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

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

S6

Figure 1.1

S5

S1/2

Boiler

S4

S3

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

SZ

Figure 1.2

Expansion

vessel

PRV

Solar Panel

SC

Mounted horizontally

on top of the appliance

Temp. Gauge

Check Valve

Fill and
flush valves

0

20 100

120

40 80

60

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

15

21

31

30

39

1

2

3

4

6

5

14

12

24
7

20

19

18

17

10

16

35

8

22

23

9

33

13
38
11

37

29
28
26

25

27

32

35

36

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

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

35

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

B

E

C

BoilerMate A-Class

OV SOL

300 **350A100 *350

D

F

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

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

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

45

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

85

Connection Details/Dimensions - 245 model

Figure 1.6

55

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.

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 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

Qs

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

SC

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

SZ

- 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

Q

F

Sp

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

Press S2

Press S2

Press S2

Press S2

S2 S1

Press

S1

Press

S1

Press

S1

Press

S1

Appliance

type

Press

S1

Press

S1

Press

S1

Press

S1

Fault code indicator

block outs

Press

S1

Press

S1

Press

S1

Press

S1

Fault code indicator

lock outs

Press

S1

Press

S1

Press

S1

Press

S1

Control set-point

reading

Press

S1

Press

S1

Press

S1

Press

S1

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

SV

a a a a

Bath

H C

Hand basin

H C

WC - fitted

with BS1212

ballvalve

C

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)

a

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.

The Building Regulations L1A: New dwellings/L1B: Existing dwellings and the
requirements set out in the Domestic Heating Compliance Guide specify that “where
the mains water hardness exceeds 200ppm provision should be made to treat the
feed water to water heaters and the hot water circuit of combination boilers to reduce
the rate of accumulation of lime scale”.

To comply with this requirement the hardness
of the mains water should be checked by the
installer and if necessary the optional factory
fitted in-line scale inhibitor should be specified
at the time of order for hardness levels between
200 and 300 ppm (mg/l).

Where the water is very hard ie 300ppm (mg/l)
and above the optional polyphosphate type,
inhibitor should be specified at the time of
order. However, this will need to be fitted by
the installer at a suitable point in the cold water
supply to the appliance.

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