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gledhill BMA 120 SP Design, Installation And Servicing Instructions

Boilermate a class sp
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BOILERMATE A CLASS SP
DESIGN, INSTALLATION AND
SERVICING INSTRUCTIONS
Gas Council Approved Reference Numbers
AN SEALED CENTRAL HEATING
89-317-14 / BMA 120 SP
AND MAINS PRESSURE HOT WATER SUPPLY
89-317-15 / BMA 140 SP
SYSTEM INCORPORATING
89-317-16 / BMA 180 SP
A THERMAL STORE
89-317-17 / BMA 200 SP
ALL MODELS COMPLY WITH THE
89-317-18 / BMA 220 SP
WATER HEATER MANUFACTURERS
SPECIFICATION FOR INTEGRATED
THERMAL STORES
TEL: 0800 14 55 55 7
www.gledhill-boilermate.co.uk

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  • Page 1 BOILERMATE A CLASS SP DESIGN, INSTALLATION AND SERVICING INSTRUCTIONS Gas Council Approved Reference Numbers AN SEALED CENTRAL HEATING 89-317-14 / BMA 120 SP AND MAINS PRESSURE HOT WATER SUPPLY 89-317-15 / BMA 140 SP SYSTEM INCORPORATING 89-317-16 / BMA 180 SP...

  • Page 2: Table Of Contents

    Patents Pending Gledhill fully supports the Benchmark aims to improve the standards of installation The Gledhill Group’s fi rst priority is to give a and commissioning of central heating systems in the UK and to encourage the regular high quality service to our customers.

  • Page 3: Design

    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.
  • Page 4 However, this will need to be fi tted by the installer at a suitable point in the cold water supply to the appliance. Gledhill are part of the ‘Benchmark’ scheme and a separate commissioning/service log book is included with the product.

  • Page 5: Technical Data

    1.0 DESIGN 1.2 TECHNICAL DATA Model BMA 120 SP BMA 140 SP BMA 180 SP BMA 200 SP BMA 220 SP Weight (empty) 49.4 kg 51.8 kg 54.2 kg 56.5 kg 60.8 kg Weight (full) 174.4 kg 191.3 kg 201.2 kg 220.5 kg...

  • Page 6: Issue 6

    1.0 DESIGN 1.2 TECHNICAL DATA Standard Equipment The standard confi guration of the BoilerMate 12 (F & E Tank A-Class SP is shown opposite. The Appliance Control Board (A.C.B.), mounted inside the not shown appliance, controls the operation of the complete system.
  • Page 7 1.0 DESIGN 1.2 TECHNICAL DATA APPLIANCE DIMENSIONS MODEL Height Width Depth BMA 120 SP 960mm 530mm 595mm BMA 140 SP 1000mm 530mm 595mm BMA 180 SP 1040mm 530mm 595mm BMA 200 SP 1145mm 530mm 595mm BMA 220 SP 1300mm 530mm...
  • Page 8 1.0 DESIGN 1.2 TECHNICAL DATA Cut out area in base All dimensions in mm - to centre line of pipework The BoilerMate A-Class units are supplied on an installation base to allow the pipe runs to connect to the appliance from any direction. It is easier if all pipes protrude vertically in the cut out area shown.
  • Page 9 1.0 DESIGN 1.2 TECHNICAL DATA GRUNDFOS 15/50 GRUNDFOS 15/60 PERFORMANCE GRAPHS OF GRUNDFOS PUMPS Page 9...
  • Page 10 1.0 DESIGN 1.2 TECHNICAL DATA Push button Appliance Control Board The appliance control board (shown opposite) has a 2 digit display and 2 push buttons which Ext_led_k Tank_middle ID_resistor are used to check the status of the appliance, Ext_se_1 PC Connector T_overh_2 T_overh_1 check and set its identity and interrogate it for...
  • Page 11 1.0 DESIGN 1.2 TECHNICAL DATA Sensor Tempature Readings Details of the various sensors S1-S6 used in the BoilerMate A-Class are shown opposite. The sensor reference i.e. S1 and the actual temperature at that sensor fl ash alternately on the display when selected. Sensors used in BoilerMate A-Class Sensor Sensor...
  • Page 12 If you encounter a situation where the water pressure is adequate but fl ow rates are Gledhill. poor please contact our technical helpline for details of an effective solution. The hot water fl ow rate from the BoilerMate Note: Each BoilerMate A-Class is fi...

  • Page 13: System Details

    fl ow/ important in any mains pressure system, that the piping in a dwelling should be pressure outlets please discuss with the Gledhill sized in accordance with BS 6700. This is particularly important in a large property technical department.
  • Page 14 1.0 DESIGN 1.3 SYSTEM DETAILS Remote F&E 3 port divertor valve Cistern Cold feed Open Vent Automatic bypass valve Hot Out A-Class Mains Cold In Heating Circuit Summer use towel Expansion Vessel rail blanked connection Optional Components fitted sealed system Pressure Gauge/Filling Loop within appliance case Boiler...
  • Page 15 Cistern necessary. Allowance for Domestic Hot Water Model (kW) BMA 120 SP BMA 140 SP BMA 180 SP BMA 200 SP BMA 220 SP BoilerMate A-Class SP Boiler Sited Below BoilerMate A-Class SP...
  • Page 16 1.0 DESIGN 1.3 SYSTEM DETAILS Expansion Heating System Vessel Pressure gauge Filling loop Boiler sited above the BoilerMate or with Pressure relief (safety) valve dipped fl ow and return pipes Boiler An automatic air vent will be required on the Remote flow adjacent to the boiler and depending F &...
  • Page 17 1.0 DESIGN 1.3 SYSTEM DETAILS Heating System Method of connecting two BoilerMates to one heat source If the primary fl ow and return pipework continuously rises from the boiler to the BoilerMate the recommended method for connecting two BoilerMates to one heat source is to fi...
  • Page 18 1.0 DESIGN 1.3 SYSTEM DETAILS Heating System Expansion Vessel Requirements The BoilerMate expansion vessel is pre-charged to 1.0 bar. The maximum water content of the heating system (boiler + radiators + connecting pipework + primary coil but NOT store volume) must not be greater than those shown in the table below. A fi...

  • Page 19: Installation

    1.0 DESIGN 1.3 SYSTEM DETAILS ‘Switch’ The BoilerMate A-Class SP is supplied with ‘Switch’ which provides a 6kW electrical emergency back up in the case of failure of the main heat source i.e. gas boiler. This must NOT be used to provide hot water only in summer if the main system is working correctly.

  • Page 20: Site Requirements

    2.0 INSTALLATION 2.1 SITE REQUIREMENTS An electrical supply must be available which is The appliance is designed to be installed in an airing/cylinder cupboard and the correctly earthed, polarized and in accordance relevant minimum dimensions are provided in section 1.2 Technical Data. with the latest edition of the IEE requirements for electrical Installations BS 7671.

  • Page 21: Installation

    2.0 INSTALLATION 2.2 INSTALLATION Preparation/placing the appliance in position. Details of the recommended positions for termination of the first fix pipework are provided in section 1.2 Technical Data. The pipework can be located or its position checked using the template provided with each appliance.
  • Page 22 ISSUE No : 5a DATE : MAY 2007 IS RESERVED. IT IS NOT TO BE REPRODUCED COPIED OR DISCLOSED TO A THIRD PARTY EITHER WHOLLY OR IN PART WITHOUT OUR APPROVED WRITTEN CONSENT. © GLEDHILL WATER STORAGE LTD. Page 22...
  • Page 23 0.5 mm Tri Rated Pump * All wire sizes 0.5mm² Tri-Rated cable unless otherwise stated TITLE JOB NAME GLEDHILL WATER STORAGE LTD. Electrical Schematic for BOILERMATE 'A' class SP BOILERMATE 'A' Class SP SYCAMORE TRADING ESTATE with Clock (Factory Standard)
  • Page 24 2.0 INSTALLATION 2.2 INSTALLATION Pipework connections The position of the pipework connections is shown opposite. The connection sizes and dimensions are listed in Section 1.2 Technical Data. All the connections are also labelled on the appliance. It is essential that the pipework is connected to the correct connection.
  • Page 25 2.0 INSTALLATION 2.2 INSTALLATION It is normally envisaged that the feed and expansion cistern will be located in the same cupboard as the BoilerMate appliance itself to maintain a dry roof space. The cold feed/open vent pipework assembly (as supplied) is all that is required if it is intended to install the F &...
  • Page 26 2.0 INSTALLATION 2.2 INSTALLATION Electrical Connection - Standard Appliance The BoilerMate A-Class SP 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.
  • Page 27 .............. 230VAC s uppl y Rated at 6.5kW Installer connection terminals within the 32 Amp type B Gledhill ‘A’ Class BoilerMate Appliance Circuit Breaker ROOM THERMOSTAT FROST THERMOSTAT PIPE THERMOSTAT Temperature setting range: 3 to 20 °C Set to 5 °C...
  • Page 28 BoilerMate Wiring Terminals SL L Room ther mostat Double pole Boiler Wiring Terminals Isolator (e.g. Gledhill HE Boiler) Within 2 meters of appliance Permanent mains supply 230V ~50Hz rated at 6,500W And fused at 32A 6.0mm Feed Cable Typical external wiring of a standard BoilerMate with ‘Switch’...
  • Page 29 2.0 INSTALLATION 2.2 INSTALLATION Zoned heating systems BoilerMate is available in a no clock/multi-zone version for use where a property has to have its space heating zoned. Where this appliance version is to be used it is recommended that the BoilerMate is located on a raised platform in the cupboard creating a space below the appliance to locate the zoning equipment.
  • Page 30 2.0 INSTALLATION 2.2 INSTALLATION ID_RESISTOR Page 30...

  • Page 31: Commissioning

    2.0 INSTALLATION 2.3 COMMISSIONING POWERFLUSHING/CLEANING OF THE HEATING Open the incoming stop valve and fill the domestic mains cold and hot water SYSTEM systems. If it is proposed to ‘powerfl ush’ the heating Check and adjust as necessary the expansion vessel air pressure to the fi gure specifi ed system we would recommend that the (normally 1.0 bar).
  • Page 32 2.0 INSTALLATION 2.3 COMMISSIONING performance of the installed boiler. However Once the system is fi nally fi lled turn down the servicing valve for the ballvalve the operation of the control system should be in the F & E cistern, if fi tted, to the point where the warning/overfl ow will cope checked as follows: with the discharge arising from a ballvalve failure.
  • Page 33 Warranty conditions offered This will be indicated by display segments V1.3 and V1.4 being on respectively. The by Gledhill. BoilerMate controller will now:- These Instructions should be placed along with •...
  • Page 34 2.0 INSTALLATION 2.3 COMMISSIONING Important Do’s and Don’ts DO check the incoming mains water pressure and fl ow rate are adequate. (The preferred range of mains pressure is 2-3bar). DO check that all plumbing and electrical connections are in accordance with the labelling on the thermal store.

  • Page 35: Servicing

    Gledhill during the in-warranty period (normally 12 months). After this, spares can be obtained direct from Gledhill using the ‘Speed Spares’ service, or through any of the larger plumbers merchants/ specialist heating spares suppliers. Help and advice is also available from the Technical Helpline on 08449 310000.

  • Page 36: Short Parts List

    3.0 SERVICING 3.3 SHORTS PART LIST Description Supplier/Components Stock Code Models Gas Council PHE pump Grundfos UPR 15-50 (modulating) GT089 Plate heat exchanger (PHE) SWEP 24 Plate heat exchanger GT017 PHE pump isolating valve - inlet Martin Orgee GT133 PHE pump isolating valve - outlet Martin Orgee GT135 CW inlet Y-line strainer...

  • Page 37: Fault Finding

    3.0 SERVICING 3.4 FAULT FINDING Despite everyones best efforts some problems could occur and lead to complaints 3. Causes of ‘Unsatisfactory Space Heating’ from the householder. Check the boiler thermostat - this should be Complaints can be grouped into the following three main categories:- set at maximum.

  • Page 38: Appendix A

    APPENDIX A WATER SAVINGS WATER RELATED COSTS CAN BE REDUCED BY GOOD PLUMBING PRACTICE. TAPS & MIXERS 2 TAP 5, 6 OR HALF OPEN OVER 8 L/M 20 L/M Unregulated Fitted with regulator SHOWERS 4 FIXING OPTIONS FOR TAPS & MIXERS 1.

  • Page 39: Appendix B

    APPENDIX B MANIFOLDS Manifold type: 1 - Stock Code MIP 050 Two sets of manifolds are available as an (one bathroom, one en suite shower room, one cloakroom, one kitchen) optional extra. Each set comprises a separate Flow regulator Terminal fi tting Hot water Cold water hot and cold water manifold.
  • Page 40 APPENDIX B The pressure loss through a flow regulator at the designated fl ow rate is about 1.8 bar. Therefore for the fl ow regulator to control the fl ow rate at pre-set level, the inlet pressure must be greater than 1.8 bar. If the inlet pressure is lower, the fl...
  • Page 41 APPENDIX B 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. This is only meant to show the principles involved and the actual connection of fi...

  • Page 42: Appendix C

    APPENDIX C G U I D A N C E N O T E S Inhibitor (Corrosion & scale protection of primary heating circuit) On filling the heating system and before the boiler is fired up, it is important to ensure the system water is treated with a suitable corrosion inhibitor, in accordance with the boiler manufacturer’s instructions.

  • Page 43: Appendix D

    BoilerMate, SysteMate, PulsaCoil, Accolade and Stainless Lite manufactured by you intend to take that it is clear of Gledhill. any obstructions. Never jerk the load as this will add a little extra force and...

  • Page 44: Terms & Conditions

    Page 44...
  • Page 45 Page 45...
  • Page 46 Sales, Service & Repair BoilerMate A Class SP C/O Hot Water Cylinders Limited 302 Foxhunter Drive Milton Keynes MK14 6GD TEL: 0800 14 55 55 7 www.gledhill-boilermate.co.uk...

This manual is also suitable for:

Bma 180 spBma 140 spBma 200 spBma 220 sp

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