gledhill BoilerMate A-Class OV SOL Series, BMA 215 OV-SOL, BMA 225 OV-SOL, BMA 235 OV-SOL, BMA 285 OV-SOL Design, Installation & Servicing Instructions

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An open vented central heating

and mains pressure hot water

supply appliance with a thermal

store designed speciﬁcally for use

with solar energy

Design, Installation

& Servicing

Instructions

Model Numbers

ISSUE 5: 06-08

BMA 215 OV-SOL BMA 225 OV-SOL BMA 235 OV-SOL BMA 245 OV-SOL BMA 265 OV-SOL BMA 285 OV-SOL

All models comply with the water heater manufacturers

speciﬁcation for integrated thermal stores

CONTENTS

The code of practice for the installation,

commissioning & servicing of central heating systems

ISSUE 5: 06-08

Section Page

DESIGN

Introduction 3

Technical Data 6

System Details 15

INSTALLATION

Site Requirements 22

Installation 23

Commissioning 32

SERVICING

Annual Service 37

Changing Components 37

Short Parts List 38

Fault Finding 40

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.

ADDENDIX

Addendix A 41

Addendix B 42

Addendix C 44

Addendix D 45

Terms & Conditions 46

The Gledhill BoilerMate range is a WBS listed product and complies with the WMA Speciﬁcation 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

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 2

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.

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 and the solar panel manufacturer.

Any water distribution, central heating and solar 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

All the minimum requirements of the domestic heating appliance guide must be met to ensure compliance with the latest building regulations.

British Standards

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

DESIGN

A competent person as stated in the Gas Safety Regulations must install the boiler heating system. A suitably trained and competent person must also install the solar system. The manufacturer’s notes must not be taken as overriding statutory obligations.

The BoilerMate A-Class OV SOL model is only suitable for use with an open vented central heating system. An SP model is available for sealed central heating systems.

The BoilerMate A-Class OV SOL is not covered by section G3 of the current Building Regulations and has no special requirements with regard to Building Control.

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, 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.

Page 3

INTRODUCTION

DESIGN

CH system

(radiators or underfloor)

Full bore

automatic

bypass valve*

DHWS outlet

Warning/ overflow

pipe

MCWS

Safety/open vent

Expansion/cold feed

Extent of the components included with the BMA OV SOL appliance

MCWS inlet

BMA OV SOL

245 model

Figure 1.1

S1/2

Boiler

NOT REQUIRED unless the heating system incorporates mechanical thermostatic control valves eg. TRVs to all radiators or 2 port zone valves to each heating circuit.

F&E cisterns

Extent of the components included with the BMA OV SOL appliance

Pressure

gauge

BMA

OV SOL

Figure 1.2

Expansion

vessel

PRV

Solar Panel

Mounted horizontally

on top of the appliance

Temp. Gauge

Check Valve

Fill and flush valves

20 100

120

40 80

The arrangement of a typical BoilerMate A-Class OV SOL installation is shown schematically opposite in Figures 1.1 and 1.2. The basic unit incorporates all the necessary controls to allow the system to operate automatically once it has been properly commissioned.

One cistern com pl ete with ballvalve and overﬂow connector is provided separately with each 215-225 model BoilerMate A-Class OV SOL appliance. This is normally ﬁtted in the same cupboard as the BoilerMate appliance.

Two cisterns complete with ballvalve and overﬂow connector are provided separately with the 235-285 model BoilerMate A-Class OV SOL appliances, for remote ﬁxing on site by the installer as shown in Figure 1.1.

The principle of a BoilerMate A-Class OV SOL is to separate the heat generator e.g. a boiler from heat emitters (radiators) by a thermal store, which evens out the ﬂuctuating demands for heating and hot water.

INTRODUCTION

The BoilerMate A-Class OV SOL appliance generally follows the principles of the standard BoilerMate A-Class OV appliance but is ﬁtted with a separate set of coils to allow it to maximise the available amount of heat available from the solar panels/controls. This is then

used to supplement both the heating and hot water systems.

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 these appliances is that hot water can be supplied directly from the mains at conventional ﬂow 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.

The solar pump/pipework can get extremely hot and all solar pipework ﬁtted to the appliance is therefore provided with suitable insulation. However, care should be taken, particularly in high solar gain conditions.

Page 4

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 electronic 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.

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 controller built into the BoilerMate A-Class OV SOL appliance automatically opens the 2 port valves ﬁtted in the boiler return to allow the maximum possible energy input to be provided from the solar collectors whilst ensuring that at times of low solar gain/peak use the boiler is automatically energised to boost the store temperature to ensure customer satisfaction. The solar pump speed is also modulated, which alters the ﬂow rate and allows it to extract the maximum amount of heat possible from the solar collectors.

DESIGN

The built in controller also incorporates the facility to operate the heating pump for a few seconds every few days when the heating is not being used (to reduce the likelihood of the pumps sticking) as well as providing a boiler pump overrun facility.

Any automatic boiler designed to operate on an 82°C ﬂow and a 71°C return up to a maximum of 35kW can be linked to any suitable model of BoilerMate A-Class OV SOL and the deciding factor is the space heating and the hot water requirements of a dwelling. See the Technical Data section in these instructions for further details.

The BoilerMate A-Class OV SOL is supplied complete with ‘Switch’ which will provide a 6kW electrical emergency backup in case of failure of the main heat source. See page 21 for further information.

If a summer towel rail circuit is required, this will need to be a separate zoned circuit from the heating circuit complete with its own time and temperature controls.

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 reﬂect 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.

Note The BoilerMate A-Class OV SOL is a SYSTEM appliance and only requires a basic boiler. If a system boiler is chosen this will present wiring/operational difﬁculties as well as incurring extra costs.

Page 5

INTRODUCTION

DESIGN

Figure 1.3

24 7

13 38 11

29 28 26

Note 1: All the panels, pipework and other components necessary for the installation of the remainder of the solar system can be supplied by Gledhill with the BMA OV SOL appliance. For further details please contact the Gledhill Technical Sales Dept. Note 2: One plastic feed and expansion cistern will be supplied for the 215-225 models including a ballvalve ﬂoat and overﬂow ﬁtting. this is normally ﬁtted in the same cupboard as the BoilerMate appliance. Two plastic feed and expansion cisterns will be supplied separately for the 235-285 models including a ballvalve, ﬂoat and

TECHNICAL DATA

overﬂow ﬁtting for remote ﬁtting by the installer.

Standard Equipment

The standard conﬁguration of the BoilerMate AClass OV SOL is shown opposite. The Appliance Controllers mounted inside the appliance, control the operation of the complete system. These are pre-wired to a terminal strip where all electrical connections terminate. It is supplied with the following factory ﬁtted equipment:-

1 Domestic mains cold water inlet 2 Y type strainer/ﬂow regulator 3 Cold water inlet sensor (S3) 4 Plate heat exchanger (PHE) 5 Hot water outlet sensor (S4) 6 Hot water outlet 7 PHE circulating pump (modulating) 8 Central heating ﬂow 9 Central heating return 10 Central heating circulating pump 11 Boiler return connection (to boiler) 12 Boiler ﬂow connection (from boiler) 13 Boiler circulating pump 14 Boiler return zone valve (normally closed) 15 Boiler return zone valve (normally open) 16 Manual air vent for boiler circuit 17 Electrical terminal/connection strip 18 Solar controller 19 Appliance/system controller 20 User panel and 2 channel clock 21

Temperature/overheat sensor - top (S1/S2) 22 Temperature sensor - middle (S6) 23 Temperature sensor - bottom (S5)

‘Switch’ electrical emergency backup heater

24 25 Solar return (to collector) 26 Fill and ﬂush valve 27 Temperature gauge 28 Single check valve (anti gravity) 29 Solar ﬂow (from collector) 30 Solar circulating pump (modulating) 31 Flow and temperature sensor (SR) 32 Expansion vessel connection (solar circuit) 33 Temperature sensor (SZ) 34 Temperature Sensor (SC) - is supplied

complete with 2.5 metres of 2 x 0.75mm2

high temperature silicon cable 35 Safety/open vent 36 Cold feed/expansion 37 Thermal store drain 38 Solar coil drain 39 100mm high installation base

Optional Equipment

• Hot and cold water manifolds for use with

plastic pipework (Set 1 or 2).

• Electronic scale inhibitor for mains water

se rvi ces with ha rd ness lev els 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 6

DESIGN

Table 1.1

Technical Data

Model

Weight (empty) 67 67 75 85 95 106

Weight (full) 231 255 300 363 405 466

DHW pump

Heating pump

Boiler pump

Solar pump

Primary/heating pipe connections

MCW & DHW pipe connections

Cold feed/expansion connection

Safety open vent connection

Drain connections Rc ½

Maximum head 6 metres

Hot water ﬂow rate (l/m) up to

Max heating system size 8kW 10kW 13kW 17kW 22kW 28kW

‘Switch’ 6kW

Typical Dwelling Types - Model Selection

Bedrooms 2-3 2-4 3-4 3-5 4-5 4-6

Bathrooms 1 2 2 1 2 1 2 1 3

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

Max. ﬂoor area (m2) 80 100 130 170 220 280

BMA 215

OV SOL

BMA 225

OV SOL

Grundfos UPS 15/50 Grundfos UPS 15/60

22mm 28mm

BMA 235

OV SOL

Grundfos UPR 15/50

Grundfos UPR 15/60 Solar

BMA 245

OV SOL

22mm

15mm

22mm

BMA 265

OV SOL

BMA 285

OV SOL

Notes:-

1. For larger properties the incoming main should be a minimum of 32mm MDPE with a pressure of not less than 2 bar dynamic and an adequate ﬂow in line with the pipe sizing calculations.

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

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

4. The domestic hot water outlet temperature is automatically regulated to approximately 52°C (± 2°c) at the bath ﬂow rate of 18 litres/min recommended by BS 6700. The temperature is not user adjustable.

5. The suggestions under Model Selection for any appliance size are maximums, and in the same way as the criteria used for sizing the water distribution systems, are based on a typical diversity of use. Therefore it will be impractical to expect the appliance or the water distribution system to be able to support simultaneous use of the sanitary ﬁttings shown.

Page 7

6. In projects requiring Building Regulations approval, the maximum floor area figure must not be exceeded to ensure compliance with ADLI requirements. However, final selection should be made on the basis of the minimum model (appliance size) that meets all the criteria i.e. heating load/number of bathrooms and shower rooms/ﬂoor area.

TECHNICAL DATA

DESIGN

Figure 1.4

BoilerMate A-Class

OV SOL

300 **350A100 *350

Maintenance

access

*Minimum access / maintenance access above the appliance case.

**To comply with the access requirements of the Water Regulations.

The minimum clear

opening in front of the appliance to be at least the same as

the depth of the

appliance

plus 50mm.

The cupboard door opening will need to take into account the various sizes of appliances.

F&E cistern

BMA 215-225 OV SOLBMA 235-285 OV SOL

Model

BMA 215

OV SOL

BMA 225

OV SOL

BMA 235

OV SOL

BMA 245

OV SOL

BMA 265

OV SOL

BMA 285

OV SOL

Appliance Dimensions

Height

(A)

1330 560 620

1575 560 620

1575 610 690

1575 640 715

1485 710 785

Width

(B)

Depth

(C)

The above dimensions do not include the 100mm high installation base.

Minimum Cupboard Dimensions

Model

BMA 215

OV SOL

BMA 225

OV SOL

BMA 235

OV SOL

BMA 245

OV SOL

BMA 265

OV SOL

BMA 285

OV SOL

The above dimensions include the 100mm high installation base. In the case of the 215225 models, they assume the F&E cistern is in the same cupboard. However, for the 235-285 models they allow space for in stallatio n/ maintenance of the appliance only.

Height

(D)

2080 660 630

2025 660 630

2025 710 700

2025 740 725

1935 810 795

Width

(E)

Depth

(F)

TECHNICAL DATA

Note: With the 235-285 models, space will

be required, in addition to the above, for two feed and expansion cisterns (280mm wide x 420mm deep x 300 high), which are provided separately, complete with a ballvalve and overﬂow connector. 350mm will still be required above the cisterns to meet the minimum access requirementsof the Water Regulations for the ballvalve.

Page 8

DESIGN

Connection Details/Dimensions - 215, 225 and 235 models

Figure 1.5

480 - Heating Flow

520 - Primary Return

560 - Heating Return

560 - Primary Flow

580 (620 including the door/clock)

560

530 - Domestic Hot Water

545 - Cold Feed

210

275

480

515

Connection Details/Dimensions - 245 model

Figure 1.6

530 - Heating Flow

585 - Primary Return

630 - Heating Return

630 - Primary Flow

650 (690 including the door/clock)

610

605 - Domestic Hot Water

630 - Cold Feed

240

295

525

565

110

Connection Details/Dimensions

Diagrams opposite show the connection details and dimensions for the BoilerMate A-Class OV SOL appliance.

The BoilerMate A-Class OV SOL 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. A 15mm cold water supply and a 22mm warning/overflow pipe will also be required for the separate feed and expansion tank.

Note: All dimensions are shown in mm and are to the centre line of pipework/gland.

Page 9

TECHNICAL DATA

DESIGN

Connection Details/Dimensions - 265 model

Figure 1.7

Heating Flow

Primary Return

Heating Return

Primary Flow

675 (715 including the door/clock)

640

Domestic Hot Water

Cold Feed

Connection Details/Dimensions - 285 model

Figure 1.8

Heating Flow

Primary Return

Heating Return

Primary Flow

745 (785 including the door/clock)

710

Domestic Hot Water

Cold Feed

Connection Details/Dimensions

Diagrams opposite show the connection details and dimensions for the BoilerMate A-Class OV SOL appliance.

Note: All dimensions will be updated in the next issue of the manual.

TECHNICAL DATA

Page 10

Front Panel Controls

The front panel user controls are shown in the picture opposite and their functions are described below.

Three different windows can be displayed in the visual display panel on the front of the appliance. Pressing the select button below the display allows you to move from one window to the next.

Standard Display Window

In normal automatic operation the display will be as shown opposite.

DESIGN

If a fault occurs with the boiler, the ‘Switch’ emergency electric back-up system can be selected by pressing and holding the ’Switch’ 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.

Active/Demand Window

Press the select button when the display is in standard mode to move to this window.

Use this window to check the current active status of the appliance/systems.

Symbol Description

No active demand

Demand present/component active

P-HW

Store

Boiler Shows if the boiler is on

P-CH

Rstat Shows if there is a demand from the room thermostat

CHpump Shows if the central heating pump is on

SolH

Spump Shows if the solar pump is on

DHWuse

Shows if a demand is present for hot water from channel 1 of the clock

Shows if there is a demand for the store to be heated by a boiler/ primary circuit

Shows if the demand is present for central heating from channel 2 of the clock

Shows if there is a demand for heat from the solar circuit - the solar system can be disabled, if required, by pressing and holding the ‘Switch’ button for 5 seconds when the window is in this mode

Shows if there is a sufﬁcient temperature differential between sensors S3 and S4 to activate the domestic hot water system

Shows the total contribution in kilowatt hours made by the solar system (scale 0-9999 when it will automatically reset)

Normal mode

Switch mode

Active/demand window

Current Status Window

Press the select button when the display is in the Active/Demand mode to move to this window.

Use this window to check the actual current temperatures/performance of the appliance.

The top two rows of the display show the actual current temperature at the various store/solar sensors used to control the operation of the appliance i.e. in the example shown opposite, the actual temperature at S1 is 75°C and at S6 is 65°C etc.

Page 11

Current status window

TECHNICAL DATA

DESIGN

The duty/location of the various sensors is as follows.

Sensor Duty Location

S1 T Overheat 1

S2 T Overheat 2

S3 T DHW in In cold water inlet pipe (Wet i.e. direct)

S4 T DHW out In hot water outlet pipe (Wet i.e. direct)

S5 T Store bottom Bottom of store in dry pocket for store charging

S6 T Store middle Middle of store in dry pocket for store charging

T Solar collector

SR T Solar return In solar return pipe - integrated with ﬂow sensor

- ﬂow

T Solar zone

- store

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

Supplied wired - to be ﬁtted by the installer in the sensor pocket provided in the solar panel (collector) or in the flow pipe immediately adjacent to the collector.

Bottom of store in dry pocket for solar charging of store

Symbol Description

Show the actual current temperature at the domestic cold water

S3 and S4

The temperature at which the thermal store is satisﬁed, when being supplied with heat from the boiler is 77°C (i.e. the off control set point of sensor S6).

The solar system will start from a minimum 10°C differential between the temperature in the store SZ and the temperature at the solar panel (collector) SC i.e. the solar circulating pump only runs if the temperature as SC is at least 10°C above the temperature at SZ. The solar will continue to run, once started, until the differential narrows to 2°C and will then stop until a differential of 10°C is achieved between SZ and SC. The pump speed will continually modulate to ensure that any available solar energy is always being transferred to the store.

2 Channel Clock

A 2 channel digital Grasslin clock is provided to allow separate control of the hot water and heating requirements in accordance with the latest Building Regulations.

inlet/hot water outlet sensors respectively. The respective control set points are 35°C and 55°C respectively

Shows the current actual energy input in kilowatts from the solar system

Shows the actual current flow rate in litres/minute in the solar circuit

Shows the actual current speed of the modulating solar circulating pump as a percentage of the maximum

Details of how to set the clock are provided on the User label and in the User Instructions.

Channel 1 controls the operating times for the boiler/primary circuit. This should normally be set to constant to allow the hot water to be available 24 hours a day.

The appliance controls will always give priority to heat input from the solar system and will only energise the boiler if this is required to meet the hot water and heating demands placed on the appliance.

Channel 2 controls the operating times for the central heating circuit and should be set to suit the householders lifestyle.

TECHNICAL DATA

Page 12

DESIGN

APPLIANCE CONTROL BOARD (A.C.B)

Fuse T3.15L 250V

2 DIGIT ACB BOARD DISPLAY FLOW CHART

Press S2

S2 S1

Press

Appliance

type

Press

Fault code indicator

block outs

Press

Fault code indicator

lock outs

Press

Control set-point

reading

Press

Sensor temperature

reading

Normal - standby state

Indicate system status

S2 S1

2 digit

display

2 push

buttons

Main

processor

Appliance Control Board

The appliance control board (shown above) has a 2 digit display and 2 push buttons. Although this can be used to check the status of the appliance, we would suggest that this is done on the control panel/display window on the front of the appliance, unless this is faulty. However the controls should be used to check and set the appliance identity and to interrogate it for any current faults and the fault history.

The 2 digit display is controlled by 2 buttons S1 and S2 The ﬂow chart of display modes is shown above. Generally, each press of button 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. Details of the function/operation of the display are described in the Installation section of these instructions.

Appliance Type Selection

The BoilerMate 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 ﬂag the error code until the fault is rectiﬁed. The controller codes and the ID resistor values for the BoilerMate are A01 and 1K5 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 ‘ locking 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 A01.

Press the reset button, S2, to accept the setting.

TECHNICAL DATA

Page 13

DESIGN

If the selected appliance code does not match with the ID resistor ﬁtted to the appliance, then, an error ‘33’ will be displayed.

A table showing this and other common fault codes is shown below.

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.

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.

Please ring Gledhill Technical Helpline for details.

TECHNICAL DATA

Page 14

DESIGN

Warning/ overflow

pipe

MCWS

Safety/open vent

Shower

Expansion/ cold feed

Second

dwelling

Pressure limiting valve

NOT REQUIRED at

pressures below 5 bar

unless any components

have a lower

maximum working

pressure

Double check valve

NOT REQUIRED unless

chemical water

treatment unit is fitted

‘a’ - flow regulator recommended for better balance of hot and cold water supplies

MCWS supply

pipe

Sink

H C

a a

a a a a

Bath

H C

Hand basin

H C

WC - fitted

with BS1212

ballvalve

Figure 1.9

Typical hot and cold water distribution (to a smaller property)

Check valve

NOT REQUIRED unless

chemical water

treatment unit is fitted

Optional polyphosphate scale inhibitor

NOT REQUIRED unless the hardness

level exceeds 300ppm (mg/l)

F&E cistern

BMA OV SOL

225 model

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 OV SOL 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 AClass at the time of the maximum calculated simultaneous demand. If the manifolds (available 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 ﬁtted in the system) a pressure limiting (reducing) valve set to 3 bar will be required (or the pressure rating of the piece of equipment or component).

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

Note: Each BoilerMate A-Class OV SOL is ﬁtted with a strainer and ﬂow 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 ﬂow regulators the ﬂow regulator on the cold inlet should be removed.

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

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.

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 ﬂow rate from the BoilerMate AClass OV SOL is directly related to the adequacy of the mains cold water supply to the dwelling. This must be capable of providing for those services, which could be required to be supplied simultaneously, and this maximum demand should be calculated using procedures deﬁned in BS 6700.

If a water meter is ﬁtted 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.

Page 15

SYSTEM DETAILS

DESIGN

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 sufﬁcient for a small 1bathroom dwelling (depending upon the ﬂow rate available), but the minimum recommended size for new dwellings is 22mm (25mm MDPE). For the BMA 245 OV SOL model and above 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 the same size pipework as the incoming mains supply. The cold main and hot draw-off should also be run in 22mm as far as the branch to the bath tap.

3. The ﬁnal 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 and before the pressure reducing valve (if ﬁtted).

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

by ﬁtting appropriate ﬂow 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 storey. Details of suitable ﬂow regulators are provided in Appendix A.

Note: If manifolds (available as an optional extra) are being used suitable ﬂow 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 ﬁttings.

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.

If it is proposed to use a ‘whole body’ or similar shower with a number of high ﬂow/pressure outlets please check suitability with the Gledhill Technical Department before installation.

The hot water supply to a shower-mixing valve should be fed wherever practical directly from the BoilerMate A-Class OV SOL or be the first draw-off 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 backsyphonage 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 ﬂushing 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 time before hot water is available at the tap may be unacceptable. In these circumstances, you may wish to consider using trace 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.

It is also essential that if an alternative pipework material/system is chosen the manufacturer conﬁrms that the design criteria of the new system is at least equivalent to the use of BS/EN Standard copper pipework and ﬁttings or the pipework sizes are increased accordingly.

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. This 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 recommend 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.

SYSTEM DETAILS

The shower head provided must also be suitable for mains pressure supplies.

Page 16

Warning/

overflow

pipe

MCWS

Safety/

open vent

Expansion/ cold feed

Figure 1.10

Full bore automatic bypass valve NOT REQUIRED

unless the heating system incorporates mechanical thermostatic control valves

e.g. T.R.V’s to all radiators or 2 port zone valves.

Primary flow

Primary

return

Boiler

250mm as a

minimum

Head recommended

by boiler manufacturer

as a minimum

6 metres

maximum

F&E cisterns

BMA OV SOL

245 model

Heating System

DESIGN

General

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

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

The BoilerMate A-Class OV SOL is only suitable for an open vented system.

The F & E cisterns can be ﬁtted remotely up to 6 m above the base of the BoilerMate AClass OV SOL i.e. the maximum static pressure in the store must not exceed 0.6 bar.

The F&E cisterns must be installed at the same level and a typical arrangement is shown above. If installed in a roofspace, suitable insulation will need to be provided to the cisterns/any pipework to protect them from damage by frost.

If any radiators are located above the level of the BoilerMate A-Class OV SOL the system should be designed so that gravity circulation does not occur when the heating pump is not running. To be certain of preventing this it is recommended that a check valve, or valves, are ﬁtted on the vertical ﬂow pipes.

The F & E cisterns should be at least 250mm above the highest point on the system including the radiators and must also be high enough to provide the minimum head required by the boiler being used.

The boiler manufacturer’s instructions with regard to minimum head must always be followed. This is particularly important in situations where the headroom is restricted (e.g. in a ﬂat).

Range rated boilers can be used but should always be set at the highest output. The system efﬁciency will not be impaired while the recovery rate will be improved.

It is not necessary to provide a boiler bypass on the primary circuit (i.e. between the boiler and the thermal store).

Page 17

SYSTEM DETAILS

DESIGN

Heating System

Equipment/Pipe Sizing and Materials

The primary pipework connecting the boiler and the thermal store should be sized to achieve a maximum of 8°C rise across the boiler or the maximum temperature rise speciﬁed by the boiler manufacturer, whichever is smaller, but in any instance it should not be less than 22mm copper tube.

The store sensor off control point is 77°C and it is important that the boiler/primary circuit are capable of providing this temperature at the store sensor.

Note: There should be no valves in the pipework connecting the boiler to the BoilerMate A-Class OV SOL.

The heating circuit operates on the normal primary boiler temperatures i.e. 82°C ﬂow and 71°C return. Therefore any traditional hot water radiators or convectors can be used with this system and no special over-sizing of the heat emitters is necessary.

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

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 heating systems by the manufacturer and is installed fully in accordance with their recommendations. We always recommend the use of barrier pipe for these systems.

Allowance for domestic hot water

Model (kw)

BMA 215 OV SOL 3

BMA 225 OV SOL 4

BMA 235 OV SOL 5

BMA 245 OV SOL 6

BMA 265 OV SOL 6

BMA 285 OV SOL 6

It is only necessary to calculate the heating requirements in accordance with BS 5449. The allowances shown below should be added for domestic hot water. The control system automatically gives priority to hot water when necessary.

SYSTEM DETAILS

Page 18

DESIGN

Figure 1.12

Primary flow

Primary return

Gravity

check

valve

AV - Automatic air vent

F&E cisterns

BMA OV SOL

Boiler

Figure 1.11

Primary flow

Primary return

F&E cisterns

BMA OV SOL

Boiler

Boiler Sited Below BoilerMate A-Class

Any temperature controlled boiler can be used when the ﬂow pipe from the boiler to the BoilerMate A-Class rises continuously. The primary ﬂow also acts as the open vent/safety for the boiler, therefore no valve shall be ﬁtted in the primary ﬂow or open vent.

Boiler sited above the BoilerMate

Any boiler used must be ﬁtted with an overheat thermostat i.e. it must be suitable for use in a sealed system.

An automatic air vent will be required on the ﬂow and return connections adjacent to the boiler.

The F & E cistern must be ﬁtted at a height which will provide the minimum head required for the boiler and must also be at least 250mm above the highest point of the system.

The height of the bottom of the F & E cistern from the base of the store should be no greater than 6m.

A gravity check valve should be ﬁtted in the boiler return pipework to prevent gravity circulation between the BoilerMate A-Class and the boiler during dormant periods.

Connection of Bathroom Radiator/Towel-Rail for Summer use

If separate Summer/Towel rail circuits are required, these must be piped as a separate zone from the main heating circuit with their own zone valve and time/temperature control (programmable room thermostat) as shown in the Installation section of these instructions - Zoned Heating Systems.

SYSTEM DETAILS

Page 19

DESIGN

Extent of the components included with the BMA OV SOL

Fill and flush valve, check valve and temperature gauge assembly

Appliance

control board

Solar pump

BMA

OV SOL

Figure 1.13

PRV discharge pipe

5 amp

junction box

Flow (from panel)

Return (to panel)

Solar panel (collector)

SC - Collector flow temperature sensor

20 100

120

40 80

Pressure

gauge

SR - return temperature/ flow sensor

SZ - Thermal store

solar zone sensor

Solar coil

Solar

control board

Expansion

vessel

Solar System

A s chema tic l ayou t of a s olar sys te m incorporating a BoilerMate A-Class OV SOL appliance is shown above.

As can be seen, the BoilerMate A-Class OV SOL appliance includes almost all the equipment normally provided in a solar pumping station.

On this basis, the ﬂow and return pipework from the solar panel(s) (collectors) should be run directly from the panel to the BoilerMate A-Class OV SOL.

A 6 bar pressure relief (safety) valve will be required on the solar return to the solar collector. To allow future maintenance/testing, its location shall be accessible. The discharge pipe shall be of a rigid and non-deformable constitution ie. metal. No valves should be ﬁtted in the

pipework between the solar collector and the pressure relief (safety) valve. The discharge

from the pressure relief (safety) valve shall terminate in a position where the discharge of steam/scalding water will not cause any injuries or harm to persons or property. A suitably sized, high temperature receptacle, an internal gulley or at low level externally, are all normally considered acceptable termination points. However, a high level termination from walls or on roofs is not normally considered acceptable because of the possible harm to people below.

System Height

(metres)

System Volume

(litres)/Maximum

Collector Area (m2)

<10/5 18/1.3/1.6 18/1.5/1.8 18/2.0/2.3

20/7.5 25/1.3/1.6 25/1.5/1.8 35/2.0/2.3

30/12.5 35/1.3/1.6 35/1.5/1.8 40/2.0/2.3

50/15 40/1.3/1.6 50/1.5/1.8 50/2.0/2.3

Note: System height refers to the difference in height from the top of the collector to the expansion vessel.

SYSTEM DETAILS

Expansion Vessel Sizing Chart

2.5 5.0 10.0

Vessel size/pre-charge pressure/initial ﬁll pressure

(litres/bar/bar)

A suitable solar expansion vessel will also be required and a 15mm connection with pressure gauge is provided on the top of the appliance. The vessel shall be sized and the initial ﬁlling pressure established in accordance with an approved method such as set out in Appendix D of the Solar Heating, Design and Installation Guide produced by the Domestic Building Services Panel of the Chartered Institute of Building Services Engineers.

However, the chart opposite provides an indication of the likely vessel size and fill pressures required when using a flat plate collectors and a 6 bar safety valve (allowing 1.0 bar over pressure).

The collector ﬂow temperature sensor (SC) is wired into the BoilerMate OV SOL complete with 2.5 metres of cable (2 x 0.75mm2 double insulated). However, dependant on the location of the solar panel(s) this may need extending by the installer on site (up to a maximum of 50 metres). It is recommended that the cable is jointed in a 5amp junction box ﬁtted in the roof space adjacent to the panel(s). The sensor (6mm diameter) will need to be ﬁtted in the solar panel or ﬂow pipe from the solar panel as near to the panel as possible.

The solar panel(s), expansion vessel, pressure

Page 20

DESIGN

relief valve and the necessary length of pre-insulated corrugated stainless steel pipework and sensor cable to complete the solar installation can be supplied by Gledhill. Please ring our Technical Sales Department for details.

If it is proposed to use copper pipework, the components and insulation will need to take account of the extremely high temperatures and pressures which can be experienced, and the ethylene glycol antifreezes which are used. Standard soft soldered ﬁttings and pipe insulation will not be adequate. The insulation needs to be Class ‘O’ standard and the bracketting needs to allow for the increased thickness required. Brazing, press ﬁt type with green viton seals or copper weld type ﬁttings are all acceptable. Any compression joints will need to have brass olives. Because of the high temperatures, the pipework should be routed to allow for the necessary expansion or provided with ﬂexible connectors.

It is recommended that a ﬁlling tank/pump should be used to ﬁll and vent the solar system but the ﬁll and ﬂush valve does incorporate a spare connection for a standard temporary ﬁlling loop (as used for central heating systems) so that once the system has been ﬁlled with the necessary antifreeze mixture, mains water pressure can

be used to charge the system. Details of the ﬁlling/commissioning procedure using a ﬁlling tank/pump are included later in the Installation section of these instructions.

All the necessary Health and Safety requirements should be followed when lifting and ﬁtting the solar panels (collectors) on the roof.

To prevent overheating in the summer (and discharge from the pressure relief valve), we suggest a saving of 50% of the energy required for the domestic hot water should be used as the target when calculating the number/area of solar panels (collectors) required. In addition to this we believe that a further 10-15% saving will be achieved because the BoilerMate A-Class OV SOL also contributes energy to the heating system.

Switch

The BoilerMate A-Class OV SOL is supplied with a 6kW electrical emergency back up system called ‘Switch’ which can be used to provide some heating/hot water in the case of failure of the main heat source i.e. gas boiler.

This must NOT be used for prolonged periods or used to supplement hot water production only in summer if the main system is working correctly.

Full details of the electrical requirements are provided in the Site Requirements and Installation sections of these instructions.

‘Switch’ will be activated by pressing the centre push button (marked ‘Switch’) located on the front control panel for at least 5 seconds (see diagram opposite). This replaces the function of the external boiler with the internal electric emergency boiler. The operating mode shown on the display will change fron ‘Normal’ to ‘Switch’. The ‘Switch’ symbol will ﬂash as long as Switch is active.

Once the fault has been resolved return to normal boiler operation by pressing in the centre push button marked ‘Switch’ for at least 5 seconds. The operating mode on the display will return to ‘Normal’.

During Switch operation the hot water and central heating will still operate in a timed mode. The operating times can be altered by resetting the clock, if required, to suit the reduced energy input available.

Page 21

SYSTEM DETAILS

INSTALLATION

Site Requirements

The appliance is designed to be installed in an airing/cylinder cupboard and the relevant minimum dimensions are provided in the Technical Data section.

Because of the ease of installation we recommend that the cupboard construction is completed and painted before installation of the appliance. The cupboard door can be ﬁtted after installation.

If the unit needs to be stored prior to installation it should be stored upright in a dry environment and on a level base/ﬂoor.

Installation and maintenance access is needed to the front of the appliance and above the F & E cisterns. See page 8 for further details.

The minimum dimensions shown allow for the passage/connection of pipes under the appliance from any direction as long as the appliance is installed on the installation base provided. If the installation base is not used extra space may be needed to allow connection to the pipework and the whole of the base area should be continuously supported on a material which will not easily deteriorate if exposed to moisture.

The ﬂoor of the cupboard needs to be level and even and capable of supporting the weight of the appliance when full. Details of the weight when full is provided in the Technical Data section.

The appliance is designed to 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.

Cupboard temperatures will normally be higher than in a conventional system and the design of the cupboard and door will need to take this into account. No ventilation is normally required to the cupboard.

A suitable location will be needed for the two separate feed and expansion cisterns. With the two smaller appliances, it may be possible to ﬁt these at high level in the cupboard housing the BoilerMate A-Class OV SOL. However, it is normal for these to be ﬁtted elsewhere in the property such as the roofspace. The 2 cisterns must be ﬁtted at the same level and above the appliance in accordance with the details shown in Figure

1.10. The location will need to provide a suitable route from the appliance for the cold

feed/expansion pipe and the open vent/safety pipe, as well as the warning/overﬂow pipe and the ballvalve supply from the mains cold water system.

An electrical supply must be available which is correctly earthed, polarized and in accordance with the latest edition of the IEE requirements for electrical Installations BS 7671.

The electri ca l mains supply nee ds to be 230V/50Hz.

Connection must be made using a double-pole linked isolator which has a contact separation of 3mm in both poles and is located within 1m of the appliance. The supply must only serve the appliance.

The minimum breaking capacity of the main isolator/cable sizes/lengths at 230V shall follow the recommendations in the table shown opposite.

A 3 core and earth 1.0mm2 cable will be required from the BoilerMate A-Class OV SOL appliance to the remote boiler.

A 3 core and earth 1.0mm2 cable will be required from the BoilerMate A-Class OV SOL appliance to the room thermostat.

If the boiler incorporates a frost thermostat an extra 3 core and earth 1.0mm2 supply cable will be required between the boiler and the BoilerMate to provide a supply to the boiler pump - see Electrical Connection for further details.

Note: A 2 x 0.75mm2 sensor cable will be needed between the BoilerMate A-Class OV SOL and the solar panel. Dependant on the location of the panels/appliance, this may need to be ﬁtted at ﬁrst ﬁx stage.

Nominal

full load

current

28.5 Amps 32 Amps

Recommended circuit

protection device - based on

0.4 second disconnection time

SITE REQUIREMENTS

Min rating of

Electrical Supply requirements for BoilerMate A-Class

the isolator

Max. recommended

cable run-based on

Cable size

6 mm

(2 core & earth)

32 A type B circuit breaker to

32A type B RCBO to BSEN 61009

not exceeding 4% of the nominal voltage

supply of 230 VAC

using a type B breaker

44 metres

BS EN 60898 or

Page 22

INSTALLATION

HANDLING

When lifting the unit work with someone of similar build and height if possible.

Choose one person to call the signals.

Lift from the hips at the same time, then raise the unit to the desired level.

Move smoothly in unison.

A speciﬁc manual handling assessment is shown in Appendix D

at the rear of this manual.

Pr epa rat ion /pl aci ng the appl ian ce in position.

Details of the recommended positions for termin at ion of the first fix pip ework are provided in section the Technical Data section. The pipework can be located or its position checked using the template provided with each appliance. If these have been followed installation is very simple and much quicker than any other system.

The appliance is supplied shrink wrapped on a timber installation base. Carrying handles are also provided in the back of the casing.

The two feed and expansion cisterns complete with ballvalve and overflow/warning fitting are provided in a separate box. If manifold sets have been ordered these will also be provided separately.

The appliance should be handled carefully to avoid damage and the recommended method is shown opposite. Before installation the site requirements should be checked and confirmed as acceptable. The plastic cover and protective wrapping should be removed from the appliance and the installation base (provided) should be separated and placed in position.

The appliance can then be lifted into position in the cupboard on top of the base and the front panel removed by unscrewing the 2 screws and lifting the door up and out, ready for connection of the pipework and electrical supplies. The feed and expansion cistern support shall be installed ensuring that the base is fully supported, the working head of the appliance is not exceeded and the recommended access is provided for maintenance - see the Technical Data section.

Note: Although the above guidance is provided any manual handling/lifting operations will need to comply with the requirements of the Manual Handling Operations Regulation s issued by the H.S.E. See Appendix D for further details.

Page 23

The appliance can be moved using a sack truck on the rear face although care should be taken and the route should be even.

In apartment buildings containing a number of storeys we would recommend that the appliances are moved vertically in a mechanical lift.

If it is proposed to use a crane expert advice should be obtained regarding the need for slings, lifting beams etc.

INSTALLATION

Figure 1.14

Connection/Supply Arrangements

The position of the pipework connections is shown opposite. Dimensions are shown in the Technical Data section.

All the connections are also labelled on the appliance. It is essential that the pipework is connected to the correct connection.

1 - Safety/open vent connection - 22mm

copper tube

2 - Cold feed/expansion connection - 15mm

copper tube

3 - Solar expansion vessel connection -

15mm compression

4 - Solar return connection (to collector)

- 22mm compression

5 - Solar flow connection (from collector

- 15mm compression

6 - H eat ing fl ow co nne ction - 22mm

compression

7 - Primary return connection (to boiler)

- 22mm compression

8 - Heating return conn ec tion - 22mm

copper tube 9 - Solar coil drain connection - Rc 1/2 10 - Primary ﬂow connection (from boiler)

- 22mm copper tube 11 - Thermal store drain connection - Rc 1/2 12 - Domestic mains cold water connection

- 22mm compression 13 - Domestic hot water connection - 22mm

compression

All factory made joints should be checked after installation in case they have been loosened during transit.

All the fittings for the feed and expansion cistern should be installed to meet the Water Regulations, in a position to suit the particular site location and the cister n fitte d on its supports/base.

The cold feed/expansion and safety/open vent pipework provided should be installed between the appliance and the feed and expansion cistern.

INSTALLATION

Page 24

INSTALLATION

Note: When ﬁtting the cistern, it must not be more than 6 metres above the base of

the BoilerMate A-Class OV SOL appliance.

The open vent must have a continuous rise from the appliance to its discharge point above the F&E cistern.

Check and comply with the requirements of the Water Regulations/boiler manufacturer regarding the arrangement of the open vent.

Obviously, if the feed and expansion cistern is being ﬁtted in the roof space, then this and the pipework will need to be adequately insulated to protect against frost damage.

Combined feed and open vent pipe arrangements must not be used.

No valves should be ﬁtted in the safety open vent which must be a minimum of 22mm copper pipe or equivalent.

The overﬂow/warning pipe shall have a continuous fall, be ﬁtted to discharge clear of the building and be sited so that any overﬂow can be easily observed. It shall also be installed in a size and material suitable for use with heating feed and expansion cisterns in accordance with BS 5449 i.e. HT plastic or copper and should not have any other connections to it.

Page 25

INSTALLATION

S1 & S2

(Heating SL-H)

(Hot Water SL-W)

(Frost Protection SL-F)

(Room Stat SL-R)

Zone Valve

Normally Closed

R Wh Wh

Status LED

MCB 2

MCB 1

MCB 3

16A

L N

SL-W

SL-B

SL-R

L1L2L3

NNN

SL-F

N-IH

L-IH

2 x 3kW Heating Elements

PE-IH

2.5 mm SID Silicone

4.0 mm Tri-Rated

2.5 mm SID Silicon

2.5 mm SID Silicone

4.0 mm SIF Silicone

2.5 mm SIF Silicone

Solar Collector Sensor fitted in the panel sensor pocket provided by manufacturer. Minimum pocket size 8mm.

Solar Sensor cable will need to be extented to reach the panel,

0.75mm two core flex and 5 amp 2 post junction box will be required fitted in the roof space close to the Solar panel sensor pocket.

Remove link to fit room stat.

3 WAY BUS BAR

SL-H

147SC-0-1

147DI_2

20K NTC

Sensor Body

Mains Supply

230VAC 50Hz 32Amps

6.0/10.0mm² Twin & Earth Cable PVC

(10.0mm² is only required when there is a high

ambiant temperature and/or long cable run)

CH1

HOT WATER

CH2

TWO C HANNEL DIG ITAL CLOCK

3 4

31 2 87654

ISSUE No : 4

APPROVED

DATE : MARCH 2008

GLEDHILL WATER STORAGE LTD.

DO NOT SCALE FROM THIS DRAWING. COPYRIGHT OF THIS DRAWING

IS RESERVED. IT IS NOT TO BE REPRODUCED COPIED OR DISCLOSED

TO A THIRD PARTY EITHER WHOLLY OR IN PART WITHOUT OUR

WRITTEN CONSENT.

SYCAMORE TRADING ESTATE SQUIRES GATE LANE BLACKPOOL LANCASHIRE FY4 3RL

DRN.

SIGN. DATE DATE

APP'D.CH'KD.DATE

03-03-08 03-03-08

03-03-08

S. McGachie

S. Gataora

S. Gataroa

Zone Valve

Normally Open

SIGN.

VAL-N

VL-N/O

VAL-SL

Sc Solar Panel Sensor

VAL-PE

2.5 mm SID Silicone

2 4

1 3

2.5 mm SID Silicone

Temperatu re signal

Flow signa l

Pipe syst em

Pin numb ers

UPR 15/50 Modulating Solar Pump

Sz Solar Zone Sensor

VL-N/C

J7a J7b

Additional Solar Add On Rail

BoilerMate OV Solar Mode> Normal

INSTALLATION

Page 26

INSTALLATION

‘A’ Class BoilerMate OV SOL issue4.ai

G/Y

Br Br

G/Y

ID_RESISTOR

S1 & S2

Green Neon Illuminated

ON / OFF Switch

J33

J32

J28

J29

* All wire sizes 0.5mm² unless otherwise stated

White Covering

(1) Connection only used if Modulating Pump is fitted

(1)

('SWITCH' ON / OFF)

(Boiler ON / OFF)

(Heating SL-H)

(Hot Water SL-W)

(Frost Protection SL-F)

(Room Stat SL-R)

DHW Pump

Heating

Pump

Boiler Pump

Rocker Switch terminal conections

Mod

3 Speed

BlueBl

BrownBr

Green

Grey

Green / Yellow

G/Y

WIRE COLOUR LEGEND

Black

Orange

Yellow

White

Red

S 3

S 4

S 5

S 6

Store overheat sensors

Cold Water IN

Domestic Hot Water OUT

Bottom store sensor

1K5 Resistor ID_Resistor (White)

Middle store sensor

S1 & S2

SENSOR LEGEND

Solar Collector sensor 20K

Dedicated Solar Zone 20K

Br Br

O O

S 7

Solar Return Temp 147DI

Solar Flow Rate 147DI

G/Y

J34

J30

J31

(1)

Solar Collector Sensor fitted in the panel sensor pocket provided by manufacturer. Minimum pocket size 8mm.

Dedicated Solar Zone Sensor fitted in the pocket provided in the bottom 1/3 of the thermal store.

147MP_34

20K NTC

DRG. NAME

DRG. SIZE

JOB NAME

TITLE

BOILERMATE 'A' Class OV SOL ADL1

With Gledhill Solar Controller and two 2 port valves, factory fitted 2 channel digital clock.

Electrical Schematic for : BOILERMATE 'A' class OV SOL Appliance fitted with 2 channel digital clock

GLEDHILL WATER STORAGE LTD. SYCAMORE TRADING ESTATE

SQUIRES GATE LANE BLACKPOOL LANCASHIRE FY4 3RL

2 3 41

SPD1/2A

OPTIONAL EXTRA IF FITTED

PART No. XB142

Page 27

INSTALLATION

MCB 2

MCB 1

MCB 3

16A

L N

SL-W

SL-B

SL-R

L1L2L3

NNN

SL-F

N-IH

L-IH

SL-H

PE-IH

230 VAC ~

ROOM STAT CONNECTIONS

230 VAC ~

SUPPLY TO BOILER

INSTALLER ELECTRICAL

CONNECTIONS

2 x 3 Core & Earth

1.0 mm

2 Core & Earth

6.0 mm

Feed Into

Appliance

Feed From

Appliance

This is supplied with 2.5m of 2 x 0.5mm

double insulated cable. If necessary, this

will need extending. It is recommended

that it should be jointed into a 5amp

junction box located in the roof space

adjacent to the solar panel(s).

BOILERMATE ‘A’ CLASS OV SOL EXTERNAL CABLE CONNECTION DIAGRAM

G/YG/Y

Bl Bl

BrBr Blk Blk

VAL-N

VL-N/O

VAL-SL

VAL-PE

VL-N/C

SC Solar Panel Sensor

Electrical Connection

The BoilerMate A-Class OV SOL is pre-wired to DIN rail terminals from the A.C.B. and plumbers are well able to complete the electrical installation provided they adhere strictly to the IEE Requirements for Electrical Installations BS 7671.

All the terminals are suitably labelled.

Note: Do not attempt the electrical work unless you are competent to carry it out to the above standards.

Before commencing check that the power source is in accordance with the Site Requirements section and ensure that it is isolated.

Run the external wiring through the service slot provided in the base of the appliance.

The twin and earth 2 core input cable from the isolator to the appliance must not be less than 6mm2 PVC grade to BS 6500.

This supply cable must be fed via a 32 amp double pole isolator no more than 2 metres from the appliance.

Make the connections as shown opposite.

The appliance is provided with a link between terminals L2 and SL-R on the terminal connections. This must be removed if a room thermostat is ﬁtted see opposite.

Clamp the cables in the clamps provided below the terminal connections and ensure all cables are routed to avoid hot surfaces.

The supply to the BoilerMate A-Class OV SOL must be protected by a type B MCB to BS EN 60898 of at least 32 amps rating.

Two installer supplied cables are required to connect the external room thermostat and boiler. These cables must each be 4 core and at least 1mm2 or above in size.

For maintenance purposes it is essential that a 3 pole isolator is positioned within 2 metres of the remote boiler installation. This ensures the installation meets Corgi requirements for future maintenance/service.

Note: The appliance controller is polarity sensitive therefore if the live and neutral cables are connected incorrectly the red light on the front panel will ﬂash rapidly and can not be reset by operating the push button.

INSTALLATION

Page 28

INSTALLATION

Blk

PIPE THERMOSTAT

4 Core

ROOM THERMOSTAT

FROST THERMOSTAT

Temperature setting range: 3 to 20 °C Set to 5 °C

BoilerMate ‘A’ Class OV SOL Frost External Wiring Diagram

Drawn by: Stephen McGachie Date: 01/08/2007

Issue No: 2

Checked by :

Signed :

............................................................

Sandy Gataora

Date: 01/08/2007

G/Y G/Y

Bl BlBr Br

Blk Blk

Installer connection terminals within the Gledhill ‘A’ Class BoilerMate Appliance

External installer supplied Room & Frost Thermostat wiring example

230VAC suppl y Rated at 6.5kW 32 Amp type B Circuit Breaker

MCB 2

MCB 1

MCB 3

16A

L N

SL-W

SL-B

SL-R

L1L2L3

NNN

SL-F

N-IH

L-IH

SL-H

PE-IH

VAL-N

VL-N/O

VAL-SL

SC Solar Panel Sensor

VAL-PE

SZ Solar Zone Sensor

VL-N/C

The BoilerMate A-Class OV SOL incorporates a pump overrun for the boiler pump. If a permanent live is required for the boiler then use L3 which is live whenever the power ON/OFF rocker switch is in the ON position

The boiler manufacturers wiring instructions should be read in conjunction with this manual.

Before switching on the electrical supply check all the factory made terminal connections to ensure they have not become loose during transit.

Frost Protection

When frost protection is required for the whole house or where a base temperature is required during cold weather the central heating channel (2) of the clock should be put in the constant position and the room thermostat adjusted to a suitable setting.

When the location of the boiler means that frost protection is required for the boiler circuit then a frost thermostat and pipe mounted thermostat should be ﬁtted in the normal way and wired back to the special terminal (SL-F) provided in the appliance as shown below.

Page 29

INSTALLATION

Roomthermostat

SL L E N

Factory fitted 2 channel

digital clock (prewired)

Typical external wiring of a BoilerMate A-Class OV SOL

SL_B

L_P

N_P

Boiler WiringTerminals (e.g. Gledhill HE Boiler)

Double pole Isolator Within 2 meters of appliance

Permanent mains supply

230V ~50Hz rated at 6,500W

And fused at 32A

6.0mm Feed Cable

MCB 2

MCB 1

MCB 3

16A

L N

SL-W

SL-B

SL-R

L1L2L3

NNN

SL-F

N-IH

L-IH

SL-H

PE-IH

G/YBlBrBlk G/Y

Br Blk

VAL-N

VL-N/O

VAL-SL

SC Solar Panel Sensor

VAL-PE

SZ Solar Zone Sensor

VL-N/C

This is supplied with 2.5m of 2 x 0.5mm

double insulated cable. If necessary, this

will need extending. It is recommended

that it should be jointed into a 5amp

junction box located in the roof space

adjacent to the solar panel(s).

Factory fitted

Electrical Power/Control Supplies

WARNING: THE BOILERMATE A-CLASS OV SOL IS FITTED WITH AN

ELECTRIC BACKUP SYSTEM ‘SWITCH’.

IMPORTANT: ELECTRICIAN/INSTALLER PLEASE NOTE.

THE 2 x 16A MCB’s (MCB1 and MCB2) FOR THE ‘SWITCH’ ELECTRIC BACKUP SYSTEM ARE SUPPLIED SET IN THE ‘OFF’ POSITION BY AN ADHESIVE WARNING LABEL. MCB3 IS SUPPLIED SET IN THE ‘ON’ POSITION. THE GAS BOILER CAN BE COMMISSIONED WITH THE SWITCHES IN THESE POSITIONS AND MCB1 AND 2 MUST NOT BE SWITCHED ON BEFORE THE GAS BOILER HAS BEEN FULLY TESTED/COMMISSIONED.

AFTER THE GAS BOILER HAS BEEN COMMISSIONED MOVE MCB’S 1 AND 2 TO THE ‘ON’ POSITION WHICH WILL BREAK THE WARNING LABEL AND THEN COMMISSION THE SWITCH FACILITY.

INSTALLATION

Page 30

INSTALLATION

Manual Isolating

Valves

Connection

to BoilerMate OV SOL

heating return pipe

Connection

to BoilerMate OV SOL

heating flow pipe

Connection

to BoilerMate OV SOL

elec terminals

Zone 1

Programmable

room thermostat

Zone 2

Programmable

room thermostat

Zone 1 Flow

Zone 2 Flow

Zone 1 Return

Zone 2 Return

TYPICAL SCHEMATIC ARRANGEMENT OF MULTIZONE HEATING

MCB 2

MCB 1

MCB 3

16A

SL-W

SL-B

SL-R

L1L2L3

NNN

SL-F

N-IH

L-IH

SL-H

PE-IH

4 Core cable

VAL-N

VL-N/O

VAL-SL

SC Solar Panel Sensor

VAL-PE

SZ Solar Zone Sensor

VL-N/C

BOILERMATE MULTI-ZONE

EXTERNAL WIRING DIAGRAM

COM

OFF3ON

TP5000 Programmable room

Thermostat

Zone valve Spring return

with auxiliary switch

Junction Box

3 core 0.75mm²

flex

N E

COM

OFF

L1SLENL

5 Core flex from zone valve

COM

OFF3ON

TP5000 Programmable room

Thermostat

Zone valve Spring return

with auxiliary switch

Junction Box

3 core 0.75mm²

flex

N E

COM

OFF

L1SLENL

5 Core flex from zone valve

Zone 1

Zone 2

Zoned Heating Systems

If a zoned heating system (or a separate towel rail circuit) is required, this can be provided in the conventional way from the main heating ﬂow and return.

In many cases this has been achieved by raising the appliance in the cupboard to create an accessible space which will allow easy maintenance of the necessary zone valves etc.

A typical schematic arrangement for a 2 zone system is shown opposite. Further zones can be added in the same way if required.

Time and temperature control of each zone valve can be achieved by ﬁtting a programmable room thermostat.

A typical wiring arrangement based on the use of a Danfoss TP5000 programmable room thermostat is shown below.

Ho wever other ways of c ontro lli ng t he zones using multi channel clocks and room thermostats can be used if preferred.

When used in this way channel 1 of the digital clock ﬁtted to the front of the BoilerMate A-Class OV SOL can be set as normal to control the hot water but channel 2 must be set to continuous operation mode.

Page 31

INSTALLATION

Domestic Water and Heating Systems

Open the incoming stop valve and fill the domestic mains cold and hot water systems.

Fill the whole of the primary heating system with potable water through the feed and expansion cisterns.

Check the water level in the feed and expansion cisterns and adjust the ballvalve if necessary.

Check the whole of the primary heating and domestic hot and cold distribution system, including the boiler and BoilerMate A-Class OV SOL, for leaks.

It is essential that all systems function properly for optimum performance.

To achieve this, the primary system should be commissioned in accordance with good practice and generally in accordance with the requirements of BS 6798, BS 5449 and BS 7593.

Full details of the requirements for system preparation/water treatment and commissioning are given in the Domestic Heating Compliance Guide.

When using either cleansing or corrosion inhibitor chemical, the manufacturers instructions must be followed.

Although the BoilerMate A-Class OV SOL has no special water treatment requirements because of the nature of materials in these systems, we recommend the use of a cleansing agent as well as a corrosion inhibitor. We generally recommend the use of Fernox products with the BoilerMate A-Class OV SOL appliances.

Model

BMA 215 OV SOL 2.25

BMA 225 OV SOL 2.50

BMA 235 OV SOL 3.00

BMA 245 OV SOL 3.75

BMA 265 OV SOL 4.50

BMA 285 OV SOL 5.25

Model

BMA 215 OV SOL 2.25

BMA 225 OV SOL 2.50

BMA 235 OV SOL 3.00

BMA 245 OV SOL 3.75

BMA 265 OV SOL 4.50

BMA 285 OV SOL 5.25

Minimum volume to be added to the system (packs)

Cleansing agent - Fernox cleaner (F3)

Minimum volume to be added to the system (packs)

Corrosion inhibitor agent - Fernox protector (F1)

Cleansing the Primary System

When determining the quantity of cleanser required, be sure to allow for the increased volume of water in the primary circuit due to the thermal store - see the Technical data section for volumes.

In most cases the quantities shown opposite will be adequate for a typical installation.

Primary Water System Treatment

When determining the quantity of inhibitor required, be sure to allow for the increased volume of water in the primary circuit due to the thermal store - see the Technical data section for volumes.

In most cases the quantities shown opposite will be suitable for a typical installation.

Failure to adequately clean and inhibit the heating system will lead to problems which will not be covered by the appliance warranty.

POW ER FLUSH IN G/ CLEAN IN G O F T HE HEATING SYSTEM

If it is proposed to ‘powerﬂush’ the heating system the BoilerMate appliance must be isolated from the heating system being cleaned. Failure to do this could seriously da mage the applia nce. Ther efore, any damage caused to the appliance during powerﬂushing will not be covered by the appliance warranty.

Note: Do not plug the cold feed/open vent to carry out powerﬂushing as this will also cause serious damage to the appliance.

When carrying out the work always comply fully with the manufacturers instructions for the powerﬂushing equipment being used.

If in any doubt please consult our Technical Helpline.

Note: The above quantities have been based on 500ml pack/100 litres of primary water in accordance with the manufacturers recommendations.

COMMISSIONING

Page 32

INSTALLATION

‘Flashing’ Lockout/Failure

‘Flashing’ Controller working OK

Display 2 Display 1

H1.3

V1.3

V1.4

H1.2

H1.1

V1.1

V1.2

H2.3

V2.3

V2.4

H2.2

H2.1

V2.1

V2.2

Once the system is ﬁnally ﬁlled turn down the servicing valve for the ballvalve in the F & E cistern to the point where the warning/overﬂow will cope with the discharge arising from a ballvalve failure.

Cleansing Hot/Cold Water System Treatment

Fully ﬂush and if necessary chlorinate the hot and cold water system in accordance with the recommendations in the Model Water Byelaws and BS 6700.

Note: Incorrect chlorination will damage the plate heat exchanger so care must be taken that the system is fully ﬂushed. Failure to do this will lead to problems that are not covered by the appliance warranty.

Commissioning the BoilerMate/Primary System

For maximum system efﬁciency the store thermostat must be in control of the boiler i.e. the boiler will operate to suit the demands of the store thermostat and not on its own integral thermostat. Once commissioned, the appliance will operate automatically on its controls.

• The operation of the BoilerMate A-Class OV SOL appliance is controlled by the main appliance control board. The functions can be checked on the display window on the front of the appliance or on the 2 digit display on the appliance control board. The following descriptions generally refer to the 2 digit display but details of the operation of the display window on the front of the appliance are covered on pages 13-14 of these instructions. Either can be used. The demands are shown on display 2 (left hand) and the resultant actions on display 1 (right hand).

• Press in the centre button on the front panel marked ‘Switch’ for 5 seconds. The mode indication on the display panel will change from normal to Switch and will ﬂash. Check that current is being drawn (it should be about 26 amp) with the aid of a clamp meter on the supplies to the element.

• If a suitable meter is not available once the bath full of hot water has been drawn from the appliance the store temperature should be noted. With no further demand a rise in store temperature of 5 - 10°C in about 15 - 20 minutes (dependent on store size) should be observed. Display segment V2.2 will be on whilst ‘Switch’ is working.

• Switch the boiler back on and set channel 1 (HW) of the clock as required.

• A diagram and table showing the function of each LED is shown opposite.

• Set the BoilerMate A-Class OV SOL power switch to on (the dot in the right hand corner of display 2 will ﬂash).

• Set the hot water channel (1) on the digital clock on the front of the appliance to ‘Continuous Operation Mode’. V1.1, H1.1 and H1.2 will be on.

• Set the heating channel (2) on the digital clock to the off position.

• Set the boiler power switch to the on position and the thermostat to maximum (H2.3 and V2.1 will be on).

• Commission the boiler as per the boiler manufacturers instructions, making sure any air is vented from the primary circuit.

• Check that the store sensor reaches its set point (77°C) and switches off the boiler. The primary pump will continue to run for a period of time to ensure the boiler cools down safely and any residual heat is transferred to the BoilerMate A-Class OV SOL (V2.1 will go off but H2.3 will remain on for 3 minutes).

• Check and adjust the speed of the boiler pump to provide a differential temperature of less than 8°C across the primary ﬂow and return (with the heating off).

• Once the boiler/primary circuit is commissioned, the operation of the ‘Switch’ emergency electric back up system can be checked.

• Switch off the boiler.

• Draw a bath full of hot water to lower the store temperature and allow ‘Switch’ to operate.

• Switch on MCB1 and MCB2 which will break the warning label and allow power to be provided to the system.

Note: If both ‘dots’ are flashing the n th e controller is working. However it is a warning of limited/alternative control functionality.

LED Description

H1.1 Middle store sensor calling for heat

H1.2 Bottom store sensor calling for heat

H1.3 Spare

V1.1 Clock (channel 1) calling for heat (HW)

V1.3 Clock (channel 2) calling for heat (CH)

V1.4 Room thermostat calling for heat

H2.1 PHE pump on

H2.2 Heating pump on

H2.3 Boiler system pump on

V2.1 Boiler on

V2.2 Switch on / electric boost on

V2.4 Boiler boost mode on

COMMISSIONING

Page 33

INSTALLATION

Commissioning the Space Heating

• The central heating is best commissioned when the store is hot and therefore should be carried out after commissioning the BoilerMate A-Class OV SOL/Primary system.

• Set channel 2 of the digital clock to continuous operation mode and ensure that the room thermostat is calling for heat. This will be indicated by display segments V1.3 and V1.4 being on respectively. The BoilerMate A-Class OV SOL controller will now turn on the central heating pump and this will be indicated by display segment H2.2 being lit.

• The boiler will switch on to achieve/maintain the temperature in the heating circuit which will be indicated by V2.1 and H2.3 being lit.

• Wait until the heating circuit has reached its normal temperature before balancing the system in the usual way to achieve a temperature drop of about 10°C.

• Set channel 2 of the digital clock and room thermostat as per manufacturer’s instructions supplied and ensure that the digital clock instructions along with the user instructions for the appliance are left with the user.

Commissioning the Domestic Hot Water System

• When the store is fully up to temperature, open a hot water tap nearest to the appliance at approximately 10 litres/minute. After about 2 – 3 seconds, the plate heat exchanger pump will start. This is indicated on the A.C.B. by display segment H2.1.

• The hot water ﬂow temperature should settle at about 52°C. Close this tap and open the hot bath tap at maximum ﬂow rate and record the ﬂow rate and the hot water temperature in the ‘Benchmark’ logbook.

• Close the hot water tap(s) and after few seconds, the plate heat exchanger pump will stop running and display segment H2.1 will turn off.

COMMISSIONING

Page 34

Figure 1.15

Figure 1.16

Flush/drain connection

Fill

connection

Return to tank

Flow from pump

Quarter turn

regulating/

isolating valve

Flush/drain connection

Fill

connection

Return to tank

Flow from pump

Quarter turn

regulating/

isolating valve

INSTALLATION

Filling/Commissioning The Solar System Using A Solar Filling Tank/Pump

• Make sure all solar connections are fully tightened and all electrical connections are sound.

• Make sure the BoilerMate A-Class OV SOL appliance has been commissioned and is working correctly.

• Check the air side of the solar expansion vessel is set to the correct pressure (normally 1bar) and top up if necessary.

• Ensure controller display on the BoilerMate A-Class OV SOL is illuminated and that no error messages are present.

• Close the regulating valve between the ﬁll and drain connections on the ﬁll and ﬂush valve using a ﬂat blade screwdriver.

• Connect the hoses to the connections provided on the ﬁll and ﬂush valve on the top of the appliance ensuring the ﬂow pipe from the pump is connected to the ﬁlling connection (nearest the temperature gauge) and the return pipe is connected to the ﬂush/drain connection.

• Close the quarter turn regulating valve, sited below the ﬁlling tank on the return to the pump.

• Fill the pumping station tank with at least 30 litres of the antifreeze solution1.

• Ensure the switch on the pump is in the OFF position.

• Connect the pump to an available electrical supply. Make sure you use an RCD safety device. (IF THE FILLING PUMP IS IN A POSITION AWAY FROM THE FILL AND FLUSH VALVE, IT MUST BE CONTROLLED VIA AN EXTENSION LEAD AND RCD CIRCUIT BREAKER. THIS IS SO THE POWER TO THE FILLING PUMP CAN BE ISOLATED SAFELY LOCAL TO THE FILLING POINT).

• Open both the quarter turn valve handles on the ﬁll and ﬂush valve fully.

• Fully open the quarter turn isolation valve on the return pipe on the top of the ﬁll tank.

• Slightly open the quarter turn isolation valve on the feed to the pump.

• Slightly loosen the connection on the expansion vessel.

• Turn on the ﬁlling pump - checking all the connections you have made.

• Now wait for the antifreeze solution to slowly vent from the loosened expansion vessel connection, closing the connection when venting is complete.

• Visually inspect all connections you have made for leakage.

• You should see bubbles appearing from the return pipe into the ﬁlling tank from the ﬂush/drain connection point.

• Occasionally you will have to vent air from the system until the antifreeze solution is evident.

• As the bubbles lessen you will need to open the quarter turn valve on the feed to the pump more, but only slightly. This is a continuous process that needs to be done as the bubbling decreases.

• When all bubbles have stopped, (WHICH WILL NORMALLY TAKE OVER AN HOUR) you need to turn off the return isolation tap on the ﬁlling pump and pressure the system to 4 bar (WATCHING THE LEVEL OF FLUID IN YOUR BOTTLE) and adding more antifreeze solution if required.

• When a pressure of 4 bar is achieved close the ﬁlling point on the ﬁll and ﬂush valve at the SAME time switch off the power at the RCD safety device.

• Now leave the system under this pressure for at least 30 minutes. Check the system for leaks, including the roof connections.

• If after 30 minutes the pressure has not dropped and there are no leaks evident,

• Repeat the above operations identiﬁed by the grey background.

• You will now see bubbles in your bottle again (this is because you left the system

• Continue until the bubbles stop. Stop the pump on the ﬁlling tank and open the

• Leave this running for approximately 10 minutes (venting any air as required).

• Re-set the system pressure to the expansion vessel calculation.

• The system is now commissioned and will operate automatically under control of

NB: THE MINIMUM SYSTEM PRESSURE SHOULD BE SET AT NO LESS THAN 1.3 BAR THE EXPANSION VESSEL PRESET PRESSURE SHOULD BE SET AT NO LESS THAN 1.0 BAR.

slowly drop the pressure in the system to 1 bar.

at rest and the air has settled).

regulating point on the ﬁll and ﬂush valve with a screw driver. Set the solar pump on the Gledhill Sol appliance running.

the solar controller ﬁtted to the BoilerMate A-Class OV SOL appliance.

Note: You should only ﬁll the collector when

there is no direct irradiation from the sun (or cover the collectors). You must only use the correct antifreeze for the type of panel/ collector being installed (Premixed FS10 for the ORET evacuated tube collectors and FS10 antifreeze mixed 40% antifreeze/60% water (-24°c) for the IRCP and ORCP ﬂat plate collectors. As it may not be possible to fully empty the panels/collectors once they have been ﬁlled, we would recommend that any collector arrays likely to be exposed to frost should only be ﬁlled with the correct antifreeze at the right strength even for pressure/function tests.

The method of ﬁlling/commissioning the solar system is relevant to the Gledhill Solar Package and is based on the use of ﬁlling tank/pump which is available as an optional extra.

Although the previously described method of ﬁlling is recommended, other methods can be used if required. A connection is provided on the ﬁll and ﬂush valve (opposite the ﬁll connection), to allow a temporary ﬁlling loop to be ﬁtted to allow the system to be repressurised back to system pressure without the need for the ﬁlling tank/pump during subsequent maintenance visits.

COMMISSIONING

Page 35

INSTALLATION

Important Do’s and Don’ts

1. DO check the incoming mains water pressure and ﬂow rate are adequate. (The preferred range of mains pressure is 2-3bar).

DO check that all connections are in accordance with the labelling on the thermal

2. store.

DO adjust the ballvalve so that the water level in the F & E cistern when the system is cold is correct and does not overﬂow when the whole of the system is at maximum temperature.

DO make sure that there is adequate clearance above the F & E cistern to service the ballvalve/meet the Water Regulation Requirements.

DO ensure that any range rated boilers are set at the highest output and the

5. boiler thermostat is set to maximum for all boilers.

6. DO ensure that the bottom of the F & E cistern is at least 250mm above the highest point on the radiator circuit or the highest point of the system.

DO check that the bottom of the F & E cistern is not more than 6m above the base

7. of the BoilerMate appliance.

8. DO insulate any exposed pipework in the BoilerMate A-Class OV SOL cupboard.

9. DO plumb the overﬂow/warning pipe in a 20mm internal diameter pipe material which is suitable for use with a heating F & E cistern, in accordance with BS 5449 (such as copper or H.T. plastic) and ensure that it has a continuous fall and discharges in a conspicuous external position.

Hand over to User

• Explain the system and the BoilerMate A-Class OV SOL appliance controls to the user.

• Explain how to operate the heating and hot water controls to the user. This should include setting ‘on’ and ‘off’ times and the room temperature on the room thermostat as well as the use of thermostatic radiator valves.

• Advise on boiler operation and maintenance advised in the boiler manual.

• Explain how to select and check the operation of the emergency backup electric boiler ‘switch operation’ - if there is a failure of the boiler.

• Handover appliance and room thermostat user instructions and put the completed “Benchmark” logbook and the appliance instruction manual in the pocket on the inside of the appliance front panel.

• DON’ T p lace a ny c lothi ng o r o th er combustible materials against or on top of this appliance.

DO check the pump settings

10. a. The boiler pump should be set to give a temperature difference across the

boiler of 8°C or less.

b. The heating pump should be set to give a temperature difference across the

ﬂow and return of not more than 11°C.

c. The hot water plate heat exchanger pump should be set at maximum.

11. DO ensure that the bypass valve for the heating system (if ﬁtted) is set correctly.

12. DON’T use a combined feed and vent on BoilerMate A-C lass OV SOL

installations.

13. DON’T use a BoilerMate A-Class OV SOL on a sealed primary i.e. closed system.

14. DON’T use pipe smaller than 28mm between the boiler and the BoilerMate A-Class

OV SOL when the boiler rating exceeds about 20kW (about 70,000 Btu/h).

15. DON’T use dipped ﬂow and return between the boiler and the BoilerMate A-Class

OV SOL unless the boiler is ﬁtted with an overheat thermostat. If necessary check with the suppliers of the boiler.

16. DON’T operate the ‘switch’ backup facility until the system is fully ﬁtted, vented

and commissioned.

17. DON’T place any clothing or other combustible materials against or on top of this

appliance.

This product is covered by the ‘Benchmark’ scheme and a separate commissioning/ service log bo ok is incl uded wi th th is product. This must be completed during commissioning and left with the product to meet the Warranty conditions offered by Gledhill.

These Instructions should be placed along with the component manufacturers instructions in the pocket provided on the rear of the front panel. The front panel should then be reﬁtted.

COMMISSIONING

Page 36

Annual Servicing

No annual servicing of the BoilerMate A-Class OV SOL appliance is necessary.

However, if required, the operation of the controls and a hot water performance test can be carried out when servicing the boiler to prove the appliance is working satisfactorily and within its speciﬁcation.

At the same time, a check should be made of the solar system pressure/expansion vessel charge pressure along with a visual check of the solar panels.

It is recommended that after ﬁve years, the concentration/quality of the solar system antifreeze solution is checked and, if necessary, replaced.

Changing Components

Free of charge replacements for any faulty components are available from Gledhill during the in-warranty period (normally 12 months).

After this, spares should be obtained direct from Gledhill using the ‘Speed Spares’ service, or through any of the larger plumbers merchants/specialist heating spares suppliers.

SERVICING

Help and advice is also available from the Technical Helpline on 01253 474401.

However, all components are readily accessible and can be changed quickly and easily by the installer using common plumbing practice.

Note:

The PHE circulating pump is a Grundfos UPR 4 wire type and any replacement must be the same model obtained direct from Gledhill. Failure to do this will affect the hot water performance.

The solar ﬂow / temperature sensor ﬁts in to a wet pocket. DO NOT REMOVE before isolating / safely draining down this part of the solar circuit using the valve provided as part of the ﬁll / ﬂush valve and the solar pump isolating valve.

The solar circulating pump is also a Grundfos UPR 4 wire type produced specially for solar systems and is identiﬁed by the yellow label on the head. Again, any replacement must be the same model obtained direct from Gledhill. Failure to do this will affect the solar performance.

Take care when carrying out any work on the solar circuit as the pipework / solar ﬂuid could be extremely hot.

Page 37

ANNUAL SERVICE / CHANGING COMPONENTS

SERVICING

Key No.

1 PHE pump Grundfos UPR 15-50 (modulating) GT089 All

2 Plate heat exchanger (PHE) SWEP 24 Plate heat exchanger GT017 All

3 PHE pump isolating valve - inlet Vemco GT133 All

4 PHE pump isolating valve - outlet Vemco GT135 All

5 CW inlet Y-line strainer XB314 Al

6 DHW in/out sensor Tasseron GT198 All

7 Central heating pump Grundfos, UPS 15-50 XB004 215, 225, 235

8 Central heating pump isolating valves Vemco, Inlet & Outlet XB121 215, 225, 235

9 Boiler pump Grundfos, UPS 15-50 XB004 215, 225, 235

10 Boiler pump isolating valves Vemco, Inlet & Outlet XB121 215, 225, 235

11 Boiler return zone valves Honeywell 28mm 2 port valve n/o (top) XB165 235 - 285

12 F&E cistern ball valve Vemco FT206 All

13 1 x 6 kW switch immersion heater Wardtec XB468 All

14 Bottom store sensor Tasseron GT198 All

15 Middle store sensor Tasseron GT198 All

16 Top (OHT) store sensor Tasseron GT199 All

17 Main PCB controller Argus Vision XB442 All

18 Front panel digital display membrane R H Technical XB473 All

19 Front panel display wiring harness R H Technical XB057 All

20 Internal fuses/circuit protection MCB Single Pole 6A x 1 XB449 All

21 Switch contactor Telemecanique XB014 All

22 DIN rail terminals Wago NSI All

23 Complete DIN rail assembly Wago XB466 All

24 Complete wiring harness All

25 On-Off rocker switch Arcoelectric CA006 All

26 2 channel digital programmer Grasslin XB218 All

27 Solar pump Grundfos, UPR 15-60 (modulating) All

28 Solar pump inlet valve GT135 All

29 Solar ﬂow/temperature sensor (SR) Grundfos All

30 Solar ﬁll/ﬂush valve assembly Sonnenkraft XB160 All

31 Solar anti gravity check valve Sonnenkraft XB161 All

32 Solar temperature gauge Sonnenkraft XB162 All

33 Solar pressure gauge Sonnenkraft XB163 All

34 Solar store sensor (SZ) Tasseron All

35 Solar collector sensor (SC) Tasseron All

36 Solar control board Argus Vision All

Description Supplier/Components Stock

Code No.

Grundfos, UPS 15-60 XB241 245, 265, 285

Vemco, Inlet & Outlet XB122 245, 265, 285

Grundfos, UPS 15-60 XB241 245, 265, 285

Vemco, Inlet & Outlet XB122 245, 265, 285

Honeywell 28mm 2 port valve n/c (bottom) XG012 235 - 285

Honeywell 22mm 2 port valve n/o (top) XB164 215, 225

Honeywell 22mm 2 port valve n/c (bottom) XG083 215, 225

MCB Single Pole 16A x 2 XB450 All

Models Gas

Council No.

SHORT PARTS LIST

Page 38

SERVICING

1 2 3 4/28 5

6/14/15 7/9 8/10 11 12

13 17 18 19

25 27 29

24232220

Page 39

34/35333231

SHORT PARTS LIST

SERVICING

Fault Finding

Despite everyones best efforts some problems could occur and lead to complaints from the householder.

The main appliance control board has some fault diagnostic ability, particularly in relation to the electrical system/sensors. Details of this are provided on page 13. Other complaints can generally be grouped into the following three main categories:-

1. The system is noisy

2. Hot water service is unsatisfactory

3. Space heating is unsatisfactory

The following checks should be carried out by the installer before calling the manufacturer.

1. Causes of a ‘Noisy’ System

Noisy pump operation Check the level of water in the F & E cistern - adjust and vent the pump/system if necessary. Check the pump speed setting of the boiler pump - reduce if necessary but ensure that the temperature rise across the boiler does not exceed 8°C. Check the pump speed setting of the heating pump - reduce if necessary but ensure a temperature difference across the ﬂow and return does not exceed 11°C.

Check and adjust if necessary the heating system bypass valve. Check that the radiators are correctly balanced.

Noisy boiler operation Check the ﬂow rate through the boiler at full gas rate by measuring the temperature rise across the boiler. If the temperature rise is greater than 8°C, then increase the pump speed.

Check the level of water in the F & E cistern and the working head on the boiler. Check and vent the system if necessary. Check that the ﬁring of the boiler is being controlled by the BoilerMate A-Class OV

SOL appliance and that it is not cycling on its own thermostat.

Noise when hot water tap is opened If the plate heat exchanger pump is noisy when the hot water tap is opened, then check the level of water in the F & E cistern and vent the pump if necessary.

Water hammer - loose pipework and/or tap washers.

3. Causes of ‘Unsatisfactory Space Heating’

Check the boiler thermostat - this should be

set at maximum. Check that the boiler flow temperature is adequate to satisfy the store sensor. Check the operation and th e settings of th e heat ing pr ogram mer an d the r oom thermostat. Check that th e heating system pump is circulating the water to the radiator circuit. If some rooms are not being heated properly, then balance the system/check the operation of the thermostatic radiator valves (if ﬁtted).

Overﬂow from Feed and Expansion Cistern

Check that the controlled level of water in the

cistern is no higher than necessary. Adjust if required.

If problems occur with the solar system, they should be investigated by a suitably qualiﬁed solar installer.

Powerflushing/Cleaning Of The Heating System

If it is proposed to ‘powerflush’ the heating sy ste m we wou ld r eco mme nd t hat the BoilerMate A-Class OV SOL appliance is isolated from the he at ing sys te m being cleane d. Failure to do this could seriously damage the appliance.

When carrying out the work always comply fully with the manufacturers instructions for the powerﬂushing equipment being used.

If in any doubt please consult our Technical Helpline.

2. Causes of ‘Unsatisfactory Hot Water Service’

Check that the BoilerMate is full of water i.e. level of water in the F & E cistern is correct

when system is cold.

Check boiler thermostat - this should be set at maximum. Check that the boiler ﬂow temperature is adequate when it stops ﬁring. Check that the store is charging to at least 77°C. Check that the hot water plate heat exchanger pump stops and starts when the hot

water tap is opened and closed. Check that the space heating and hot water load is not greater than the boiler output and that the BoilerMate A-Class OV SOL model is suitable for the type of dwelling.

If all the above checks are satisfactory then it is possible that the performance of the heat exchanger is impaired by scale. In this case the hot water ﬂow rate will be noticeably less than the cold water ﬂow rate. Replace with a factory exchange unit and re-check hot water performance.

FAULT FINDING

Page 40

Note: If the A.C.B. board is replaced it will need setting to the appliance type - see page 13 for further details.

The system controls/operation should then be checked.

If the problem cannot be resolved the switch emergency electric backup should be switched on and operated in accordance with the instructions on the label ﬁtted to the appliance until the installer/manufacturer can attend.

Whe n r equest i ng a v isit f r o m t he manufacturer the installer must have the completed ‘Benchmark’ commissioning/ service record sheet to hand to enable help to be provided.

Water Savings

TAPS & MIXERS

SHOWERS

Unregulated

25 - 30 l/m

Regulated

10 - 12 l/m

Over

20 l/m

5, 6 or

8 l/m

2 tap

half open

Fitted with regulator

Unregulated

Water Related Costs Can Be Reduced By Good Plumbing Practice

APPENDIX

Vast quantities of water are needlessly run off to waste due to Taps, Mixers and Showers discharging ﬂow rates far in excess of the rates required for them to perform their duties.

The contrasting ﬂow rates shown on this leaﬂet clearly illustrate the savings that can be made whilst still providing a good performance.

British made Aquaﬂow Regulators provide constant ﬂow rates by automatically compensating for supply pressure changes between 1 bar & 10 bars.

To facilitate installation into the wide range of plumbing equipment which is

encountered in the U.K, Four Fixing Options are available:-

4 Fixing Options For Taps & Mixers

1. MK Range - Combined Regulators & Aerator for screwing onto Taps & Mixers with internal or external threads on their noses. Anti Vandal models also available.

2. MR05-T Range - Internal Regulators. Pushfit into Tap or Mixer seats. Produced in three sizes - 12.5mm (BS1010), 12mm & 10mm, Flangeless models also available for Taps with Low Lift washers.

3. MXF Stan da rd Ran ge - S crew on tail

models for Taps & Mixers. Fix onto the tails

before ﬁtting the tap connectors. Available in 3/8", 1/2", 3/4" and 1" BSP.

4. Compression Fitting Range - “In Line” regulators housed in 15mm & 22mm CXC Couplers & Isolating Valves. “ ”UK WFBS listed by the Water Research Centre. Isolation valves available for slotted screwdriver operation or with coloured plastic handles. Now available also in plastic bodied push-ﬁt couplers & valves.

Options For Showers

1. MXF “DW” Range - For ﬁtting behind Fixed Shower Heads or onto Flexible Hoses for Handshowers (preferably onto the inlet end when lightweight hoses are used).

2. Compression Fitting Range. “In Line” regulators as in Option 4 for Taps & Mixers.

Haywood House, 40 New Road, Stourbridge, West Midlands DY8 1PA

Information by courtesy of

TELEPHONE (01384) 442611 FAX: (01384) 442612

AQUAFLOW REGULATORS LTD

APPENDIX A

Page 41

18 l/min

12 l/min

9 l/min

12 l/min

18 l/min

inlet

595mm

18 l/min

12 l/min

9 l/mm

9 l/min

12 l/min

18 l/min

inlet

55mm

595mm

195 mm

90mm

85mm

90mm

(hot)

(cold)

APPENDIX

595mm

2 No 6mm fixing holes

18 l/mm

12 l/mm

9 l/mm

12 l/mm

inlet

55mm

18 l/mm

12 l/mm

9 l/mm

12 l/mm

inlet

165mm

595mm

A (hot)

B (cold)

blank

Manifolds

Manifold type: 1 - Stock Code MIP 050

(one bathroom, one en suite shower room, one cloakroom, one kitchen)

Flow regulator

(litres/minutes)

Terminal ﬁtting Hot water

manifold outlets

Quantity

Cold water

manifold outlets

Quantity

18 Bath tap 1 1

9 Hand basin 3 3

12 Kitchen sink 1 1

9 Toilet cistern None 3

9 Shower 1 1

12 Washing machine 1 1

9 Dishwasher None 1

Total 7 11

Two sets of manifolds are available as an optional extra. Each set comprises a separate hot and cold water manifold. Both are provided with a 22mm inlet connection located centrally. All outlet connections are 15mm compression. The centre to centre dimension of each branch is 55mm.

Manifold type: 2- Stock Code MIP 060

(two bathrooms, one en suite shower room, one cloakroom, one kitchen,

one utility room)

Flow regulator

(litres/minutes)

Terminal ﬁtting Hot water

manifold outlets

Quantity

Cold water

manifold outlets

Quantity

18 Bath tap 2 2

9 Hand basin 4 4

12 Kitchen sink 2 2

9 Toilet cistern None 4

9 Shower 1 1

12 Washing machine 1 1

9 Dishwasher None 1

Total 10 15

The arrangement of each manifold is supplied as shown. This provides the best balance of ﬂows but the ﬂow regulators/duty of each branch can be changed if required as long as a reasonable balance is maintained. If it is necessary to change or clean the ﬂow regulator this can be done without needing to drain the system by closing the valve and removing the screwed cover below the white plastic cover.

The manifolds are designed to be used with plastic pipework and are supplied complete with isolation valves and ﬂow regulators on each branch. They would normally be installed in the same cupboard as the thermal storage appliance (as shown below) but can be installed in another cupboard close to the appliance if required.

APPENDIX B

Page 42

The preferred solution where

Bath Toilet

cistern

Hand basin

Toilet

cistern

Hand basin

Toilet cistern

Mains supply

Shower

Kitchen sink

Kitchen

En-Suite

Bathroom

Check valve NOT REQUIRED unless chemical water treatment is fitted

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

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

Cloak room

Thermal Store

Scale

inhibitor

NOT REQUIRED

Airing

cupboard

See Note 1

space will allow

An optional location where

cupboard space is tight

APPENDIX

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.

The maximum equivalent pipe lengths from the manifold to the terminal ﬁttings can be estimated from the above information and the resistance characteristics of the pipes. The examples presented below are for 15mm copper pipe in table 1 and for plastic pipework in table 2.

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.

Table 1: Maximum equivalent pipe length in 15mm copper

Inlet pressure

(bar)

Maximum equivalent length of pipe (m)

@ 9 l/m @ 12 l/m @ 18 l/m

2.0 25 10 5

2.5 75 30 15

3.0 150 60 30

Table 2: Maximum equivalent pipe length in plastic pipe

Inlet pressure

(bar)

Maximum equivalent length of pipe (m)

@ 9 l/m @ 12 l/m @ 18 l/m

2.0 1.5 15mm : 10 15mm : 4.5

2.5 3.0 15mm : 20 15mm : 9.0

3.0 4.5 15mm : 30 15mm 13.5

22mm : 40

22mm : 80.0

22mm : 120

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 42.

Note: If it is proposed to ﬁt chemical water treatment such as a water softener this should be ﬁtted in this location and the cold water branch in the sink should be branched off the cold water main prior to the treatment device instead of the cold water manifold.

Any other isolating/control valves and backﬂow protec tion devices should be provided as necessar y t o c o mply w it h the W ater Regulations.

Page 43

APPENDIX B

APPENDIX

APPENDIX C

Page 44

Description

Manual handling means any transporting or supporting of a load (including lifting, putting down, pushing, pulling, carrying or moving) by hand or bodily force.

Scope

This assessment will cover the largest Appliance, namely ElectraMate, GulfStream, BoilerMate, SysteMate, PulsaCoil, Accolade and Stainless Lite manufactured by Gledhill.

The maximum weight of the largest product in each range is 98kg and the size is 595 x 595 x 2020 mm high.

Main Hazards

Vision may not be clear due to the size of the products. Adopting an incorrect method of lifting may cause injury, attempting to lift these products will require help from others. (Team lifts)

Control Measures

Manual lifting procedure

The lift, key factors in safe lifting are:

a. Balance b. Position of back c. Positioning of the arms and body d. The hold e. Taking the lead for team lifts

a. Balance - Since balance depends essentially upon the position of the feet,

they should be apart about hip breadth with one foot advanced giving full balance sideways and forward without tension. In taking up this position, lifting is done by bending at the knees instead of the hips and the muscles that are brought into use are those of the thigh and not the back.

b. Position of back - Straight - not necessary vertical. The spine must be

kept rigid, this coupled with a bent knee position, allows the centre line of gravity of the body to be over the weight so reducing strain.

c. Positioning of arms and body - The further arms are away from the side,

the greater the strain on the shoulders, chest and back. Keep elbows close to the body arms should be straight.

d. The hold - Before lifting ensure you have a good hold. Two handles are

provided on Appliance products at the top rear side, these allow one or two persons to have a purposely-designed hold at the top of the appliance to ensure easy lifting at the top of the product. Each appliance is supplied with a pallet, which has been attached to the unit via the packaging. The pallet will also allow for one or two persons to get a good hold.

e. Taking the lead for team lifts- As

more than one person is required for these products ensure that one person is taking the lead. This may be you so ensure that each person that is helping is made aware of the weight and of the items listed within this assessment. Make sure you and any others helping know the route you intend to take that it is clear of any obstructions. Never jerk the load as this will add a little extra force and can cause severe strain to the arms, back and shoulders. If there are steps involved decide on where you will stop and take a rest period. Move smoothly andin unison taking care to look and listen to others helping with the lift. Where possible use a sack truck to move the product over long ﬂat distances, only lift the products when necessary. If in doubt stop and get more help. The unit handles and packaging with the pallet have been designed to ensure that two-four people can assist when lifting up stairs or over longer distance.

Individual capability

Individual capability plays an important part in handling these products. Persons above average build and strength will ﬁnd it easier and should be in good health. Persons below average build and strength may require more rest periods during the handling process. Pregnant women should not carry out this operation. Persons who are not in good health should seek medical advice prior to commencing any lifting or manual handling operation.

Residual risk

Following the guidelines given above will reduce any risk to injury. All persons carrying out this operation must be fully trained and copies of the speciﬁc risk assessment made available for inspection and use in their training process.

Further guidance on Manual Handling can be obtained from the Health and Safety Executive. Manual Handling Operations Regulations 1992.

MANUAL HANDLING OF APPLIANCE PRODUCTS

APPENDIX

Page 45

APPENDIX D

Gledhill (Water Storage) Ltd

AMD. JUNE 2008

CONDITIONS OF SALE & GUARANTEE TERMS

1. Gledhill (Water Storage) Ltd (“We” or “Gledhills”) only do business upon the Conditions which appear below

and no other. Unless we so agree in writing these Conditions shall apply in full to any supply of goods by us to the exclusion of any Conditions or terms sought to be imposed by any purchaser. These Conditions of Sale and Warranty Terms override those which are contained on the Invoice Forms and all Sales are now subject to these Conditions of Sale and Warranty terms only.

2. PRICE Once an order or call off has been accepted the price will be held for three months but if delivery is extended beyond that period at the customer’s request, then we reserve the right to amend the price when necessary.

The company reviews its pricing annually to adjust for changes in our cost base. We reserve the right to alter prices at any time for severe movements in raw materials (mainly copper and steel). If there is to be a change we will give customers at least four weeks notice but anything delivered after that date will be at the revised price. An order may not be cancelled or varied after acceptance without the written consent of the company. Such cancellation or variation shall be subject to such reasonable charges as may be appropriate.

3. SPECIFICATION

The goods are supplied in accordance with the Specifications (if any) submitted to the Purchaser and any additions and alterations shall be the subject of an extra charge. Any goods not so specified shall be in accordance with our printed literature or the literature of any of our component suppliers (subject to any modifications made since publication). If we adopt any changes in construction or design of the goods, or in the specification printed in our literature, the Purchaser shall accept the goods so changed in fulfilment of the order.

4. PAYMENT

The invoice price of goods shall be payable within 30 days of despatch by us of our invoice for the goods or such longer time as may be stated by our quotation or invoice. If we receive payment in full on or before the due date we will allow an appropriate settlement discount except where we have quoted a special net price. If payment is not received in full on or before the due date we shall be entitled in addition to the invoice price to: (i) payment of a sum equal to any increase in the copper price supplement applicable to the particular goods

sold between the date of receipt of order and the date of receipt of payment in full; and

(ii) interest on any part of the invoice price unpaid after the due date at the rate of 3% per annum over the base

rate for the time being of HSBC Bank plc.

5. TIME

We give estimates of delivery dates in good faith and time of delivery is not nor shall be made of the essence of any contract nor shall we be liable for any loss or damage occasioned by delay in delivery.

6. DELIVERY

We deliver free normally by our own vehicles within 25 miles of any of our manufacturing depots. Delivery to any place more than 25 miles from one of our manufacturing depots may be subject to our quoted delivery charges. We reserve the right to make delivery of goods contained in one order by more than one consignment and at different times. Where a period is agreed for delivery and such period is not extended by our Agreement, the Purchaser shall take delivery within that period. If the Purchaser fails to take delivery, we shall be entitled at the Purchaser’s risk and expense to store the goods at the Purchaser’s premises or elsewhere and to demand payment as if they had been despatched. Off loading at point of delivery shall be the responsibility of and be undertaken by the Purchaser.

7. SHORTAGES OR DAMAGE

Goods must be inspected before signature of delivery note and any damage, shortage or discrepancy noted on the delivery note and the goods returned on the same vehicle. The buyer must also give us immediate written notice of the damage, shortage or discrepancy so that we may prompt investigation.

8. RETURN OF GOODS

Goods may not be returned to the Company except by prior written permission of an authorised officer of the Company and such return shall be subject to payment by the Purchaser of handling and re-stocking charges, transport and all other costs incurred by the Company.

9. COMPANY LIABILITY AND GUARANTEE

9.1. Subject to the terms of these Conditions of Sale and Guarantee Terms Gledhills provide Guarantees in respect of specific products as set out in this clause.

9.2. Each Guarantee is strictly conditional upon the following:-

9.2.1. Complaints must be given to us immediately, before any action is taken, as responsibility cannot be accepted if repairs or renewals are attempted on site without our written approval.

9.2.2. The unit has been installed in accordance with our installation and service instructions and all relevant codes of practice and regulations in force at the time of installation.

9.2.3. All necessary inlet controls and safety valves have been fitted correctly.

9.2.4. The unit has only been used for the storage of potable water supplied from the public mains.

9.2.5 Where appropriate the unit has been regularly maintained as detailed in the installation and service instructions

9.2.6. Defects caused by corrosion or scale deposits are not covered by any Guarantee.

9.2.7. Where we agree to rectify any defect we reserve the right to undertake the work on our own premises.

9.3. Guarantees are provided in respect of specified goods supplied by Gledhills as follows:-

(a) Domestic and Commercial Open Vented 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 of the then current list price and any copper price supplement and

delivery charge during the second year after delivery by us and increasing by a further one-tenth on the second and subsequent anniversary of delivery by us.

(b) Domestic Mains Fed Products [Primary Stores]

The copper storage vessel is guaranteed for five years and if it or any integral pipework as part of the storage vessel assembly proves to be defective either in materials or workmanship, we reserve the right to either repair or supply replacements or the closest possible substitute in the case of any obsolete product and will collect and deliver to any address in England, Wales and Scotland (excluding all Scottish Islands). (i) free of all charge during the first year after delivery by us. (ii) thereafter at a charge of one-fifth of the then current list price or any copper price supplement and

delivery charge during the second year after delivery by us increasing by a further one-fifth on the second and subsequent anniversary of delivery by us.

In the case of the GulfStream range of products and the Gledhill boiler range of products, Gledhill guarantees the heat exchanger (boiler) for material and construction faults for two years. THE RESPONSIBILITY FOR THE EXECUTION OF THIS GUARANTEE LIES WITH THE INSTALLER. The guarantee becomes null and void if the appliance is used incorrectly, or in the event of proven negligence or incorrectly implemented repairs OR FAILURE TO CARRY OUT THE RECOMMENDED INSPECTION/ MAINTENANCE. The guarantee also becomes null and void if changes are made to the appliance without our knowledge, or if the serial number on the appliance is removed or made illegible.

The annual service must be carried out by a competent installer in accordance with the advice given by Gledhill and using Gledhill approved parts.

(d) Stainless Steel Unvented Cylinders

Gledhill guarantee the components including controls, valves and electrical parts for two years from the date of purchase. IT SHOULD BE NOTED THAT THE FACTORY FITTED TEMPERATURE AND PRESSURE RELIEF VALVE MUST NOT BE REMOVED OR ALTERED IN ANY WAY OR THE GUARANTEE WILL NOT BE VALID. GLEDHILL WILL NOT BE RESPONSIBLE FOR ANY CONSEQUENTIAL LOSS OR DAMAGE HOWEVER IT IS CAUSED. The guarantee for the stainless steel vessel is for twenty five years if the original unit is returned to us AND PROVIDED THAT: (i) It has been installed as per the Design, Installation

& Servicing Instructions, relevant standards,

regulations and codes of practice. (ii) It has not been modified, other than by Gledhill. (iii) It has not been subjected to wrong or improper

use or left uncared for. (iv) It has only been used for the storage of potable

water. (v) It has not been subjected to frost damage. (vi) The benchmark log book is completed after each

annual service. (vii) The unit has been serviced annually. It should be noted that the guarantee does not cover:

- the effects of scale build up

- any labour charges associated with replacing the

unit or parts. If the stainless steel vessel proves to be defective either in materials or workmanship we reserve the right to either repair or supply replacements or the closest possible substitute in the case of any obsolete product and will collect and deliver to any address in England, Scotland and Wales (excluding all islands): (i)

free of charge during the first year after delivery by us. (ii) thereafter at a charge of one twenty fifth of the

then current list price during the second year

after delivery by us and increasing by a further

one twenty fifth on the second and subsequent

anniversary of delivery by us. ACTION IN THE EVENT OF FAILURE If the stainless steel cylinder develops a leak we will ask for a deposit against the supply of a new one. This will be refunded if the failure is within the terms of the warranty when it has been examined by us.

(e) Solar Panels and ancillary equipment

Gledhill provides a five year warranty for defects in the collectors (except broken glass and collector accessories eg metal edgings). If the collector demonstrably fails to meet one of the requirements of the standard DIN 4757 part 3 we will replace it free of charge based on the date of invoice. We can not be responsible for damage caused by mechanical stress and/or changes caused by weather related influences. The warranty excludes minor surface damage that does not affect performance or malfunction due to improper assembly or installation.

Please note:

- Installation must have been carried out by a

licensed specialized company (heating contractor

or plumber) following the version of installation

instructions in force.

- Gledhill or its representative was given the

opportunity to check complaints on site

immediately after any defect occurred.

- Confirmation exists that the system was

commissioned properly and that the system

was checked and maintenance was performed

annually by a specialised company licensed for

this purpose.

(f) Components of our products other than Storage Vessels and Integral Pipework.

We will either extend to the purchaser the same terms of warranty as we are given by the manufacturer of the component or if the manufacturer does not give any warranty, replace free of charge any component which becomes defective within two years after the date of the delivery by us and is returned to us at the purchaser’s expense but we shall not meet the cost of removal or shipping or return of the component or any other cost charges or damages incurred by the purchaser. If the appliance manufactured by Gledhill incorporates a factory fitted scale inhibitor then during the period

TERMS AND CONDITIONS

Page 46

of three years from the date of delivery Gledhill will replace, free of charge, any plate heat exchanger fitted in the appliance as original equipment in which scale formation occurs that materially reduces the effectiveness of the plate heat exchanger. This guarantee does not extend to any other component installed within the Gledhill appliance or elsewhere in the Purchasers domestic water system.

9.4.

9.4.1. In respect of goods supplied by us and in respect of any installation work carried out by or on our behalf, our entire liability and the purchaser’s sole remedies (subject to the Guarantees) shall be as follows:(a) We accept liability for death or personal injury to the extent that it results from our negligence or that of

our employees

(b) Subject to the other provisions of this clause 9 we accept liability for direct physical damage to tangible

property to the extent that such damage is caused by our negligence or that of our employees, agents or subcontractors.

in contract or in tort including negligence) in respect of any one cause of loss or damage claimed to result from any breach of our obligations hereunder, shall be limited to actual money damages which shall not exceed £20,000 provided that such monetary limit shall not apply to any liability on the part of ourselves referred to in paragraph (a) above

(d) Except as provided in paragraph (a) above but otherwise not withstanding any provision herein contained

in no event shall we be liable for the following loss or damage howsoever caused and even if foreseeable

by us or in our contemplation: (i) economic loss which shall include loss of profits, business revenue, goodwill or anticipated savings (ii) damages in respect of special indirect or consequential loss or damage (other than death, personal

injury and damage to tangible property)

(iii) any claim made against the purchaser by any other party (save as expressly provided in paragraph (b)

above)

(e) Except in respect of our liability referred to in paragraph (a) above no claim may be made or action

brought (whether in contract or in tort including negligence) by the purchaser in respect of any goods

supplied by us more than one year after the date of the invoice for the relevant goods.

(f) Without prejudice to any other term we shall not be liable for any water damage caused directly or

indirectly as a result of any leak or other defect in the goods. We cannot control the conditions of use of

the goods or the time or manner or location in which they will be installed and the purchaser agrees to

be fully responsible for testing and checking all works which include the goods at all relevant times (up

to, including and after commissioning) and for taking all necessary steps to identify any leaks and prevent

any damage being caused thereby.

(g) Nothing in these Conditions shall confer on the purchaser any rights or remedies to which the purchaser

would not otherwise be legally entitled

10. LOSS OR INJURY

Notwithstanding any other provision contained herein the purchaser’s hereby agree to fully indemnify us against any damages losses costs claims or expenses incurred by us in respect of any claim brought against us by any third party for:(a) any loss injury or damage wholly or partly caused by any goods supplied by us or their use. (b) any loss injury or damage wholly or partly caused by the defective installation or substandard workmanship

or materials used in the installation of any goods supplied by us. (c) any loss injury or damage in any way connected with the performance of this contract. (d) any loss resulting from any failure by the purchaser to comply with its obligations under these terms as to

install and/or check works correctly. PROVIDED that this paragraph will not require the purchaser to indemnify us against any liability for our own acts of negligence or those of our employees agents or sub-contractors FURTHER in the case of goods supplied by us which are re-sold and installed by a third party by the purchaser it will be the sole responsibility of the purchaser to test the goods immediately after their installation to ensure that inter alia they are correctly installed and in proper working order free from leaks and are not likely to cause any loss injury or damage to any person or property.

11. VARIATION OF WARRANTY AND EXCLUSION

Should our warranty and exclusion be unacceptable we are prepared to negotiate for variation in their terms but only on the basis of an increase in the price to allow for any additional liability or risk which may result from the variation. Purchasers are advised to insure against any risk or liability which they may incur and which is not covered by our warranty.

12. RISK AND RETENTION OF TITLE

(a) goods supplied by us shall be at the Purchaser’s risk immediately upon delivery to the Purchaser or into

custody on the Purchaser’s behalf or to the Purchaser’s Order. The Purchaser shall effect adequate insurance

of the goods against all risks to the full invoice value of the goods, such insurance to be effective from the time

of delivery until property in the goods shall pass to the Purchaser as hereinafter provided. (b) property in the goods supplied hereunder will pass to the Purchaser when full payment has been made by the

Purchaser to us for :-

(i) the goods of the subject of this contract.

(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.

above.

(i) the Purchaser shall hold the goods in a fiduciary capacity for us and shall store the same separately from

any other goods in the Purchaser’s possession and in a manner which enables them to be identified as our goods.

(ii) the Purchaser shall immediately return the goods to us should our authorised representative so request.

All the necessary incidents associated with a fiduciary relationship shall apply.

(d) the Purchaser’s right to possess the goods shall cease forthwith upon the happening of any of the following

events, namely :-

(i) if the Purchaser fails to make payment in full for the goods within the time stipulated in clause 4 hereof.

(ii) if the Purchaser, not being a company, commits any act of bankruptcy, makes a proposal to his or her

creditors for a compromise or does anything which would entitle a petition for a Bankruptcy Order to be presented.

(iii) if the Purchaser, being a company, does anything or fails to do anything which would entitle an

administrator or an administrative receiver or a receiver to take possession of any assets or which would entitle any person to present a petition for winding up or to apply for an administration order.

(e) the Purchaser hereby grants to us an irrevocable licence to enter at any time any vehicle or premises owned

or occupied by the Purchaser or in the possession of the Purchaser for the purposes of repossessing and

recovering any such goods the property in which has remained in us under paragraph (2) above. We shall not be responsible for and the Purchaser will indemnify us against liability in respect of damage caused to any vehicle or premises in such repossession and removal being damaged which it was not reasonably practicable to avoid.

(f) notwithstanding paragraph (3) hereof and subject to

paragraph (7) hereof, the Purchaser shall be permitted to sell the goods to third parties in the normal course of business. In this respect the Purchaser shall act in the capacity of our commission agent and the proceeds of such sale :(i) shall be held in trust for us in a manner which

enables such proceeds to be identified as such, and :

(ii) shall not be mixed with other monies nor paid into

an overdrawn bank account. We, as principal, shall remunerate the Purchaser as commission agent a commission depending upon the surplus which the Purchaser can obtain over and above the sum, stipulated in this contract of supply which will satisfy us.

(g) in the event that the Purchaser shall sell any of the

goods pursuant to clause (6) hereof, the Purchaser shall forthwith inform us in writing of such sale and of the identity and address of the third party to whom the goods have been sold.

(h) if, before property in the goods passes to the

Purchaser under paragraph (2) above the goods are or become affixed to any land or building owned by the Purchaser it is hereby agreed and declared that such affixation shall not have the effect of passing property in the goods to the Purchaser. Furthermore if, before property in the goods shall pass to the Purchaser under paragraph (2) hereof, the goods are or become affixed to any land or building (whether or not owned by the Purchaser), the Purchaser shall:(i)

ensure that the goods are capable of being removed

without material injury to such land or building. (ii) take all necessary steps to prevent title to the

goods from passing to the landlord of such land

or building. (iii) forthwith inform us in writing of such affixation

and of the address of the land or building

concerned. The Purchaser warrants to repair and make good any damage caused by the affixation of the goods to or their removal from any land or building and to indemnify us against all loss damage or liability we may incur or sustain as a result of affixation or removal. (i) in the event that, before property in the goods

has passed to the Purchaser under paragraph (2)

hereof, the goods or any of them are lost, stolen,

damaged or destroyed :(ii) the Purchaser shall forthwith inform us in writing

of the fact and circumstances of such loss, theft,

damage or destruction. (iii) the Purchaser shall assign to us the benefit of any

insurance claim in respect of the goods so lost,

stolen, damaged or destroyed.

13. NON-PAYMENT

If the Purchaser shall fail to make full payment for the goods supplied hereunder within the time stipulated in clause 4 hereof or be in default of payment for any other reason then, without prejudice to any of our other rights hereunder, we shall be entitled to stop all deliveries of goods and materials to the Purchaser, including deliveries or further deliveries of goods under this contract. In addition we shall be entitled to terminate all outstanding orders.

14. VALUE ADDED TAX

All prices quoted are exclusive of Value Added Tax which will be charged at the rate ruling at the date of despatch of invoice.

15. TRADE SALES ONLY

We are only prepared to deal with those who are not consumers within the terms of the Unfair Contract Terms Act 1977, the Sale of Goods Act 1979 and the Supply of Goods and Services Act 1982. Accordingly any person who purchases from us shall be deemed to have represented that he is not a consumer by so purchasing.

16. JURISDICTION

The agreement is subject to English law for products delivered in England and Scottish law for products delivered in Scotland and any dispute hereunder shall be settled in accordance therewith dependent upon the location.

Page 47

TERMS AND CONDITIONS

The code of practice for the installation,

commissioning & servicing of central heating systems

gledhill BoilerMate A-Class OV SOL Series, BMA 215 OV-SOL, BMA 225 OV-SOL, BMA 235 OV-SOL, BMA 285 OV-SOL Design, Installation & Servicing Instructions

Specifications and Main Features

Frequently Asked Questions

User Manual