Benchmark mCHP BoilerMate Design, Installation And Servicing Instructions

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mCHP

Gas Council Approved Reference Numbers

mCHP BMA 225-R

mCHP BMA 235-R

mCHP BMA 225-N

mCHP BMA 235-N

benchmark

The code of practice for the installation,

commissioning & servicing of central heating systems

BoilerMate

DESIGN, INSTALLATION AND

SERVICING INSTRUCTIONS

PLEASE LEAVE THESE INSTRUCTIONS IN THE POCKET PROVIDED ON

THE BACK OF THE FRONT PANEL

89-317-07A

89-317-08A

89-317-07A

89-317-08A

Supplied By www.heating spares.co Tel. 0161 620 6677

AN OPEN VENTED CENTRAL HEATING

AND MAINS PRESSURE HOT WATER

APPLIANCE INCORPORATING AN

INTERGRATED THERMAL STORE - FOR USE

WITH mCHP UNITS IN DOMESTIC DWELLINGS

ALL MODELS COMPLY WITH THE

WATER HEATER MANUFACTURERS

SPECIFICATION FOR INTEGRATED THERMAL

STORES

A - C L A S S

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Summary of Contents for Benchmark mCHP BoilerMate

Page 1: Servicing Instructions
BMA 235-R 89-317-08A mCHP BMA 225-N 89-317-07A mCHP BMA 235-N 89-317-08A benchmark AN OPEN VENTED CENTRAL HEATING The code of practice for the installation, AND MAINS PRESSURE HOT WATER commissioning & servicing of central heating systems APPLIANCE INCORPORATING AN...
Page 2 • Read these Instructions in conjunction with the mCHP appliance installation instructions before installing or commissioning the appliance. • Leave these instructions and the ‘Benchmark’ Log Book in the pocket provided on the back of the appliance front panel. The Gledhill BoilerMate range is a WBS...
Page 3: Table Of Contents
CONTENTS Section Page SERVICING IMPORTANT NOTICES ANNUAL SERVICE SYSTEM DESCRIPTION CHANGING COMPONENTS INTRODUCTION OPERATION SHORT PARTS LIST 2.2.1 Domestic Hot Water 2.2.2 Space Heating ‘N’ Models 2.2.3 Space Heating ‘R’ Models APPENDIX A 2.2.4 Store Heating - Not Active 2.2.5 Store Heating - Active (‘N’...
Page 4: Important Notices
1.0 IMPORTANT NOTICES 1.1 HANDLING AND STORING THE APPLIANCE This appliance should be handled carefully to avoid damage and the recommended method is shown opposite. A team lift - When lifting the unit:- • Work with someone of similar build and height if possible.
Page 5: System Installation
(b) All goods are sold subject to our Conditions of Sale which are set out in the Appendix to this document. 1.5 WARNINGS As part of the industry wide‘Benchmark’initiative all mCHP BoilerMate appliances A-CLASS now include a Benchmark Installation, Commissioning and Service Record Logbook.
Page 6: System Description
. All models are fitted with A-CLASS electric central heating and hot water backup and boost facility. The principal of a mCHP BoilerMate A-CLASS to separate the heat generator e.g. mCHP appliance from the ﬂuctuating space heating and domestic hot water demands by means of a thermal energy store.
Page 7 ‘Y’ plan in a traditional heating system to minimise pipe work changes during installation. To comply with the Benchmark Guidance Note for Water Treatment in heating and hot water systems the installer should check the hardness levels of the water supply and if necessary ﬁt an in-line...
Page 8: Operation
2.0 SYSTEM DESCRIPTION The mCHP BoilerMate A-CLASS appliance user controls are shown in ﬁgure 2.5. All models F & E cistern are ﬁtted with a single channel programmer and summer winter switch for programming S1/S2 heating and hot water ‘on’ times. All models...
Page 9: Space Heating 'R' Models
SYSTEM DESCRIPTION 2.0 (d) The store heating demand ceases when both When either the programmer or the room thermostat stop calling for heat, the store temperatures T5 and T6 are greater controller senses loss of space heating demand and switches off the central heating than S5_OFF and S6_OFF set points or if pump, P2.
Page 10: Store Heating - Active ('R' Models)
2.0 SYSTEM DESCRIPTION When both store and space heating demands are active and the average If the store temperature exceeds 95ºC store temperature is greater than ‘T-CH_boost2_Off’ set point and the rate when the store heating demand is active, of temperature rise in the store is greater than the R_CH_boost 2 set point, the controller will switch off all active heat the controller will switch off the electric boost.
Page 11: User Controls
Indicates the : heating ‘on’ and ‘off’ times. Off: Normal Slow ﬂashing:‘Switch’ backup system failure Note: If requested the mCHP BoilerMate Medium ﬂashing:‘Switch’ backup selected A-Class can be fitted with an external Rapid ﬂashing: Overheat/safety trip 2 channel programmer to time control On:‘Switch’...
Page 12: Technical Specification
3.0 TECHNICAL SPECIFICATION 350mm Min access �� to comply with 'Water Regulations' F & E 300mm Cistern �� 100mm high plinth ��...
Page 13: General
F&E cistern. Any extra space required for shelving etc in the case of airing cupboard etc must be added. A-CLASS Table 3.1 Technical Speciﬁcation of mCHP BoilerMate - Physical Data BMA225N BMA235N...
Page 14 (4) Based on the average store charge temperature of 77ºC and mains cold water inlet temperature of 10ºC (5) Heat losses measured at 55K steady temperature difference as speciﬁed in the WMA Speciﬁcation for Thermal Stores (6) 6kW ‘Switch’ is integrated in the mCHP BoilerMate control system. Therefore electricity supply to the appliance A-CLASS via the two pole isolator must be rated at 6.5kW at 230V ac, 50Hz.
Page 15 TECHNICAL SPECIFICATION 3.0 Table 3.3 Model Selection Guide BMA225N BMA235N BMA225R BMA235R Maximum design heat loss of the dwelling (kW) Maximum number of bathrooms & En-suite shower room Table 3.4 Factory ﬁtted or supplied standard and optional equipment BMA 225N BMA 225R BMA 235N BMA 235R...
Page 16: Bypass Valve Performance
Flow rate (m and the cold water inlet temperature is 10 C.Also during the draw-off it is assumed that there is no Figure 3.6 Hot water performance of mCHP BoilerMate heat input from the mCHP unit. �� ...
Page 17: Electricity Supply And Wiring Diagrams
TECHNICAL SPECIFICATION 3.0 3.5 ELECTRICITY SUPPLY AND WIRING FIGURE 3.7 DIAGRAMS ID_RESISTOR Page 17 Supplied By www.heating spares.co Tel. 0161 620 6677...
Page 18 3.0 TECHNICAL SPECIFICATION FIGURE 3.8 ID_RESISTOR Page 18 Supplied By www.heating spares.co Tel. 0161 620 6677...
Page 19: Appliance Controller
TECHNICAL SPECIFICATION 3.0 3.5 ELECTRICITY SUPPLY AND WIRING DIAGRAMS A-CLASS All mCHP_BoilerMate models are ﬁtted with electric backup heaters rated at 6kW as standard. Therefore the single mains electricity supply to the appliance must be rated at 32A at 230V ac and connected to the appliance through a 2-pole local isolator. All fuses must be ASTA approved to BS 1362.
Page 20 Models ID Resistor Value Controller Code mCHP BMA 225-N mCHP BMA 235-N mCHP BMA 225-R mCHP BMA 235-R Table 3.7 sensor used in mCHP BoilerMate Display Sensor Connector J9 pins Location T Overheat 1 6 & 14 Top of store in dry pocket (S1 & S2 are in single housing) T Overheat 2 2 &...
Page 21 TECHNICAL SPECIFICATION 3.0 Table 3.8 Sensor Sensor control set point readings Display Sensor Top/middle store sensor, S6, ON set point Top/middle store sensor, S6, OFF set point DHW Inlet sensor, S3, set point DHW Outlet sensor, S4, set point Bottom store sensor, S5, ON set point Bottom store sensor, S5, OFF set point Table 3.9 Controller Error Codes and Descriptions LOCKING ERRORS...
Page 22: Computer Interface
3.0 TECHNICAL SPECIFICATION 3.6.6 COMPUTER �� INTERFACE �� The laptop computer can be connected to �� the controller for commissioning, system �� monitoring and fault diagnostics.Typical �� system status display screen on a PC is shown ��...
Page 23 TECHNICAL SPECIFICATION 3.0 Figure 3.11 mCHP BoilerMate A-Class N Computer Screen Display Not yet available Figure 3.12 mCHP BoilerMate A-Class R Computer Screen Display Not yet available Page 23 Supplied By www.heating spares.co Tel. 0161 620 6677...
Page 24: Heating And Hot Water System Design
This could be 50 litres per minute in some properties. suitable for a working pressure of up to (c) All models of the mCHP BoilerMate will operate at pressure as low as 1 bar but the 5bar. recommended range is between 2 and 3 bar. These pressures must be dynamic and be available at the appliance when local demand is at its maximum.
Page 25: Use In Hard Water Areas
(Para 15, Schedule 2) of the Water Supply Regulations 1999. 4.1.5 (d) A bidet can be supplied from the mCHP BoilerMate appliance as long as it is of DEAD LEG VOLUMES the over rim ﬂushing type and incorporates a suitable air gap.
Page 26: Space Heating System Design
(e.g.garage,outhouse and ventilated roof space),a frost thermostat(s) must be ﬁtted and wired as shown in sections 5 of this manual.Before ﬁtting the frost protection, the mCHP manual should also be consulted. (e) User controls: The mCHP BoilerMate 2000 models are supplied with a factory ﬁtted 1-channel programmer and summer winter switch and the room thermostat can be connected to the appliance (see section 5).
Page 27: Mchp Circuit Design
HEATING AND HOT WATER 4.0 The (R) models primarily designed for the retroﬁt market, are ﬁtted with an automatic bypass valve to allow thermostatic radiator valves (TRV’s) to be ﬁtted to all radiators.The bypass valve is set at the factory to 2m head but this should be adjusted on site by the installer to ensure that the temperature rise across the boiler is not greater than 12 C when the mCHP unit is ﬁring at its maximum rating.
Page 28: Installation And Wiring
5.0 INSTALLATION AND WIRING 5.1 SITE REQUIREMENTS (a) The appliance is designed to be installed in an airing/cylinder cupboard on the 100mm high plinth supplied with the appliance and the minimum relevant dimensions are provided in section 3. The minimum dimensions shown in ﬁgures 3.1 and 3.2 (section 3),allow for the passage/connection of pipes to the appliance from any direction as long as the appliance is installed on the base provided.
Page 29 INSTALLATION AND WIRING 5.0 �� ...
Page 30: Pipework Connections
5.0 INSTALLATION AND WIRING PIPEWORK CONNECTION (a) The position of the pipework connections is shown opposite in ﬁgures 5.3 and 5.4 and the connection sizes and dimensions are shown in figure 3.2a, section 3.2b, section 3. All connections are also labelled on the appliance.
Page 31: Electrical Wiring
WisperGen mCHP unit is shown in The mCHP BoilerMate is supplied with a pre-wired 2m long twin + E cable rated at ﬁgure 5.5. 32A. Connect this cable to the local BoilerMate isolator (See ﬁgure 5.5)
Page 32 5.0 INSTALLATION AND WIRING Colour Legend Brown WhisperGen mCHP 230V 50Hz supply Blue fused at 8A Black (Anti surge HRC fuse) Factory fitted & wired Grey Note: Supply to be brought directly from consumer unit Green / Yellow G / Y Local 2 pole isolator within 2m of appliance WhisperGen mCHP...
Page 33 INSTALLATION AND WIRING 5.0 Colour Legend Brown WhisperGen mCHP 230V 50Hz supply Blue fused at 8A Black (Anti surge HRC fuse) Grey Note: Supply to be brought directly from consumer unit Green / Yellow G / Y Local 2 pole isolator within 2m of appliance WhisperGen mCHP appliance connections...
Page 34: Commissioning
6.0 COMMISSIONING 6.0 COMMISSIONING (a) Ensure that all cleansing/treatment of (a) It is essential that the system functions properly for optimum performance. To the heating system is carried out fully in achieve this, the heating and the hot water system should be commissioned in accordance with the instructions provided accordance with the good practice and generally with the requirements of BS 6798, by Fernox.
Page 35: Cleansing Hot & Cold Water And Treatment
6.3 COMMISSIONING mCHP UNIT & BOILERMATE (b) Check that the front panel switch is in (a) Check that the mCHP BoilerMate front panel switch is in ‘On’ position and the ‘winter’ position, set heating programmer summer/winter switch is in summer position.
Page 36: Commissioning Domestic Hot Water
(b) Record the hot water outlet temperature in the ‘Benchmark’ logbook. Close this tap and open the hot bath tap at maximum ﬂow rate and record the ﬂow rate and the hot water temperature in the ‘Benchmark’ logbook.
Page 37: Short Parts List
SERVICING 7.0 Table 7.1 Speciﬁcation of main components and Parts List Description Supplier & model Part Stock Models number Code PHE pump Grundfos, UPR 15-50 (modulating) 59505432 GT089 Plate heat exchanger (PHE) SWEP, 24 Plate heat exchanger E8T/24 GT017 PHE pump isolating valve - inlet Martin Orgee, 90°...
Page 38: Appendix A
APPENDIX A WATER SAVINGS WATER RELATED COSTS CAN BE REDUCED BY GOOD PLUMBING PRACTICE. TAPS & MIXERS 2 TAP 5, 6 OR HALF OPEN OVER 8 L/M 20 L/M Unregulated Fitted with regulator SHOWERS 4 FIXING OPTIONS FOR TAPS & MIXERS 1.
Page 39: Appendix B
APPENDIX B MANIFOLDS Two sets of manifolds are available as an optional extra. Each set comprises a separate hot and cold water manifold. Both are provided with a 22mm inlet connection t t i t i l located centrally. All outlet connections are 15mm compression.
Page 40 APPENDIX B The pressure loss through a flow regulator at the designated ﬂow rate is about 1.8 bar. Therefore for the ﬂow regulator to control the ﬂow rate at pre-set level,the inlet pressure must be greater than 1.8 bar. If the inlet pressure is lower, the ﬂow rate will be correspondingly less than the pre-set values.
Page 41 APPENDIX B The size of the distribution pipes supplying the manifold should be calculated using the method set out in BS 6700. A typical diagrammatic arrangement of a system using Manifold Type 1 is shown below. This is only meant to show the principles involved and the actual connection of ﬁttings to the manifold will need to suit the arrangements shown on page 35.
Page 42: Appendix C
The levels of water hardness may be measured using a water hardness test kit. BUILDING REGULATIONS Completion of the BENCHMARK log book requires that the ‘competent person’ undertaking the installation and commissioning provide information relating to Cleaning, Inhibitor and Scale Protection.
Page 43: Appendix D
APPENDIX D �� ...
Page 44: Terms And Conditions Of Trading
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Page 45 �� ...
Page 46 Supplied By www.heating spares.co Tel. 0161 620 6677...
Page 47 Supplied By www.heating spares.co Tel. 0161 620 6677...
Page 48 Supplied By www.heating spares.co Tel. 0161 620 6677...

Benchmark mCHP BoilerMate Design, Installation And Servicing Instructions

1 Important Notices

2 System Description

3 Technical Specification

4 Heating and Hot Water System Design

5 Installation and Wiring

6 Commissioning

7 Servicing

8 Short Parts List

Appendix A

Appendix B

Appendix C

Appendix D

9 Terms and Conditions of Trading

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