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gledhill mCHP BMA 225 Installation And Servicing Instructions

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A - C L A S S
mCHP
BoilerMate
DESIGN, INSTALLATION AND
SERVICING INSTRUCTIONS
Model Numbers
mCHP BMA 225
mCHP BMA 235
benchmark
TM
A CENTRAL HEATING
The code of practice for the installation,
AND MAINS PRESSURE HOT WATER
commissioning & servicing of central heating systems
APPLIANCE INCORPORATING A THERMAL
STORE - FOR USE WITH mCHP UNITS IN
DOMESTIC DWELLINGS
ALL MODELS COMPLY WITH THE
WATER HEATER MANUFACTURERS
SPECIFICATION FOR INTEGRATED THERMAL
STORES

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Summary of Contents for gledhill mCHP BMA 225

  • Page 1 A - C L A S S mCHP BoilerMate DESIGN, INSTALLATION AND SERVICING INSTRUCTIONS Model Numbers mCHP BMA 225 mCHP BMA 235 benchmark A CENTRAL HEATING The code of practice for the installation, AND MAINS PRESSURE HOT WATER commissioning & servicing of central heating systems...
  • Page 2 Quality System audited by BSI. With the introduction of a self certification scheme, the Benchmark Logbook is being Patents Pending 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.

  • Page 3: Table Of Contents

    CONTENTS Section Page SERVICING IMPORTANT NOTICES ANNUAL SERVICE SYSTEM DESCRIPTION CHANGING COMPONENTS iNTRODUCTiON OPERATiON 2.2.1 Domestic Hot Water SHORT PARTS LIST 2.2.2 Space Heating 2.2.3 Store Heating - Not Active APPENDIX A 2.2.4 Store Heating - Active 2.2.5 Electric Backup APPENDIX B USER CONTROLS APPENDIX C...

  • 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 A-CLASS appliances now include a Benchmark installation, Commissioning and Service Record Logbook.

  • Page 6: System Description

    2.0 SYSTEM DESCRIPTION 2.1 INTRODUCTION The mCHP BoilerMate A-CLASS appliance shown in figure 2.1 is designed to provide improved space heating and mains pressure hot water and better electric and heat energy management when coupled to a domestic Micro Combined Heat and Power (mCHP) appliance.
  • Page 7 SYSTEM DESCRIPTION 2.0 2.1 INTRODUCTION The mCHP BoilerMate A-Class shown schematically in figures 2.1 and 2.2 is primarily designed for the new build market. The thermal store completely isolates the mCHP unit from the space heating and hot water demands and functions. The heat losses from thermal stores should not be directly compared with heat losses from unvented or vented cylinders because they are treated differently in SAP.

  • Page 8: Operation

    2.0 SYSTEM DESCRIPTION The mCHP BoilerMate A-CLASS appliance user controls are shown in figure 2.5. All models are fitted with a single channel clock for programming heating ‘on’ times. All models can be supplied without this clock for use with a remote 2 channel programmer or programmable room thermostat etc.

  • Page 9: Store Heating - Not Active

    SYSTEM DESCRIPTION 2.0 if the store temperature falls below the pre-set limit (see table 3.5), the controller will either switch off the space heating pump or run it at minimum speed if modulating When both store and space heating demands pump is fitted.

  • Page 10: Electric Backup

    2.0 SYSTEM DESCRIPTION 2.2.5 ‘ SWITCH’ ELECTRIC BACK UP FACILITY The mCHP_BoilerMateA-CLASS is fitted with an electric backup facility. if the mCHP unit does not supply heat when requested and fails to heat the store, the user has the option of selecting the electric backup system until the mCHP appliance operation is restored.

  • Page 11: User Controls

    SYSTEM DESCRIPTION 2.0 2.3.4 ‘SWITCH’ OPERATION 2.3 USER CONTROLS By moving the mode rocker on the front The front panel controls are shown in figure 2.5 below. panel from ‘normal’ to ‘switch’ position the electric backup boiler (switch) can be 2.3.1 ON-OFF SWITCH used as an alternative heat source for hot water and central heating, should there...

  • Page 12: Technical Specification

    3.0 TECHNICAL SPECIFICATION 350mm Min access to comply with 'Water Regulations' F & E* 300mm Cistern *2 F&E cisterns are provided with the 235 model. To accommodate these the width of the cupboard will have to increase to 800mm or the cisterns will need to be located elsewhere All dimensions in mm...

  • Page 13: General

    TECHNICAL SPECIFICATION 3.0 3.1 GENERAL The mCHP_BoilerMate A-CLASS is only suitable for sealed heating systems and the The appliance pipe connection positions technical specification is presented in tables 3.1 and 3.2. The model selection are shown in figure 3.2. All pipe positions data is shown in table 3.3.
  • Page 14 3.0 TECHNICAL SPECIFICATION A-CLASS Table 3.2 Technical specification of mCHP BoilerMate Thermal and Electrical Data BMA225 BMA235 8kW thermal mCHP Time to heat whole 10kW thermal mCHP store (10-75ºC) 15kW thermal mCHP 6kW electric backup Time to heat top of ‘Switch’(1) store (10-75ºC) 8kW thermal mCHP...
  • Page 15 TECHNICAL SPECIFICATION 3.0 Table 3.3 Model Selection Guide BMA225 BMA235 Maximum design heat loss of the dwelling (kW) Maximum number of bathrooms/En-suite shower rooms Table 3.4 Factory fitted or supplied standard and optional equipment BMA 225 BMA 235 mCHP / System pump - Grundfos UPS 15-50 mCHP / System pump - Grundfos UPS 15-60 Space heating pump - Grundfos UPS 15-50 Space heating pump - Grundfos UPR 15-50 (Modulating)

  • Page 16: Pump Performance

    3.0 TECHNICAL SPECIFICATION Figure 3.3 Performance range of Grundfos UPS 15-50 pump PUMP PERFORMANCE The performance of Grundfos UPS 15-50 and UPS 15-60 pumps fitted in the appliances are shown in figures 3.3 and 3.4 respectively. The maximum performance of the modulating pumps (UPR range) is the same as the UPS range set at speed 3.
  • Page 17 TECHNICAL SPECIFICATION 3.0 3.4 ELECTRICITY SUPPLY AND WIRING FiGURE 3.6 DIAGRAMS ID_RESISTOR Page 17...

  • Page 18: Electricity Supply And Wiring Diagrams

    3.0 TECHNICAL SPECIFICATION 3.4 ELECTRICITY SUPPLY ID_resistor ID_resistor AND WIRING DIAGRAMS A-CLASS The mCHP_BoilerMate is fitted with a Ext_led_k Tank_middle ID_resistor electric backup heater rated at 6kW as standard. PC Connector Ext_se_1 T_overh_2 T_overh_1 Therefore the single mains electricity supply Tank_bot T_dhw_in T_dhw_out...

  • Page 19: Display In Normal Mode

    TECHNICAL SPECIFICATION 3.0 3.6.5 checking and setting the appliance code on the controller is described below. COMPUTER INTERFACE • The appliance selection menu (A0 ... A9) on the controller is hidden. it is only possible to get to the appliance selection using the reset button (Left hand, B1) on the main A laptop computer can be connected to board.
  • Page 20 Only when modulating pump option is specified Table 3.6 mCHP BoilerMate A-CLASS Indentification Values Models ID Resistor Value Controller Code mCHP BMA 225 mCHP BMA 235 Table 3.7 sensor used in mCHP BoilerMate Display Sensor Connector J9 pins Location T Overheat 1 6 &...
  • 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: Heating And Hot Water System Design

    4.0 HEATING AND HOT WATER 4.1 HEATING AND HOT WATER SYSTEM DESIGN (a) 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. (b) However the 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 fully designed and installed in accordance with their recommendations.

  • Page 23: Use In Hard Water Areas

    HEATING AND HOT WATER 4.0 4.1.2 USE IN HARD WATER AREAS (a) The control system prevents the domestic water from exceeding 55 C for most of the operational time of the appliance and 4.1.3 therefore limits the formation of scale . COLD AND HOT WATER DISTRIBUTION (b) The Building Regulations L1A: New dwellings/L1B: Existing dwellings and...

  • Page 24: Space Heating System Design

    4.0 HEATING AND HOT WATER 4.2 SPACE HEATING DESIGN Thermal Store 1 bar Standard Sealed heating flow expansion kit to be supplied and fitted by installer. Cold Raising Main Space heating circuit Approved Filling Loop PRV 3 Bar Figure 4.2 Schematic diagram of the sealed heating system (a) mCHP BoilerMate A-CLASS is only available for sealed heating systems and the schematic...

  • Page 25: Mchp Circuit Design

    HEATING AND HOT WATER 4.0 To meet the requirements of Building Regulations for a boiler interlock it is recommended that the radiator in the area where the room thermostat is installed should be fitted with lock shield valves on both connections. (f) Plastic pipework: All the recommendations with regard to pipework systems in this manual are generally based on use of BS/EN Standard copper pipework and fittings.

  • Page 26: 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 figure 3.2 and Table 3.1, 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 27 INSTALLATION AND WIRING 5.0 Pump supply From mCHP 230V ac (3) Electric boost on signal (L) SL_E (2) mCHP_boost ‘switched’ live (L) SL_B (1) mCHP_on/off ‘switched’ live (L) SL_O Room stat ‘switched’ live (L) SL_R Programmer HW ‘switched’ live (L) SL_W Programmer CH ‘switched’...

  • Page 28: Pipework Connections

    5.0 INSTALLATION AND WIRING PIPEWORK CONNECTION (a) The position of the pipework connections is shown opposite in figure 5.3 the connection sizes and dimensions are shown in figure3.2 and Table 3.1. All connections are also labelled on the appliance. it is essential that the pipework is connected to the correct connection.

  • Page 29: Electrical Wiring

    INSTALLATION AND WIRING 5.0 5.4 ELECTRICAL WIRING The appliance circuit diagram is shown in figure 3.6 and the external wiring terminal details are shown in figures 5.4 and 5.5. All external controls and equipment must be wired to these terminals. The mCHP unit manufacturers wiring instructions should be read in conjunction with this manual before commencing the wiring process.
  • Page 30 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 31 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 32: Commissioning

    6.0 COMMISSIONING 6.0 COMMISSIONING (a) it is essential that the system functions properly for optimum performance. To (e) Heat the system to full operating temperature and check for water leaks achieve this, the heating and the hot water system should be commissioned in accordance with the good practice and generally with the requirements of BS 6798, and rectify if necessary.

  • Page 33: Commissioning Mchp Unit & Boilermate

    COMMISSIONING 6.0 6.3 COMMISSIONING mCHP UNIT & BOILERMATE (b) Set heating clock to continuous and ensure (a) Check that the mCHP BoilerMate front panel switch is in ‘On’ position and the that the room thermostat is calling for heat. mode switch is in the ‘normal’ position. This will be indicated by display segments V1.3 and V1.4 being on respectiveley.

  • Page 34: 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 For mCHP unit service requirements please refer the hot water temperature in the ‘Benchmark’...

  • Page 35: Short Parts List

    SERVICING 7.0 Table 7.1 Specification of main components and Parts List Description Supplier & model Part Stock 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 36: 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 37: Appendix B

    APPENDIX B MANIFOLDS Manifold type: 1 - Stock Code MiP 050 Two sets of manifolds are available as an (one bathroom, one en suite shower room, one cloakroom, one kitchen) optional extra. Each set comprises a separate Flow regulator Terminal fitting Hot water Cold water hot and cold water manifold.
  • Page 38 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 39 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 40: 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 41: Appendix D

    APPENDIX D MANUAL HANDLING OF APPLIANCE PRODUCTS e. Taking the lead for team lifts- As Description more than one person is required for these products ensure that one Manual handling means any transporting or supporting of a load (including lifting, person is taking the lead. This may putting down, pushing, pulling, carrying or moving) by hand or bodily force.

  • Page 42: Terms And Conditions Of Trading

    (vi) The benchmark log book is completed after each sold between the date of receipt of order and the date of receipt of payment in full; and annual service.
  • Page 43 of three years from the date of delivery Gledhill will replace, free of charge, any plate heat exchanger fitted in recovering any such goods the property in which the appliance as original equipment in which scale formation occurs that materially reduces the effectiveness has remained in us under paragraph (2) above.

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Mchp bma 235

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