gledhill BMA 120 SP, BMA 180 SP, BMA 140 SP, BMA 200 SP, BMA 220 SP Design, Installation And Servicing Instructions

DESIGN, INSTALLATION AND

SERVICING INSTRUCTIONS

TEL: 0800 14 55 55 7

www.gledhill-boilermate.co.uk

AN SEALED CENTRAL HEATING

AND MAINS PRESSURE HOT WATER SUPPLY

SYSTEM INCORPORATING

A THERMAL STORE

ALL MODELS COMPLY WITH THE

WATER HEATER MANUFACTURERS

SPECIFICATION FOR INTEGRATED

THERMAL STORES

BOILERMATE A CLASS SP

Gas Council Approved Reference Numbers

89-317-14 / BMA 120 SP 89-317-15 / BMA 140 SP 89-317-16 / BMA 180 SP 89-317-17 / BMA 200 SP 89-317-18 / BMA 220 SP

Page 2

C ONTENTS

Section Page

1.0 DESIGN

1.1 Introduction 3

1.2 Technical Data 5

1.3 System Details 13

2.0 INSTALLATION

2.1 Site Requirements 20

2.2 Installation 21

2.3 Commissioning 31

3.0 SERVICING

3.1 Annual Servicing 35

3.2 Changing Components 35

3.3 Short Parts List 36

3.4 Fault Finding 37 Appendix A 38 Appendix B 39 Appendix C 42 Appendix D 43 Terms & Conditions 44

The Gledhill BoilerMate range is a WBS listed product and complies with the WMA Speciﬁ cation for integrated thermal storage products. The principle was developed in conjunction with British Gas. This product is manufactured under an ISO 9001:2000 Quality System audited by BSI.

Patents Pending

The Gledhill Group’s ﬁ rst 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 6: 06-08

benchmark

The code of practice for the installation,

commissioning & servicing of central heating systems

Building Regulations and Benchmark Commissioning

The Building Regulations (England & Wales) r equire that the installation of a heating appliance be notiﬁ ed to the relevant Local Authority Building Control Department. From 1st April 2005 this can be achieved via a Competent Person Self Certiﬁ cation 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 Certiﬁ cation 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 certiﬁ cation 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 T hermal 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 efﬁ ciency.

Building Regulations require that the heating installation should comply with the manufacturer’s instructions. It is therefor e 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

BOILERMATE

A-CLASS

1.0 DESIGN

1.1 INTRODUCTION

These instructions should be read in conjunction with the Installation and Servicing Instructions issued by the manufacturers of the heat source e.g. the boiler used.

Any water distribution and central heating installation must comply with the relevant recommendations of the current version of the Regulations and British Standards listed below:-

Gas Safety Regulations Building Regulations I.E.E. Requirements for Electrical Installations Water Regulations

British Standards

BS6798, BS5449, BS5546, BS5440:1, BS5440:2, CP331:3, BS6700, BS5258, BS7593 and BS7671.

A suitably competent person as stated in the Gas Safety Regulations must install the BoilerMate and carry out any subsequent maintenance/repairs. In fact, the front panel is secured by 2 screws and should only be removed by a competent trades person. The manufacturer’s notes must not be taken as overriding statutory obligations.

The BoilerMate A-Class SP is only suitable for use with a sealed primary central heating system.

The BoilerMate A-Class is not covered by section G3 of the current Building Regulations and is therefore not notiﬁ able to Building Control.

The BoilerMate A-Class SP is not intended for use by persons (including children) with reduced physical, sensory or mental capabilities, or lack of experience or knowledge, unless they have been given supervision or instruction concerning use of the appliance by a person responsible for their safety.

Children should be supervised to ensure that they do not play with the appliance. The information in this manual is provided to assist generally in the selection of

equipment. The responsibility for the selection and speciﬁ cation 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 speciﬁ cation or for the effectiveness of an installation containing one of our products unless we have been speciﬁ cally requested to do so.

All goods are sold subject to our Conditions of Sale and Warranty Terms, which are set out at the rear of this manual.

In the interest of continuously improving the BoilerMate range, Gledhill Water 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.

Description

The BoilerMate A-Class SP shown schematically on page 4 is designed to provide sealed system space heating and mains pressure hot water at high ﬂ ow rates when coupled to any remotely sited, condensing or non condensing, boiler suitable for sealed heating systems, as long as they comply with the recommendations contained in the rest of this manual.

The BoilerMate A-Class is an indirectly heated hot water only thermal store and is supplied with the factory ﬁ tted controls and equipment shown in Section 1.2 Technical Data. The indirect heat exchanger is highly efﬁ cient and designed to provide extremely quick hot water recovery as well as back-up space heating when using ‘Switch’.

Because the F & E cistern is only used to ﬁ ll the thermal store the standard appliance is supplied as a manual fill model, i,e, without a ballvalve and overflow, which makes it particularly suitable for use in ﬂ ats/apartments. A ballvalve and overﬂ ow ﬁ tting can be supplied as an optional extra if required to provide an automatic ﬁ ll model.

Because this product does not require a safety discharge from a temperature and pressure relief valve, any installations will be easy to incorporate into the building and will not suffer from the problems associated with using PVCu soil stacks to take the discharge from unvented cylinders.

An important feature of this concept is that hot water can be supplied directly from the mains at conventional ﬂ ow rates without the need for temperature and pressure relief safety valves or expansion vessels. This is achieved by passing the mains water through a plate heat exchanger. The outlet temperature of the domestic hot water is maintained by a printed circuit board (A.C.B.), which controls the speed of the pump circulating the primary water from the store through the plate heat exchanger.

Page 4

1.0 DESIGN

1.1 INTRODUCTION

Remote

F&E

Cistern

A-Class

Boiler

Cold feed

Open Vent

Heating Circuit

Hot Out

Mains Cold In

Components fitted within appliance case

Expansion Vessel

Pressure Gauge/Filling Loop

Pressure Gauge Relief/Safety Valve

Optional sealed system kit

3 port divertor valve

Automatic bypass valve

Summer use towel rail blanked connection

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 requir ement the hardness of the mains water should be checked by the installer and if necessary the optional factory ﬁ tted in-line scale inhibitor should be speciﬁ ed 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, inhibit or should be speciﬁ ed at the time of order. However, this will need to be ﬁ tted by the installer at a suitable point in the cold water supply to the appliance.

If scale should ever become a problem the plate heat exchanger is easily isolated and quickly replaced with a service exchange unit which can be obtained at a nominal cost from Gledhill.

The A.C.B. also incorporates the facility to operate the primary pump for a few sec onds every few days when the heating is not being used (to reduce the likelihood of the pumps sticking) as well as providing a primary pump overrun facility for the boiler.

Any sealed system automatic boiler designed to operate on an 820C ﬂ ow and a 710C return up to a maximum of 35kW can be linked to any suitable model of BoilerMate A-Class and the deciding factor is the space heating and the hot water requirements of a dwelling. See Section 1.2 Technical Data for further details.

The BoilerMate A-Class is supplied complete with ‘Switch’ which will provide a 6kW electrical emergency backup in case of failure of the main heat source. See section

1.3 System Details for further information. 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. The SAP calculator takes account of the type of store and various correction factors are included to reﬂ ect the different ways that the hot water and heating operates.

For further information please request a copy of the SAP 2005 Data Sheet which provides the information required to produce SAP calculations for all Gledhill Thermal Storage products.

Gledhill are part of the ‘Benchmark’ scheme and a separate commissioning/service log book is included with the product.

A 15mm connection is provided on the primary return on all units to allow for the provision of a pumped summer use towel rail circuit if required (see page 16 for further details)

Note -The BoilerMate SP is a SYSTEM appliance and only requires a basic boiler without a pump. If a system boiler is chosen this will present wiring/operational

difﬁ culties as well as incurring extra cost

Page 5

BOILERMATE

A-CLASS

1.2 TECHNICAL DAT A

Notes:-

1. The BoilerMate 225 appliance is suitable for use in large properties because it produces the same ‘peak hour output’ as a typical 350400 litre unvented cylinder. For properties requiring the BMA 220 the incoming main should be a minimum of 32mm MDPE with a pressure of not less than 2 bar dynamic and an adequate ﬂ ow in line with the pipe sizing calculations. In many cases, properties of this size will beneﬁ t from having 2 smaller sized appliances located adjacent to the areas of peak hot water use. This will allow 2 heating zones to be provided and remove the need to provide trace heating on the hot water system.

2. A plastic feed and expansion cistern will be supplied separately including ballvalve, ﬂ oat and overﬂ ow ﬁ tting.

3. The ﬂ ow rates are based on a 35°C temperature rise and assume normal pressure and adequate ﬂ ow to the appliance. The actual ﬂ ow rate from the appliance is automatically regulated to a maximum of 28 litres/min.

4. Unit is supplied on a 100mm high installation base.

5. The domestic hot water outlet temperature is automatically regulated to approximately 52°C at the bath ﬂ ow rate of 18 litres/min recommended by BS 6700. The temperature is not user adjustable.

6. The designer/installer MUST calculate the suitability of the standard pump as part of normal design procedures.

7. The expansion vessel sizes have been calculated to be adequate for typical steel panel mini bore heating systems. The designer/ installer MUST check that these are adequate as part of normal design procedures and specify an extra expansion vessel if required.

1.0 DESIGN

Model BMA 120 SP BMA 140 SP BMA 180 SP BMA 200 SP BMA 220 SP

Weight (empty) 49.4 kg 51.8 kg 54.2 kg 56.5 kg 60.8 kg Weight (full) 174.4 kg 191.3 kg 201.2 kg 220.5 kg 245.8 kg DHW Pump

Grundfos UPR 15/50 Grundfos UPR 15/50 Grundfos UPR 15/50 Grundfos UPR 15/50 Grundfos UPR 15/50

Boiler/Heating Pump

Grundfos UPS 15/50 Grundfos UPS 15/50 Grundfos UPS 15/50 Grundfos UPS 15/60 Grundfos UPS 15/60

Primary/heating pipe connections

22mm 22mm 22mm 28mm 28mm

MCW & DHW pipe connections

22mm 22mm 22mm 22mm 22mm

Cold feed/expansion connection

22mm 22mm 22mm 22mm 22mm

Safety open vent connection

22mm 22mm 22mm 22mm 22mm

Primary ﬂ ow (for summer use bathroom towel rail)

15mm 15mm 15mm 15mm 15mm

Maximum summer towel rail load

0.5kW 0.75kW 1.00kW 1.25 kW 1.5 kW

Maximum pressure heating circuit

3 bar 3 bar 3 bar 3 bar 3 bar

Volume of primary coil

4.9 litres 4.9 litres 5.5 litres 5.5 litres 6.1 litres

Expansion vessel size 12 lts 12 lts 12 lts 25 lts 25 lts Drain connection R ½” R ½” R ½” R ½” R ½” Maximum Head

Thermal Store

6 meters 6 meters 6 meters 6 meters 6 meters

Hot water ﬂ ow rate (l/m) up to

35 35 35 35 35

Max heating system size

11.25 kW 15 kW 18.75 kW 22.5 kW 26.25 kW

‘Switch’ 6 kW 6 kW 6 kW 6 kW 6 kW

Typical Dwelling Types

Bedrooms 1-3 2-3 2-4 3-5 4-6 Bathrooms 1 1 2 1 2 1 2 En-suite shower 1 2 1 4 2 4 3

Page 6

1.2 TECHNICAL DAT A

Standard Equipment

The standard conﬁ guration of the BoilerMate A-Class SP is shown opposite. The Appliance Control Board (A.C.B.), mounted inside the appliance, controls the operation of the complete system. The A.C.B. is pre-wired to a terminal strip where all electrical connections terminate. It is supplied with the following factory ﬁ tted equipment:-

1. Boiler/heating pump

2. Domestic hot water primary (plate heat exchanger) pump - modulating

3. 3 port control valve

4. Appliance control board (A.C.B.)

5. Electro-mechanical clock and hot water and space heating control rockers.

6. Plate heat exchanger

7. DHWS temperature sensor

8. Cold water inlet sensor

9. Store temperature sensors

10. Overheat sensor

11. Y type strainer/ﬂ ow regulator

12. A feed and expansion cistern for ﬁ lling

the thermal store complete with cold feed/open vent pipework assembly is supplied separately.

13. ‘Switch’ elements (2 x 3 kW)

Optional Equipment

* A seven day digital clock/programmer to control the space heating (in conjunction with a room thermostat) * A no clock/multi-zone option. * Hot and cold water manifolds for use with plastic pipework. * Scale inhibitor for mains water services

with hardness levels above 200ppm (mg/l) * Ballvalve/overﬂ ow connector for automatic ﬁ ll model.

* Primary sealed system kit for ﬁ tting near boiler comprising: Expansion vessel (size varies with model of appliance) 15mm 3 bar pressure relief (safety) valve Pressure gauge and ﬁ lling loop.

1.0 DESIGN

Electro-mechanical clock

programmer

Digital clock programmer

11 13

12 (F & E Tank

not shown

)

Page 7

BOILERMATE

A-CLASS

1.0 DESIGN

1.2 TECHNICAL DAT A

Note: The Appliance dimensions above do not allow for

the100mm high installation base

The following table of minimum cupboard dimensions only allow the minimum space required for the appliance (including the F & E cistern) and any extra space required for shelving etc in the case of airing cupboards etc must be added.

Note: The above dimensions are based on the Appliance and the F & E cistern being in the same cupboard.

If the standard manual ﬁ ll model is chosen the height can be reduced by 100mm.

If the appliance is to be connected to a multi-zone heating then an additional 150mm must be added to the above heights to accomodate the space required for the zone equipment eg valves.

APPLIANCE DIMENSIONS

MODEL Height Width Depth

ABC BMA 120 SP 960mm 530mm 595mm BMA 140 SP 1000mm 530mm 595mm BMA 180 SP 1040mm 530mm 595mm BMA 200 SP 1145mm 530mm 595mm BMA 220 SP 1300mm 530mm 595mm

MINIMUM CUPBOARD DIMENSIONS

MODEL Height Width Depth

DEF BMA 120 SP 1710mm 630mm 600mm BMA 140 SP 1750mm 630mm 600mm BMA 180 SP 1790mm 630mm 600mm BMA 200 SP 1895mm 630mm 600mm BMA 220 SP 2050mm 630mm 600mm

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-AINTENANCE ACCESS

-INMAINTENANCE ACCESSTOCOMPLYWITH THE7ATER2EGULATIONS

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Page 8

1.0 DESIGN

1.2 TECHNICAL DATA

115

190

PRIMARY FLOW 475

CYLINDER DRAIN

PRIMARY RETURN TO BOILER

COLD FEED

DOMESTIC HOT WATER

CENTRAL HEATING FLOW 560

TOWEL RAIL FLOW

CENTRAL HEATING RETURN

560

550

220

230

115

150

210

OPEN VENT

530

COLD FEED

All dimensions in mm - to centre line of pipework

The BoilerMate A-Class units are supplied on an installation base to allow the pipe runs to

connect to the appliance from any direction. It is easier if all pipes protrude vertically in the

cut out area shown. Compression or push fit connections can be used. All pipe positions

are approximate and subject to a tolerance of +/-20mm in any direction. With the standard

appliance (supplied without a ballvalve and overflow) a 15mm valved mains cold branch

should be provided along with a temporary hose connection incorporating a double check

valve to allow the cistern to be easily topped up when necessary (the temporary hose connection must be disconnected once the appliance is filled). With the automatic fill

model a15mm cold water supply and a 22mm warning/overflow pipe will be required for

the separate feed and expansion tank.

Cut out area in base

Page 9

BOILERMATE

A-CLASS

1.2 TECHNICAL DATA

1.0 DESIGN

0RIMARYHEATEXCHANGERIECOILPRESSURE

LOSSOF"OILER-ATE!#LASS

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LITRESSEC



LITRESSEC

PERFORMANCE GRAPHS OF GRUNDFOS PUMPS

GRUNDFOS 15/50

GRUNDFOS 15/60

Page 10

1.2 TECHNICAL DATA

Appliance Control Board

The appliance control board (shown opposite) has a 2 digit display and 2 push buttons which are used to check the status of the appliance, check and set its identity and interrogate it for the current faults and the fault history.

The 2 digit display is controlled by 2 buttons S1 and S2 The ﬂ ow chart of display modes is shown below. Generally , each press of butt on S2 cycles the display from top to bottom and each press of button S1 cycles the display functions from left to right.

The button S2 is also used to reset the appliance i.e. clear the lockout errors and reset the appliance. (Note: Appliance resetting can also be carried out using the push button on the front panel)

Display in Normal (Standby) Mode

In the standard/normal mode the 2 digit display indicates the status of the appliance inputs and outputs by switching on the appropriate segments of the display - see page 29 for details.

Appliance Type Selection

The BoilerMate SP is fitted with an identity (ID) resistor which is read by the controller for comparison with the appliance type (code) set on the controller. The two must match for the controller/appliance to function. Therefore if either the appliance code setting or the ID resistor is wrong, the appliance will shut down safely and ﬂ ag the error code until the fault is rectiﬁ ed. The controller codes and the ID resistor values for the BoilerMate SP are 02 and 2K2 respectively. The procedure for checking and setting the appliance code on the controller is described below.

• 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, S2) on the main board.

• When going from the show ‘ lock ing error’ to show ‘blocking error’ menu (see opposite), do not release the button but hold it for 10 seconds. The display will change from ‘ c’ to ‘A’. At this stage the push button (S2) can be released.

• The appliance type can now be selected by using right hand push button, S1, e.g. for this appliance A02.

Press the reset button, S2, to accept the setting . If the selected appliance code does not match

with the ID resistor ﬁ tted to the appliance, then, an error ‘33’ will be displayed.

Tank_middle

T_overh_2

T_dhw_in

ID_resistor T_overh_1 Tank_bot T_dhw_out

Push button

Ext_led_k Ext_se_1

PC Connector

Reset button

Enter button

Main processor

FLIP jumper

J31

J30

SEND_TO_GAS VSS

GASV_IN 220_0

WD_RECEIVE

VSS

SAFETY

220_1

J29

DIV_OUT_2 220-0

DIV_OUT_1

220_0

EL_HEAT_OUT

BOIL_HEAT_DEM

OVERHEAT

220_0

BOIL_HEAT_DEM

CH_P_MOD

CH_P_L CH_P_L

CH_P_PE

BOIL_P_PE

BOILER_P_MOD

BOIL_P_L BOIL_P_N

DHW_P_PE

DHW_P_MOD

DHW_P_L DHW_P_N

220_1

220_PE

220_0

220_PE

220_1

220_0

CH_ON_IN

220_0

220_1

SWL_IN

DHW_ON_IN

220_INPUT

J33

J32

J34

J28

S2 S1

APPLIANCE CONTROL BOARD

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1.0 DESIGN

Page 11

BOILERMATE

A-CLASS

1.2 TECHNICAL DATA

1.0 DESIGN

Sensor Tempa ture Readings

Details of the various sensors S1-S6 used in the BoilerMate A-Class are shown opposite. The sensor reference i.e. S1 and the ac tual temperature at that sensor ﬂ ash alternately on the display when selected.

Control Set Points

The sensor control set points are shown opposite. PLEASE NOTE THAT THE DISPLAY S1 - S6 IS NOT THE SAME AS THE SENSOR REFERENCE.

Fault Codes

Fault code locations are numbered C0 - CF and

c0 - cF. CO/cO locations hold the latest fault recorded. A code of FF indicates that the fault location is empty. If a sensor is faulty instead of a temperature it will show E1 if open circuit and E2 if short circuit.

Sensors used in BoilerMate A-Class

Sensor Sensor Connector J9 pins Location

S1 T Overheat 1 6 & 14

Top of store in dry pocket (S1 & S2 are in single housing)

S2 T Overheat 2 2 & 10 S3 T DHW in 3 & 11 In cold water inlet pipe (Wet i.e. direct) S4 T DHW out 4 & 12 In hot water outlet pipe (Wet i.e. direct) S5 T Tank bottom 5 & 13 Bottom of store in dry pocket for store charging S6 T Tank middle 1 & 9 Middle of store in dry pocket for store charging

Sensor Control Set Points

Display Sensor Temp

S1 Middle store sensor on 68 S2 Middle store sensor off 75 - 77 S3 DHW in 35 S4 DHW out 55 S5 Bottom store sensor on 60 S6 Bottom store sensor off 68

Common Fault Codes

Code Code

10 Overheat error 45 S1 overheat 1 shorted 30 Phase error 48 I.D. resistor shorted 33 Appliance selection 49 S4 sensor shorted 37 S1 overheat 1 open 50 S5 sensor shorted 40 I.D. resistor open 51 S6 sensor shorted 41 S4 sensor open 52 S2 overheat 2 shorted 42 S5 sensor open 43 S6 sensor open 44 S2 overheat 2 open

Any other code displayed should be checked against the full chart

Page 12

1.3 SYSTEM DETAILS

Hot and Cold Water System

General

A schematic layout of the hot and cold water services in a typical small dwelling is shown below. BoilerMate A-Class will operate at mains pressures as low as 1 bar and as high as 5 bar although the recommended range is 2-3 bar. These pressures are the minimum dynamic pressures at the cold connection to the BoilerMate A-Class at the time of the maximum calculated simultaneous demand. If the manifolds (av ailable as an optional extra) are being used the inlet pressure to the manifold must be a minimum of 2 bar. Particular consideration should also be given to available pressures in the case of 3 storey properties. It is also important to check that all other equipment and components in the hot and cold water system are capable of accepting the mains pressure available to the property. If the mains pressure can rise above 5 bar or the maximum working pressure of any item of equipment or component to be ﬁ tted in the system a pressure limiting (reducing) valve set to 3 bar will be required.

If you encounter a situation where the water pressure is adequate but ﬂ ow rates are poor please contact our technical helpline for details of an effective solution.

Note: Each BoilerMate A-Class is ﬁ tted with a strainer and ﬂ ow regulator on the cold mains supply connection. If the supply pressure is less than 2 bar or if the manifolds (available as an optional extra) are being used or if all taps are provided with ﬂ ow regulators the ﬂ ow regulator on the cold inlet should be removed.

No check valve or similar device should be ﬁ tted on the cold water supply branch to the BoilerMate A-Class.

1.0 DESIGN

To comply with this requirement the hardness of the mains water should be checked by the installer and if necessary the optional factory ﬁ tted in-line scale inhibitor should be speciﬁ ed 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 speciﬁ ed at the time of order. However, this will need to be ﬁ tted by the installer at a suitable point in the cold water

supply to the appliance. If scale should ever become a problem the

plate heat exchanger is easily isolated and quickly replaced with a service exchange unit which can be obtained at a nominal cost from Gledhill.

The hot water ﬂ ow rate from the BoilerMate A-Class is directly related to the adequacy of the cold water supply to the dwelling. This must be capable of providing for those services, which could be requir ed to be supplied simultaneously, and this maximum demand should be calculated using procedures deﬁ ned in BS 6700.

If a water meter is ﬁ tted in the service pipe, it should have a nominal rating to match the maximum hot and cold water peak demands calculated in accordance with BS 6700. This could be up to 80ltr/min in some properties.

Pressure limiting valve NOT REQUIRED at pressures below 5 bar unless any components have a lower maximum working pressure.

Second

dwelling

M.C.W.S

supply pipe.

Sink

Open vent

Cold feed/ expansion

Hand basin

WC - fitted with BS1212 ballvalve

Bath

BM A-Class

Optional polyphosphate scale inhibitor NOT REQUIRED unless the hardness level exceeds 300ppm (mg/l)

Shower.

aaaa a

HC HC C

S.V.

Check valve NOT REQUIRED unless chemical water treatment unit is fitted.

'a'

- flow regulator recommended for better

balance of hot and cold water supplies.

Double check valve NOT REQUIRED unless supply pipe services more than one dwelling.

Typical hot and cold water distribution

F&E Cistern

Page 13

BOILERMATE

A-CLASS

1.3 SYSTEM DETAILS

Hot and Cold Water System

Pipe Sizing / Materials

To achieve even distribution of the available supply of hot and cold water, it is important in any mains pressure system, that the piping in a dwelling should be sized in accordance with BS 6700. This is particularly important in a large property with more than one bathroom.

However, the following rule of thumb guide lines should be adequate for most smaller property types as long as water pressures are within the recommended range of 2-3 bar.

1. A 15mm copper or equivalent external service may be sufﬁ cient for a small 1bathroom dwelling (depending upon the ﬂ ow rate available), but the minimum recommended size for new dwellings is 22mm (25mm MDPE). For the BMA 225 model we recommend a 28mm (32mm MDPE) supply pipe.

2. The internal cold feed from the main incoming stop tap to the BoilerMate

should be run in 22mm pipe. The cold main and hot draw-off should also be run in 22mm as far as the branch to the bath tap.

3. The ﬁ nal branches to the hand basins and sinks should be in 10mm and to

the baths and showers in 15mm. (1 metre minimum)

4. If an external hose tap is provided this should be branched in 15mm pipework

from the cold pipework as near to the incoming mains as possible.

5. We would recommend that best results for a balanced system are achieved

by ﬁ tting appropriate ﬂ ow regulators to each hot and cold outlet. This is particularly relevant where the water pressures are above the recommended water pressure range of 2-3 bar , or the dwelling is 3 store y. Details of suitable ﬂ ow regulators are provided in Appendix A.

Note: If manifolds (available as an optional extra) are being used suitable ﬂ ow regulators are automatically provided in the manifold and do not need to be provided at each outlet - See Appendix B for further details.

All the recommendations with regard to pipework systems in this manual are generally based on the use of BS/EN Standard copper pipework and ﬁ ttings.

However , we are happy that plastic pipework systems can be used in place of copper internally as long as the chosen system is recommended for use on domestic hot and cold water systems by the manufacturer and is installed fully in accordance with their recommendations.

It is also essential that if an alternative pipework material/system is chosen the manufacturer conﬁ rms that the design criteria of the new system is at least equivalent to the use of BS/EN Standard copper pipework and ﬁ ttings.

Taps/Shower Fittings

Aerated taps are recommended to prevent splashing.

Any type of shower mixing valve can be used as long as both the hot and cold supplies are mains fed. However, all mains pressure systems are subject to dynamic changes particularly when other hot and cold taps/showers are opened and closed, which will cause changes in the water temperature at mixed water outlets such as showers. For this reason and because these are now no more expensive than a manual shower we strongly rec ommend the use of thermostatic showers with this appliance. These must be used in 3 storey properties where the impact on pressure/temperature of opening another tap in the system is greater than normal. The shower head provided must also be suitable for mains pressure supplies.

1.0 DESIGN

However , if it is proposed to use a ‘whole body’ or similar shower with a number of high ﬂ ow/ pressure outlets please discuss with the Gledhill technical department.

The hot water supply to a shower-mixing valve should be fed wherever practical directly from the BoilerMate A-Class or be the ﬁ rst drawoff point on the hot circuit. The cold supply to a shower-mixing valve should wherever practical be fed directly from the rising mains via an independent branch. The shower must incorporate or be fitted with the necessary check valves to provide back-syphonage protection in accordance with the Water Regulations. The supply of hot and cold mains water directly to a bidet is permitted provided that it is of the over-rim ﬂ ushing type and that a type ‘A’ air gap is incorporated.

Hot and Cold Water System.

If the length of the hot water draw off pipework is excessive the delivery time may be unacceptable before hot water is available at the tap, you may wish to consider using tr ace heating to the hot water pipework such as the Raychem HWAT system. Please consult Gledhill Technical Department for further details.

It is important that the cold water pipework is adequately separated/protected from any heating/hot water pipework to ensure that the water remains cold and of drinking water quality.

Page 14

1.0 DESIGN

1.3 SYSTEM DETAILS

Remote

F&E

Cistern

A-Class

Boiler

Cold feed

Open Vent

Heating Circuit

Hot Out

Mains Cold In

Components fitted within appliance case

Expansion Vessel

Pressure Gauge/Filling Loop

Pressure Gauge Relief/Safety Valve

Optional sealed system kit

3 port divertor valve

Automatic bypass valve

Summer use towel rail blanked connection

Heating System

General

A schematic layout of the heating system in a typical small dwelling is shown above.

The ﬂ ow and return from the boiler must always run directly to the BoilerMate A-Class SP and the ﬂ ow should rise continuously to facilitate venting. The heating circuit is taken from the BoilerMate A-Class and is piped in the conventional manner.

The BoilerMate A-Class SP is only suitable for a sealed heating system and therefore boiler/heating pipework can run at a higher level than the store.

It is recommended that the F & E cistern for the appliance is ﬁ tted at high level in the same cupboard as the BoilerMate. Howev er, it can be ﬁ tted remotely up to 6m above the base of the BoilerMate A-Class i.e. the maximum static pressur e in the store must not exceed 0.6 bar.

The performance of the system pump and the pressure losses through the SysteMate 2000 primary coil circuit are shown in1.2 T echnical Data. The nett pump head available for the heating circuit can be determined from these ﬁ gures and this nett pump head should be used for sizing the heating circuit pipework.

For example: At 24 litres/min primary ﬂ ow rate, the pressure loss through the SysteMate 2000 model SM210 (coil and ﬁ ttings) is 2.1m W.G. (21kPa). The maximum pump head available at 24 litres/min and setting 3 is 3.2m H2O (32kPa), therefore 1.1m W.G. (11kPa) is available for the boiler circuit.

With sealed heating systems air is released during the ﬁ rst few weeks of operation. This will need to be vented and the system re-pressurised.

If the automatic model is being used the overﬂ ow/warning pipe should be installed in a material suitable for a heating system feed and expansion cistern in accordance with BS 5449.

An automatic bypass is ﬁ tted on the BoilerMate A-Class SP to compensate for pressure (i.e. ﬂ ow) rate changes in the heating circuit e.g. when the thermostatic radiator valves close. The system does not require any other bypass valves but a bypass radiator used in conjunction with a room thermostat can be used if required to provide a boiler interlock. The bypass valve must be set by the installer to suit the system ie to provide minimum ﬂ ow required for the boiler when all TRV’s are closed.

There shall be no permanent connection to the mains water supply for ﬁ lling the system, even through a non-return valve without the approval of the Local Water Authority. An approved filling loop is required with the BoilerMate A-Class (available as part of an optional extra kit) which this should be disconnected after commissioning the system. This should be located adjacent to the boiler along with a suitable expansion vessel gauge and pressure relief valve (also available as part of the optional extra kit) as shown above.

+ 32 hidden pages

gledhill BMA 120 SP, BMA 180 SP, BMA 140 SP, BMA 200 SP, BMA 220 SP Design, Installation And Servicing Instructions

Specifications and Main Features

Frequently Asked Questions

User Manual