gledhill BMA 240 SP-SOL Installation & Servicing Instructions Manual Download

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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

Summary of Contents for BMA 240 SP-SOL

Page 1: ...tic 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: ...ority 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 sit...

Page 3: ...e 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 Aneightcoresignalcableisneededtoberunbetweenthe internal BoilerMate and the external Ecodan An 8 metre supply of this cable is provided with the BoilerMate if additional length is neede...

Page 4: ... 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 ...

Page 5: ...pliance 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 r...

Page 6: ...ump 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 a3kW...

Page 7: ...s provided as part of the package Scale Protection The Building Regulations L1A New dwellings L1B Existingdwellingsandtherequirementsset out in the Domestic Heating Compliance Guide specify that where the mains water hardness exceeds 200ppm provision should be made to treatthefeedwatertowaterheatersandthehot water circuit of combination boilers to reduce the rate of accumulation of lime scale To c...

Page 8: ...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 3...

Page 9: ...erature boost assembly central heating Zone 1 only 26 S3 sensor hot water boost 27 Primary system manifold 28 Electricaltemperatureboost hotwateronly 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 termina...

Page 10: ...ircuit 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 A B Ecodan rear ...

Page 11: ... 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 A B ...

Page 12: ...bitor 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 Ex...

Page 13: ...ontrol overheat safety thermostat temperature settings HW boost immersion heater S1 S2 safety sensors 3 P T valve 900 C CH boost immersion heater Control thermostat 5 650 C Overheat thermostat 4 850 C 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...

Page 14: ... 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 inTable 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 Regulatio...

Page 15: ... 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 75 40 315 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...

Page 16: ...Dimensions Bottom 415 Heating Flow Zone 1 Expansion Relief Valve Discharge DESIGN TECHNICAL DATA 210 240ModelConnectionDetails Dimensions 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 pipe runs to connect to the appliance from any direction Itiseasier...

Page 17: ...ings and the requirements set out in the Domestic Heating Compliance Guide specify that where themainswaterhardnessexceeds200ppmprovisionshouldbemadetotreatthefeed water to water heaters and the hot water circuit of combination boilers to reduce the rate of accumulation of lime scale Tocomplywiththisrequirementthehardnessofthemainswatershouldbecheckedby theinstallerandifnecessarytheoptionalfactory...

Page 18: ...d that a small expansion vessel 0 25 0 5 litre is fitted after the pressure regulator to accommodate the pressure rise caused by the increase in temperature of the balanced cold water SH WHB SCV SCV WC BATH 22 22 15 15 WHB WC M DC DCV DC DCV To External Tap 25mm MDPE Incoming Supply WM or DWM SINK Discharge Pipe BoilerMate HP DEM Ground Level mains cold hot discharge balanced cold Location of opti...

Page 19: ...xed water outlets such as showers For this reason and because these are now no more expensive than a manual shower we strongly recommend the use of thermostatic showers with this appliance The shower head provided must also be suitable for mains pressure supplies If it is proposed to use a whole body or similar shower with a number of high flow pressure outlets please discuss with the Gledhill tec...

Page 20: ...designed and sized using the parameters for plastic pipework Selection Heat Pump Sizing General model selection guidance is given in Table 1 2 Technical Data Heat Pump Primary Circuit Theflowandreturnfromtheheatpumpmustrundirectlytotheconnectionsprovided on the BoilerMate A Class HP DEM appliance A Fernox Boiler Buddy is provided as part of the package and this must be fitted internally on the ret...

Page 21: ...volume allow 10 litres for the primary pipework coils within the appliance Sealed System Kit For The Central Heating System An optional sealed system kit as follows can be supplied with the BoilerMate A Class HP DEM Pressure gauge 0 4 bar Primary expansion vessel charged to 1 0 bar Size depends upon the model seeTable 1 1 WRAS approved primary system filling loop External Temperature Compensation ...

Page 22: ...itch button below the display for at least 5 seconds The Normal will change to Switch and will flash Once the problem has been resolved the appliance can be returned to normal operation by pressing the Switch button for at least 5 seconds Fault Condition Display Window If a fault occurs with the BoilerMate A Class HP DEM appliance the window will automatically display the fault condition The windo...

Page 23: ...d by ringing the Gledhill Technical Helpline 08449 310000 APPLIANCE CONTROL BOARD A C B Fuse T3 15L 250V 2 DIGIT ACB BOARD DISPLAY FLOW CHART Press S2 Press S2 Press S2 Press S2 Press S2 S2 S1 Press S1 Press S1 Press S1 Press S1 Appliance type Press S1 Press S1 Press S1 Press S1 Appliance type Press S1 Press S1 Press S1 Press S1 Fault code indicator block outs Press S1 Press S1 Press S1 Press S1 F...

Page 24: ...istance allowed for a straight length of 28mm pipe from a G temperature relief valve equates to 18m Subtract the resistance for 4 No 28 elbows at 1 0m each 4m Therefore the maximum permitted length equates to 14m As the actual length is 7m a 28mm copper pipe will be satisfactory In apartment flat situations the discharge pipes can be connected into a single pipe which is discharged at low level In...

Page 25: ...operate as quietly as practicable However some noise from pumps etc is inevitable in any heating system This will be most noticeable in cupboards formed on bulkheads or at the mid span of a suspended floor In these cases the situation can be improved by placing the appliance on a suitable sound deadening material i e carpet underlay or similar The appliance is very well insulated and no ventilatio...

Page 26: ...oftheseinstructions Beforeinstallationthesiterequirementsshould be checked and confirmed as acceptable The plastic cover and protective wrapping should be removed from the appliance and the installation base provided placed in position Theappliancecanbethenbeliftedintoposition inthecupboardontopofthebaseandthefront panelremovedbyunscrewingthe2screwsand liftingthedoorupandoutreadyforconnection of t...

Page 27: ... should be read in conjunction with this manual Runtheexternalwiringthroughtheserviceslot provided in the base of the appliance Make the connections as shown opposite on the terminal strip provided Theroomthermostatshouldbewiredasshown opposite The link in Z1RSL to Z1RSSL must be removed when the room thermostat is fitted The time and temperature controls for CH zone 2 should be wired as necessary...

Page 28: ...0mA 12 VDC 20mm Fuse A2 A1 HW B CH Z1 B 3kW Room thermostat call for Zone 1 Only Programmable Room thermostat call for Zone 2 Only Z1 RS E V S1 2 5 mm SID Silicone 2 3kW 3 WAY BUS BAR 2 5 mm SID Silicone 2 Remove link to wire room thermostat F1 14 11 12 R1 CC 3 1 2 4 ISSUE No 4 APPROVED DATE NOV 2007 GLEDHI DO NOT SCALE FROM THIS DRAWING COPYRIGHT OF THIS DRAWING IS RESERVED IT IS NOT TO BE REPROD...

Page 29: ...OUR LEGEND Black Orange Yellow White Red B Or Y Wh R S 3 S 4 S 5 S 6 Hot Water overheat sensors Hot Water Control sensor Zone 1 CH Flow Sensor Heat Pump Return sensor Outside Temperature Sensor Heat Pump Flow sensor S1 S2 SENSOR LEGEND S 7 3 Speed P2 P1 P3 R Bl Hot Water Valve V1 CH Zone 1 Valve V2 G Y Or Wh Bl J34 J5 J30 J31 J9 1 1 K 8 147MP_34 Wh Wh A1 B1 A5 A4 A3 A2 B2 B3 Br B 8 7 6 5 A B C D E...

Page 30: ...ected to the heat pump by the installer as shown If any additional length is required please use RS Components stock code 482 6036 25 metres and replace the entire length DO NOT JOINT Maximum length is 30 metres If using alternative cable to the above the individual cores must be a minimum of 0 5mm2 External Temperature Compensation Sensor Thisissuppliedconnectedto10metresofcable which is coiled a...

Page 31: ... corrosioninhibitor The heat pumpand external connecting pipework will also require protection against freezing For this reason a combined anti freeze and inhibitor product such as Fernox Alphi 11 must be used Thevolumes concentrationshouldbecalculatedinaccordancewiththemanufacturers instructions allowing 10 litres for the volume for the primary pipework coil in the BoilerMate A Class HP appliance...

Page 32: ... anchored 4 Do ensure that the functioning and control of the system is explained to the occupant and explain the need and importance of periodic servicing These Instructions should be replaced along with the component manufacturers instructions in the pocket provided on the appliance and the front panel refitted NOTE With sealed heating systems air is released from the water during the first few ...

Page 33: ...ddirectfrom Gledhill using the Speed Spares service or throughanyofthelargerplumbersmerchants specialist heating spares suppliers Help and advice is also available from the Technical Helpline on 08449 310000 However allcomponentsarereadilyaccessible and can be changed quickly and easily by the installer using common plumbing practice If it is necessary to replace any of the pumps fitted to the app...

Page 34: ...xpansion Vessel 24 Litre GT004 10 Primary Expansion Relief Valve and Pressure Gauge Comap XG154 11 Relay Wago 12 Contactors Heater elements Telemecanique XB014 13 Primary System Pressure Relief Valve XG169 14 Sensor S1 S2 Tasseron XB183 15 Sensor S4 S5 S6 Tasseron GT198 16 Central Heating Temperature Boost Immersion Element 17 Main Control Board Argus Vision XB442 18 External Temperature Compensat...

Page 35: ...hat the control overheat stat is replaced iii The motorised valve iv Checkthattheheatisbeingproducedbytheheatpumpandthepumpisrunning If the heat pump is running check replace the 100MA F1 fuse provided on the BoilerMate A Class HP DEM terminal strip to protect the main control board from a fault on the heat pump If for any reason heat is not being supplied to the appliance heating and or hot water...

Page 36: ...tallation die vorliegende Bedienungsanleitung und die Installationsanleitung der Innenanlage gründlich durchlesen die Klimaanlage MANUEL D INSTALLATION Avant d installer le climatiseur lire attentivement ce manuel ainsi que le manuel d installation de l appareil intérieur pour une utilisation sûre et correcte English Deutsch Français For safe and correct use read this manual thoroughly before inst...

Page 37: ...pplied pipe work must be connected to the heat pump boiler by using QTY2 600mm 1 bore steel braided rubber flexible hose one for flow and one for return which are supplied with the unit Pipe work between the unit and the Hot water tank shall be minimum 22mm Provision shall be taken to avoid this pipe work freezing during winter months 4 Anti Vibration Connections flexible hose supplied loose 5 Sys...

Page 38: ...ories are improperly installed it may cause water leakage electric shock or fire Do not remodel the unit Consult an installer for repairs If alterations or repairs are not performed correctly it may cause water leakage electric shock or fire The user should never attempt to repair the unit or transfer it to another location If the unit is installed improperly it may cause water leakage electric sh...

Page 39: ...itch can severely damage the internal parts Keep the main power switch turned on during the operating period Before starting operation check that all panels guards and other protec tive parts are correctly installed Make sure not to get injured by touching rotating hot or high voltage parts Do not touch any switch with wet hands There may be a risk to get an electric shock Do not touch the refrige...

Page 40: ...such as a typhoon etc may directly blow to the air outlet Fig 2 3 Air outlet guide 3 Position the unit so that the outlet air can blow at right angle to the seasonal wind direction if possible Fig 2 4 Wind direction 2 4 NECESSARY SPACE TO INSTALL 2 4 1 When installing a single outdoor unit Refer to the last page Minimum dimensions are as follows unless Maximum dimensions are indicated Refer to the...

Page 41: ...iring size must comply with the applicable local and national codes 2 Power supply cables and the cables between Controller and Outdoor unit shall not be lighter than polychloroprene sheathed flexible cables Design 60245 IEC 57 3 Be sure to connect the cables between Controller and Outdoor unit directly to the units no intermediate connections are allowed Intermediate connections may result in com...

Page 42: ...ed below measure the insulation resistance again The insulation resistance drops due to the accumulation of refrigerant in the compressor The resistance will rise above 1 M after the compressor is warmed up for four hours The necessary time to warm up the compressor varies according to atmo spheric conditions and refrigerant accumulation If the refrigerant accumulates within the compressor the com...

Page 43: ...e 43 Positioning the Air Source Heat Pump 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 16 Fig 2 17 mm ECODAN AIR SOURCE HEAT PUMP INSTALLATION MANUAL ...

Page 44: ...rliegende Bedienungsanleitung und die Installationsanleitung der Innenanlage gründlich durchlesen die Klimaanlage MANUEL D INSTALLATION Avant d installer le climatiseur lire attentivement ce manuel ainsi que le manuel d installation de l appareil intérieur pour une utilisation sûre et correcte English Deutsch Français For safe and correct use read this manual thoroughly before installing the unit ...

Page 45: ...ecorrect BoilerMate HP PQFY type appliance BMA 180 HP PQFY BMA 210 HP PQFY BMA 240 HP PQFY See below for the hydraulic and electrical connections See next page for full electrical schematic diagram See previous sections of this BoilerMate HP manual for all other details Hydraulic Layout Electrical Layout BoilerMate HP Mitsubishi PQFY Water Out Heat Exchanger Water In Flow from heat pump Return to ...

Page 46: ... mm SID Silicone 2 3kW 3 WAY BUS BAR 2 5 mm SID Silicone 2 Remove link to wire room thermostat D H W D H W U F H U F H U F C U F C Procon ACH1 DHW UFH UFC DHW UFH UFC PQFY Heatpump Terminals 2 core signal cable SELV Outside Temperature Sensor Sensor Select Com N O N C A2 A1 CC R1 3 1 2 4 ISSUE No 3 APPROVED DATE OCT 2007 GLEDHI DO NOT SCALE FROM THIS DRAWING COPYRIGHT OF THIS DRAWING IS RESERVED I...

Page 47: ...en Grey Green Yellow G Gr G Y WIRE COLOUR LEGEND Black Orange Yellow White Red B Or Y Wh R S 3 S 4 S 5 S 6 Hot Water overheat sensors Hot Water Control sensor Zone 1 CH Flow Sensor Heat Pump Return sensor Outside Temperature Sensor Heat Pump Flow sensor S1 S2 SENSOR LEGEND S 7 3 Speed P2 P1 P3 R Comfort Cooling Call SL C G Y Or Wh BL J34 J5 J30 J31 J9 1 147MP_34 Wh Wh CH2 CH ZONE 1 GITAL CLOCK 6 5...

Page 48: ... result in pumps or valves seizing and ultimate system failure The Boiler Buddy can be connected directly to 22 mm copper pipework using conventional pump connectors it is also compatible with 15 mm with the appropriate adapter It is not recommended for 28 mm systems as it will restrict the water flow Boiler Buddy can be installed vertically or horizontally The unit is designed to slot into the sp...

Page 49: ...e is an indication that the system has not been treated correctly with Fernox Protectors Restorers and cleansers 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 ...

Page 50: ...fore removing the Boiler Buddy place a container underneath the pipework to retain any water that may drip 1 Isolate the Boiler Buddy from the system by simply closing the quarter turn valves on the pump service connector 2 Once the Boiler Buddy has been isolated it can be removed Undo the two 11 2 BSP union nuts Once these have been fully unscrewed the Boiler Buddy can be pulled out between the t...

Page 51: ...h This will guard against accidental opening of the clamp 15 Using two new fibre washers place the Boiler Buddy back into the pipework between the two pump servicing valves 16 Tighten the union nuts until finger tight after which use a spanner to tighten 1 8th of a turn or until secure CAUTION The body casing is a plastic part and will fail if excessive force is used 17 The servicing valves can be...

Page 52: ...Page 52 FERNOX alphi 11 product data ...

Page 53: ...Page 53 FERNOX alphi 11 product data ...

Page 54: ... Cylinders and Tanks The copper storage vessel is guaranteed for ten years and if it proves to be defective either in materials or workmanship we will either repair or supply replacement at our option with the closest substitute in the case of any obsolete product to any address in Great Britain i free of all charge during the first year after delivery by us ii thereafter at a charge of one tenth ...

Page 55: ...ract ii all other goods the subject to of any other contract between the Purchaser and us which at the time of payment of the full price of the goods sold under this contract have been delivered to the Purchaser but not paid for in full c until property in the goods supplied hereunder passes to the Purchaser in accordance with paragraph 2 above i the Purchaser shall hold the goods in a fiduciary c...

Page 56: ...Thecodeofpracticefortheinstallation commissioning servicingofcentralheatingsystems ...

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