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gledhill BMA 180 HP-DEM Installation & Servicing Instructions Manual

Boilermate and ecodan air source heat pump
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Air Source Heat Pumps
A complete package to provide hot water and heating in
domestic housing from an air source heat pump
Design, Installation & Servicing
BoilerMate Model Numbers
BMA 180 HP-DEM
BMA 210 HP-DEM
BMA 240 HP-DEM
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:
Instructions
Ecodan Air Source Heat Pump Model Number
BoilerMate Model Numbers
BMA 180 HP-PQFY
BMA 210 HP-PQFY
BMA 240 HP-PQFY
Appliances
PUHZ-W90VHA

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Summary of Contents for gledhill BMA 180 HP-DEM

  • Page 1 Design, Installation & Servicing Instructions BoilerMate Model Numbers Ecodan Air Source Heat Pump Model Number BMA 180 HP-DEM PUHZ-W90VHA BMA 210 HP-DEM BMA 240 HP-DEM These instructions also include wiring/installation details for a special version of the BoilerMate HP...

  • Page 2: Table Of Contents

    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 This product is manufactured under an ISO interval record is included with all gas appliance manuals.

  • Page 3: Summary Checklist

    KEY DIFFERENCES FROM CONVENTIONAL HEATING SYSTEMS Summary Checklist for Mitsubishi Ecodan and Gledhill BoilerMate A-Class HP Installation This checklist has been created to help you understand the Externally Mounted Temperature differences from other types of heating systems that you will Sensor have installed.
  • Page 4 KEY DIFFERENCES FROM CONVENTIONAL HEATING SYSTEMS Mitsubishi Ecodan Air Source Heat Pump Hard Water Considerations • Is to be mounted external to the property in a suitable location • A factory fitted scale inhibitor using the detail provided in the manual and with a minimum can be provided and should be distance of 300mm from the nearest wall.

  • Page 5: Design

    Building Control prior to commencement. An annual inspection is recommended to ensure safe, long term operation. BMA 180 HP-DEM 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.
  • Page 6 DESIGN HWS expansion vessel(s) supplied separately with the appliance for fitting on site Secondary HWS Manual air vent (MAV) return connection T&P Primary relief relief valve valve S1/2 HWS outlet boost CH zone HW zone valve valve Externally mounted temperature System compensation boost...
  • Page 7 DESIGN HWS expansion vessel(s) supplied separately with the appliance for fitting on site Secondary HWS Manual air vent (MAV) return connection T&P Primary relief relief valve valve S1/2 HWS outlet boost CH zone HW zone valve valve Externally mounted temperature System compensation boost...
  • Page 8 DESIGN 180 model Factory Fitted/Supplied Components 5 (mid) (rear) (front) Domestic mains cold water inlet connection - see notes on page 12 Balanced pressure cold water outlet connection Combination inlet control valve - unvented store Pressure relief (safety) valve - primary system Expansion vessel connection - unvented store...
  • Page 9 DESIGN 210/240 models Factory Fitted/Supplied Components 5 (mid) (rear) (front) Domestic mains cold water inlet connection - see notes on page 12 Balanced pressure cold water outlet connection Combination inlet control valve - unvented store Pressure relief (safety) valve - primary system Expansion vessel connection - unvented store 5a Expansion vessel - unvented store - see...
  • Page 10 DESIGN Primary System Pipework Connections for BoilerMate A-Class HP 180 Model Only Please note: This is a diagramatic representation, all pipework should enter through base of appliance. All connections are 22mm. Zone 1 flow Either radiator or underfloor heating circuit Zone 1 return Water out...
  • Page 11 DESIGN Primary System Pipework Connections for BoilerMate A-Class HP 210 & 240 Models Only Please note: This is a diagramatic representation, all pipework should enter through base of appliance. All connections are 22mm. Zone 1 flow Zone 1 Either radiator or underfloor heating circuit Zone 1 return...
  • Page 12 Unvented Store Expansion Vessel (Supplied) Model Capacity (l) Size (mm) LxWxH Capacity (l) Size-each (mm) LxDiam BMA 180 HP-DEM 500 x 200 x 160 270 x 270 BMA 210 HP-DEM 500 x 200 x 160 270 x 270 BMA 240 HP-DEM...

  • Page 13: Technical Data

    DESIGN Table 1.2 Technical Data Model BMA 180 HP-DEM BMA 210 HP-DEM BMA 240 HP-DEM Nominal domestic hot water storage volume (litres) Overall app. dimensions (mm) (Height x Width x Depth) 1370 x 595 x 595 1600 x 595 x 595...
  • Page 14 DESIGN Table 1.3 Sensor Control Parameters & Default Temperature Settings Description Sensor Default Value ( HP off setting (flow) HP off setting (return) HP on-off differential setting S5/S6 HW store heating - off setting HW store heating on-off differential setting HW store overheat setting S1/S2 75 max.
  • Page 15 DESIGN 180 Model Connection Details/Dimensions 180 Model Connection Details/Dimensions - Top Diagram opposite show the connection details and dimensions for the BoilerMate A-Class HP- DEM 180 model. The BoilerMate A-Class HP-DEM units are DHWS Secondary Return supplied on an installation base to allow the pipe runs to connect to the appliance from any direction.
  • Page 16 DESIGN 210/240 Model Connection Details/Dimensions 210/240 Models Connection Details/Dimensions - Top Diagram opposite show the connection details and dimensions for the BoilerMate A-Class HP- DEM 210/240 models. The BoilerMate A-Class HP-DEM units are supplied on an installation base to allow the DHWS Secondary Return pipe runs to connect to the appliance from any direction.
  • Page 17 DESIGN Hot and Cold Water System If the incoming mains pressure exceeds 6 bar at any time in a 24 hour cycle then a pressure All recommendations with regard to pipe work systems in this manual are generally regulating valve set at 3.5 bar should be fitted based on the use of BS/EN Standard copper pipework and fittings.
  • Page 18 DESIGN Cold and Hot Water Distribution Network d. If the supply to the mixer fittings (other a. As a minimum it is recommended that the cold supply to the appliance internally is than a dual outlet type) is not taken run in 22mm copper (or equivalent in plastic) and then from the appliance, hot and from the balanced supply the system will cold services are in 22mm past the draw-off to the bath.
  • Page 19 DESIGN Taps and Shower Fittings Dead Leg Volumes and Secondary Hot Water Circulation a. Ensure that all terminal fittings are suitable for mains pressure in the range of 0.5 - 1.5 bar. Use aerated taps whenever possible to prevent splashing. If the dead leg volume of the hot water draw-off pipework is excessive and the delivery time for b.
  • Page 20 DESIGN Heat Pump/Space Heating System Design General Warning: BoilerMate A-Class HP-DEM is an unvented hot water storage appliance and therefore it is not suitable for use with a solid fuel boiler, steam or any other uncontrolled heat source. 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.
  • Page 21 DESIGN Frost Protection The BoilerMate A-Class HP-DEM appliance should not be installed in a location where the contents could freeze. Suitable precautions should be taken to protect the heat pump/ Sealed primary system filling/ pipework as recommended in the heat pump expansion kit section of this manual.
  • Page 22 DESIGN Front Panel User Controls Visual Display 2 Channel The front panel user controls are shown in the picture opposite and their functions Window Clock are described below. Different windows can be accessed in the visual display panel on the front of the appliance to indicate various temperatures and fault conditions.
  • Page 23 DESIGN Main Appliance Control Board By pressing S1 and S2 on the main appliance control board, the LED display can be used to read various values as shown below. However, fault conditions are displayed on the front user panel and normally this board should only need to be used to display the sensor conditions or select the appliance type if the board needs to be changed.
  • Page 24 DESIGN Discharge Arrangements Sizing of Discharge Pipe From Safety/ Temperature Relief Valve Tundish The Pressure and Temperature Relief Valve (P&T) and Expansion Relief Valve (ERV) are Maximum both provided with tundishes. It is normal for these to be connected into a single 22mm resistance Resistance discharge pipe but they can be run separately if required.

  • Page 25: Installation

    INSTALLATION The appliance is designed to be installed in an airing/cylinder cupboard and the relevant minimum dimensions are provided in Table 1.2 Technical Data. Because of the ease of installation we recommend that the cupboard construction is completed and painted before installation of the appliance. The cupboard door can be fitted after installation.
  • Page 26 INSTALLATION Preparation/placing The Appliance In Position Details of the recommended positions for termination of the first fix pipework are provided in figures 1.5 and 1.6. The pipework can be located or its position checked using the template provided with each appliance. If these have been followed, installation is very simple and much quicker than any other system.
  • Page 27 INSTALLATION Electrical Connection - Appliance All the power and control functions of the BoilerMate A-Class HP-DEM are pre-wired to a terminal strip located at high level inside the L1 L2 L3 appliance. The wiring to the appliance shall be carried out by a competent person in accordance with the Building Regulations (Approved Document P) and the IEE Requirements for Electrical Installations BS 7671.
  • Page 28 INSTALLATION 147DI_2 TWO CHANNEL DIGITAL CLOCK HOT WATER CH ZONE 1 ISO2 ISO1 147-HP Green Neon Illuminated ON / OFF Switch Rocker Switch terminal conections 2.5 mm SID Silicone 2.5 mm SID Silicone 2.5 mm SID Silicone 2.5 mm SID 100mA Silicone @12 VDC...
  • Page 29 INSTALLATION WIRE COLOUR LEGEND Blue Brown Black Orange Yellow White Green / Yellow S1 & S2 Grey Green SENSOR LEGEND S1/S2 Hot Water overheat sensors Hot Water Control sensor Zone 1 CH Flow Sensor Heat Pump Return sensor Heat Pump Flow sensor Outside Temperature Sensor 147MP_34 (Hot Water Valve V1)
  • Page 30 INSTALLATION Elec trical Interconnec tions Between BoilerMate A-Class HP-DEM and Mitsubishi BoilerMate A-Class HP-DEM Mitsubishi Air Source Heat Pump Electric Ecodan air source heat pump. (internal) (external) Internal External 8 metres of 8 core signal cable is provided pre- Outside Weather terminated and labeled ready to connect to the Compensation Sensor S7 Gledhill BoilerMate A-Class HP-DEM appliance...
  • Page 31 INSTALLATION System Filling/Cleansing Powerflushing/Cleaning Of The Heating System Check and adjust as necessary the hot water system expansion vessel(s) air pressure to 1.5 bar. If it is proposed to ‘powerflush’ the heating system always check and comply fully with Check that any drain valves are closed then open the incoming stop valve and fill the the manufacturers instructions for the domestic mains cold and hot water systems in the normal way ensuring there is no powerflushing equipment being used.

  • Page 32: Commissioning

    This product is covered by the ‘Benchmark’ scheme and a separate commissioning/service log book is included with this product. This must be DO ensure the discharge point is safe and in completed during commissioning and left with the product to meet the Warranty accordance with the G3 Building Regulations.

  • Page 33: Servicing

    SERVICING Servicing/Maintenance Changing Components The Registered Installer is responsible for the safe installation and operation of the If it is necessary at any time to drain the storage system. He must also make his customer aware that periodic checks of the equipment vessel either for system modifications or to are required by the Building Regulations and essential for safety.
  • Page 34 SERVICING Description Supplier & Model Stock Code 22mm Inlet Control Group Honeywell XG170 P & T Valve TP152 Honeywell XG169 Tundish Altecnic XG173 Hot Water/Heating Zone Valve 22mm V4043 with removable head Honeywell XG083 Hot Water Expansion Vessel - 12litre XG164 Varem Hot Water Expansion Vessel - 18 litre...

  • Page 35: Fault Finding

    Scale Discharge From Relief Valves In accordance with the Benchmark Guidance Notes in hard water areas, above 200ppm If cold water is discharging from the expansion (mg/l) it is recommended that an in-line scale reduction device is fitted. Reducing the...

  • Page 36: Installation Manual

    ECODAN AIR SOURCE HEAT PUMP Ecodan Air to Water Heat Pump Air to Water Heat Pump PUHZ-W90VHA PUHZ-W90VHA INSTALLATION MANUAL FOR INSTALLER English For safe and correct use, read this manual thoroughly before installing the unit. For safe and correct use, read this manual as well as the indoor unit installation manual thoroughly before installing the unit.
  • Page 37 ECODAN AIR SOURCE HEAT PUMP Installation requirement checklist for Mitsubishi Electric Ecodan Heat Pump Boiler The following items are considered essential to ensure satisfactory functioning of the Mitsubishi Electric Ecodan Heat Pump Boiler. Omission of any of these will result in unsatisfactory performance, some of which will compromise the longevity, energy efficiency, and running costs of the system.

  • Page 38: Safety Precautions

    ECODAN AIR SOURCE HEAT PUMP Contents 1. Safety precautions ..........2 5.

  • Page 39: Installation Location

    ECODAN AIR SOURCE HEAT PUMP 1. Safety precautions 1.3. Before electric work • Make sure to ground the unit. Do not connect the ground wire to gas or water pipes, lighting rods, or telephone grounding lines. If the unit is not Caution: properly grounded, there may be a risk to get an electric shock.

  • Page 40: Installation Procedure

    ECODAN AIR SOURCE HEAT PUMP 2. Installation location 2.4. NECESSARY SPACE TO INSTALL 2.5. 2.4.1. When installing a single outdoor unit (Refer to the last page) 2.5.1. Minimum dimensions are as follows, unless Maximum dimensions are indicated. Refer to the fi gures for each case. 1 Obstacles at rear only (Fig.

  • Page 41: Drainage Piping Work

    ECODAN AIR SOURCE HEAT PUMP 4. Drainage piping work Outdoor unit pipe connection Optional parts name Model name When drain piping is necessary, use the drain socket or the drain pan (option). Drain socket PAC-SG61DS-E Drain pan PAC-SG64DP-E 5. Water piping work 5.

  • Page 42: Test Run

    ECODAN AIR SOURCE HEAT PUMP 7. Test run Before test run 3. After connecting the wires to the compressor, the compressor starts to warm up once power is supplied. After supplying power for the times indicated below, After installation works are completed, check if there is no refrigerant leak- measure the insulation resistance again.
  • Page 43 ECODAN AIR SOURCE HEAT PUMP Positioning the Air Source Heat Pump (mm) Fig. 2-5 Fig. 2-6 Fig. 2-7 Fig. 2-8 Fig. 2-9 Fig. 2-10 Fig. 2-11 Fig. 2-12 Fig. 2-13 Fig. 2-14 Fig. 2-15 Fig. 2-17 Fig. 2-16 Page 43...

  • Page 44: Boilermate Hp-Pqfy/Mitsubishi Pqfy

    BOILERMATE HP-PQFY/MITSUBISHI PQFY Water Heating Unit PQFY-VRF Air to Water Heat Pump PUHZ-W90VHA INSTALLATION MANUAL FOR INSTALLER English For safe and correct use, read this manual thoroughly before installing the unit. For safe and correct use, read this manual as well as the indoor unit installation manual thoroughly before installing the unit.
  • Page 45 BOILERMATE HP-PQFY/MITSUBISHI PQFY Connection To Mitsubishi PQFY-VRF See www.mitsubishi-aircon.co.uk for full details on the PQFY. It is possible to use the BoilerMate HP to provide either hot water only, or potentially both hot water and heating by connecting to a Mitsubishi PQFY-VRF unit. If using with the PQFY-VRF model, please note that it is essential to use the correct BoilerMate HP-PQFY type appliance: •...
  • Page 46 BOILERMATE HP-PQFY/MITSUBISHI PQFY 147DI_2 TWO CHANNEL DIGITAL CLOC HOT WATER CH ZONE ISO2 ISO1 147-HP Green Neon Illuminated ON / OFF Switch Rocker Switch terminal conections 2.5 mm SID Silicone 2.5 mm SID Silicone 2.5 mm SID Silicone 2.5 mm SID Silicone 2.5 mm SID Silicone...
  • Page 47 BOILERMATE HP-PQFY/MITSUBISHI PQFY WIRE COLOUR LEGEND Blue Brown Black Orange Yellow White Green / Yellow S1 & S2 Grey Green SENSOR LEGEND S1/S2 Hot Water overheat sensors Hot Water Control sensor Zone 1 CH Flow Sensor Heat Pump Return sensor Heat Pump Flow sensor Outside Temperature Sensor OPTIONAL EXTRA...
  • Page 48 FERNOX BOILER BUDDY Designed to complement Fernox’s extensive range of chemical water treatment products, the Boiler Buddy is a premium quality in-line, high efficiency magnetic filter with patented flux plates developed for use in Formula 1 motor racing. Unlike other conventional or magnetic filters, Boiler Buddy not only traps magnetite to sub-micron levels, it does so without restricting the water flow, even when full.
  • Page 49 FERNOX BOILER BUDDY How to install a Boiler Buddy Boiler Buddy has a transparent body casing so that the build-up of contamination on the core can be observed in service. It has been designed to be fitted where it can be inspected and removed for cleaning and should be installed in the central heating return line as close to the boiler as possible.
  • Page 50 FERNOX BOILER BUDDY How to service and clean a Boiler Buddy Before removing the Boiler Buddy, place a Once the Boiler Buddy has been safely removed container underneath the pipework to retain from the system it can be disassembled. any water that may drip. Fernox recommends that waterproof gloves are worn when cleaning the Boiler Buddy.

  • Page 51: Spare Parts

    FERNOX BOILER BUDDY 7 Remove the complete core 12 Place the other body half over the ‘o’ ring; there are locator pins to help the correct alignment of the two parts 8 To clean the core either use a stiff brush or hold under running water perpendicular to the core (ensure that any magnetite is disposed of safely) 13 Once the body is assembled, place the body clamp...

  • Page 52: Fernox Alphi-11

    FERNOX ALPHI-11 Page 52...
  • Page 53 FERNOX ALPHI-11 Page 53...
  • Page 54 (v) It has not been subjected to frost damage. 7. SHORTAGES OR DAMAGE (vi) The benchmark log book is completed after each annual Goods must be inspected before signature of delivery note and any damage, shortage or discrepancy noted service.
  • Page 55 (e) the Purchaser hereby grants to us an irrevocable licence to (f ) Components of our products other than Storage Vessels and Integral Pipework. enter at any time any vehicle or premises owned or occupied We will either extend to the purchaser the same terms of warranty as we are given by the manufacturer of the by the Purchaser or in the possession of the Purchaser for component or if the manufacturer does not give any warranty, replace free of charge any component which the purposes of repossessing and recovering any such goods...
  • Page 56 The code of practice for the installation, commissioning & servicing of central heating systems...

This manual is also suitable for:

Puhz-w90vhaBma 180 hp-pqfyBma 210 hp-pqfyBma 210 hp-demBma 240 hp-demBoilermate bma 210 hp-dem ... Show all

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