gledhill BMA 180 HP-DEM Release note

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 MountedTemperature
Sensor
• A n e x t e r n a l l y m o u n t e d
temperature sensor is provided
aspart oftheequipmentpackage.
This should be mounted in a
suitablelocation ona northfacing
wall external to the property.
Radiator System Circuit
• Astheheatpumpgenerateslower
temperaturesthanaconventional
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 pre-
fitted pump for the heating
circuit(s). When using an
underfloor heating circuit, the
manifolds should be of the non-
pumped type. The blending
valve should be set at the design
temperature of the underfloor
circuit.
Room Thermostat
• A 2 channel digital programmer is
fittedtothefrontoftheBoilerMate
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 circuit. 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
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.
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,GledhillWater 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
CH
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
S4
Manual air vent (MAV)
S3
Heat
pump
IV
Discharge
pipe
MCWS
inlet
Balanced
CWS outlet
Combination
valve
S1/2
HP
(primary)
circulator
P1
S6
S5
System
circulator P2
IV
IV
Externally
mounted
temperature
compensation
sensor
S7
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
a3kWimmersionheateruptotherequiredsettemperature.All modelshave 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 alsohaveconnectionsfora zone 2circuitwhereno temperature boost is provided.
This enablesseparateradiatorand underfloor heatingcircuits tobeprovided,operatingat
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
P1
S5 S6
CH zone
valve
CH
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
S4
Manual air vent (MAV)
S3
IV
System
circulator P2
Zone 2 CH
circulator P3
Boiler
Buddy
IV
IV
IV
Discharge
pipe
MCWS
inlet
Balanced
CWS outlet
Combination
valve
S1/2
Externally
mounted
temperature
compensation
sensor
S7
IV
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
6
13
(front)
34
5 (mid)
33
13
15
28
29
2
3
1
35
31
7/22
26
14
4
36
37
25
7/22
24
16
22
8
21
18 19
30
20
12
9(10/11)
17
27
23
32
(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)
- 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 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
6
13
(front)
34
5 (mid)
33
13
15
28
29
35
36
12
2
3
1
39
31
7/22
26
14
4
40
37
25
7/22
24
16
22
8
20
21
30
10(11)
17
27
23
32
(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)
A
B
Ecodan
(rear)