x 16A MCBs (Type B)

Internal protection: Control circuit 1 x 6A MCB (Type B)

Internal protection: Heat pump L.V. control signal (12VDC signal)

1 x 100mA 20mm glass cartridge fuse (+ spare)

Control & overheat safety thermostat temperature settings

HW boost immersion heater S1/S2 safety sensors

(3)

P & T valve 900C

CH boost immersion heater Control thermostat

(5)

: 650C, Overheat thermostat

(4)

: 850C

Control/relief valve pressure set points

Mains inlet pressure regulator 1.5 bar

Expansion relief valve (CW) 3.0 bar

Expansion relief valve (CH) 3.0 bar

P & T valve 4.0 bar

Maximum hot water ﬂow rate 25-35

Dwelling type

Bedrooms 3-4 3-4 3-5

Bathrooms 1 1 2

En-suite 1 2 1

Maximum heating load 13kW

Electrical backup ‘switch’ 6kW

(1) The sizes shown allow for the unvented store expansion vessel to be ﬁtted above the appliance in the case of the 180 and 210 models, but assume that the optional primary sealed system kit will be ﬁtted elsewhere. The dimensions for the 240 model assume both the unvented store and primary expansion vessels will be ﬁtted elsewhere due to the height of the appliance itself. Clear access 650 deep will be required in front of the whole of the appliance for future maintenance. (2) Supplied loose - To be ﬁtted by installer in a suitably accessible location. (3) Temperature is automatically controlled by the controller sensors S1/S2. (4) Not adjustable - Manual reset type. (5) Temperature is automatically controlled by the controller sensor therefore should not be set lower than 650C.

Table 1.2

Page 14

Sensor Control Parameters & Default Temperature Settings

Description Sensor Default Value (0C)

HP off setting (ﬂow) S6 58

HP off setting (return) S5 56

HP on-off differential setting S5/S6 3

HW store heating - off setting

HW store heating on-off differential setting 7

HW store overheat setting S1/S2 75 max.

Sensor S1/S2: Duplex domestic hot water overheat (store temp.) Sensor S6: Heat pump ﬂow temperature Sensor S5: Heat pump return temperature Sensor S4: Central heating ﬂow temperature (zone 1 circuit) Sensor S3: Domestic hot water temperature (store temperature)

HP: Heat pump CH: Central heating HW: Hot water heating

Notes: See Figure 1.3/1.4 for sensor locations.

Table 1.3

Model Selection Data

General guidance is given in Table 1.2.

When checking the suitability of the heat pump we recommend that the heat losses of the external building fabric plus half of the ventilation losses are directly compared to the Ecodan heat pump output of 9kW.

If design calculations are carried out in the normal way, using the method set out in BS5449. The Ecodan heat pump will cope with heating systems in which boiler sizes calculated in this way are rated at up to a maximum of 13kW.

As the BoilerMate A-Class HP-DEM is a hot water storage appliance, we recommend that the model size of the appliance is chosen by calculating the hot water volume in the normal way using the criteria set out in BS 6700 / NHBC for storage appliances.

Electricity Supply

One mains supply rated at 32A, 230V~, 50Hz is required.

Minimum external fuse rating and the main supply cable ratings are given in Table 1.2 Technical Data section of this manual. This appliance MUST BE EARTHED.

All external wiring to the appliance must be in accordance with the latest I.E.E. Wiring Regulation, and any local regulations which may apply.

The appliance shall be supplied from a suitably rated double pole isolator with a contact separation of at least 3mm in both poles.

This must be suitably labelled, provide complete electrical isolation and be within 1 metre of the BoilerMate A-Class HP-DEM Unit.

In the event of an electrical fault after installation of the appliance, preliminary electrical checks must be carried out i.e. Earth Continuity, Short Circuit, Polarity, and Resistance to Earth.

DESIGN

TECHNICAL DATA

Appliance Location

The BoilerMate A-Class HP-DEM appliance must be installed on a ﬂat surface which is capable of supporting the weight of the appliance and any other ancillary equipment. (The full weight must be used, see table 1.2 on page 13).

The appliance sizes and the minimum cupboard dimensions are shown in Table 1.2. A minimum of 600mm is required in front of the appliance for maintenance purposes. (See ﬁgures 1.3 and

1.4 on pages 8 and 9).

The appliance is designed to be installed on the timber plinth supplied with the appliance.

Details of the various electrical and pipework connections required are shown in Figures 1.3 and 1.4.

Page 15

DESIGN

TECHNICAL DATA

180 Model Connection Details/Dimensions

Diagram opposite show the connection details and dimensions for the BoilerMate A-Class HPDEM 180 model.

The BoilerMate A-Class HP-DEM units are supplied on an installation base to allow the pipe runs to connect to the appliance from any direction. It is easier if all pipes protrude vertically in the cut out area shown. Compression or push ﬁt connections can be used. All pipe positions are approximate and subject to a tolerance of +/-20mm in any direction.

Note: All dimensions are shown in mm and are to the centre line of pipework/gland.

575 (595 including the door/clock)

595

315 - DHWS Expansion

440 - Primary System Vent

300

545

180 Model Connection Details/Dimensions - Top

DHWS Secondary Return

Figure 1.9

575 (595 including the door/clock)

440 - Heat Pump Return

440 - Heating Return (Zone 1)

440 - Sealed Primary Exp. Vessel

595

390

415 - Heating Flow (Zone 1)

400

440 - Heat Pump Flow

470 - P&T Relief Valve Discharge

460 - Hot To Taps

430

450

540

495 - Cold In

270

90 105

180 Model Connection Details/Dimensions - Bottom

Expansion Relief

Valve Discharge

Page 16

575 (595 including the door/clock)

595

315 - DHWS Expansion

440 - Primary System Vent

300

545

210/240 Models Connection Details/Dimensions - Top

DHWS Secondary Return

Figure 1.10

575 (595 including the door/clock)

440 - Heat Pump Return

440 - Heating Return (Zone 1)

440 - Heating Return (Zone 2)

595

390

440 - Heat Pump Flow

340

440 - Heating Flow (Zone 2)

470 - P&T Relief Valve Discharge

460 - Hot To Taps

400

435

430

535

505 - Cold In

240

90 105

210/240 Models Connection Details/Dimensions - Bottom

415 - Heating Flow (Zone 1)

Expansion Relief

Valve Discharge

DESIGN

TECHNICAL DATA

210/240 Model Connection Details/Dimensions

Diagram opposite show the connection details and dimensions for the BoilerMate A-Class HPDEM 210/240 models.

The BoilerMate A-Clas s HP-DEM units are supplied on an installation base to allow the pipe runs to connect to the appliance from any direction. It is easier if all pipes protrude vertically in the cut out area shown. Compression or push ﬁt connections can be used. All pipe positions are approximate and subject to a tolerance of +/-20mm in any direction.

Note: All dimensions are shown in mm and are to the centre line of pipework/gland.

Page 17

Hot and Cold Water System

All recommendations with regard to pipe work systems in this manual are generally

based on the use of BS/EN Standard copper pipework and ﬁttings.

However a plastic pipework system can be used in place of copper internally as

long as the chosen system is recommended by the manufacturer for use in cold

and hot water systems and is designed and installed fully in accordance with their

recommendations.

It is also important that if an alternative pipework material/system is chosen, the

manufacturer conﬁrms that the design criteria for the new system is at least equivalent

to the use of BS/EN Standard copper pipework and ﬁttings or larger pipe sizes are

considered.

In these appliances the mains inlet pressure regulating valve is set to 1.5 bar and this

setting MUST NOT be adjusted. Therefore the ﬂow rate from the appliance depends

upon the resistance of the hot water supply network, capacity of the incoming

mains and the characteristics of the pressure regulating valve

Mains Cold Water Supply

The BoilerMate A-Class HP-DEM appliance is designed to be connected directly to the

mains. The combination inlet valve incorporates the required check valve. The hot

water ﬂow rate achievable is directly related to the adequacy of the cold water mains

serving the property. For this reason the cold water supply to the dwelling must be

capable of providing for those services which could be required simultaneously and

this maximum demand should be calculated. Also if a water meter is ﬁtted its nominal

rating should match the anticipated maximum simultaneous hot and cold water

demand calculated in accordance with BS 6700. This could be 60 litres per minute in

some properties. 30 litres per minute is the minimum ﬂow rate which is recommended

for an adequate mains pressure system to any property.

The Building Regulations L1A: New dwellings/L1B: Existing dwellings and the

requirements set out in the Domestic Heating Compliance Guide specify that “where

the mains water hardness exceeds 200ppm provision should be made to treat the feed

water to water heaters and the hot water circuit of combination boilers to reduce the

rate of accumulation of lime scale”.

To comply with this requirement the hardness of the mains water should be checked by

the installer and if necessary the optional factory ﬁtted in-line scale inhibitor should be

speciﬁed at the time of order for hardness levels between 200 and 300 ppm (mg/l).

Where the water is very hard ie 300ppm (mg/l) and above the optional polyphosphate

type, inhibitor should be speciﬁed at the time of order. However, this will need to be

ﬁtted by the installer at a suitable point in the cold water supply to the appliance.

The combination valve ﬁtted to the BoilerMate A-Class HP-DEM unit incorporates a

pressure regulating valve set to provide a static operating pressure of 1.5 bar. On this

basis there must be at least 2.0 bar pressure at the inlet to the appliance. This pressure

must be dynamic (not static) and be available at the appliance when local demand

is at its maximum. For optimum performance, and for larger properties, we would

recommend that the dynamic pressure is in the range of 2.5 - 3.5 bar.

The combination valve also incorporates an expansion relief valve. The discharge from

this can be connected into the discharge pipe from the P & T valve. Further details of

how to treat this discharge are provided later in this manual.

As a general guideline, if a good pressure is available, a 15mm service may be sufﬁcient

for smaller dwellings with one bathroom. However a 22mm service (25mm MDPE) is

recommended and should be the minimum for larger dwellings, or where only the

minimum recommended pressure is available.

If the incoming mains pressure exceeds 6 bar at any time in a 24 hour cycle then a pressure regulating valve set at 3.5 bar should be ﬁtted downstream of the stop tap where the cold supply enters the property.

Equipment used in the system should be suitable for a working pressure of up to 5 bar.

SYSTEM DETAILS

DESIGN

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gledhill BMA 240 HP-PQFY, PUHZ-W90VHA, BMA 210 HP-DEM, BMA 240 HP-DEM, BMA 180 HP-PQFY Installation & Servicing Instructions Manual

Specifications and Main Features

Frequently Asked Questions

User Manual