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Benchmark BoilerMate BMA 125 OV Design, Installation And Servicing Instructions

A-class, an open vented central heating and mains pressure hot water supply system incorporating a thermal store
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A - C L A S S
BoilerMate OV
DESIGN, INSTALLATION AND
SERVICING INSTRUCTIONS
Gas Council Approved Reference Numbers
89-317-09 / BMA 125 OV
89-317-10 / BMA 145 OV
89-317-11 / BMA 185 OV
89-317-12 / BMA 215 OV
89-317-13 / BMA 225 OV
benchmark
TM
AN OPEN VENTED CENTRAL HEATING
The code of practice for the installation,
AND MAINS PRESSURE HOT WATER SUPPLY
commissioning & servicing of central heating systems
SYSTEM INCORPORATING
A THERMAL STORE
ALL MODELS COMPLY WITH THE
WATER HEATER MANUFACTURERS
SPECIFICATION FOR INTEGRATED THERMAL
STORES

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Summary of Contents for Benchmark BoilerMate BMA 125 OV

  • Page 1 89-317-10 / BMA 145 OV 89-317-11 / BMA 185 OV 89-317-12 / BMA 215 OV 89-317-13 / BMA 225 OV benchmark AN OPEN VENTED CENTRAL HEATING The code of practice for the installation, AND MAINS PRESSURE HOT WATER SUPPLY commissioning & servicing of central heating systems...

  • Page 2: Table Of Contents

    Specifi cation for integrated thermal storage products. The principle was developed in With the introduction of a self certifi cation scheme, the Benchmark Logbook is conjunction with British Gas. This product being replaced by a similar document in the form of a commissioning check list is manufactured under an ISO 9001:2000 and a service interval record is included with all gas appliance manuals.

  • Page 3: Design

    1.0 DESIGN 1.1 INTRODUCTION These instructions should be read in conjunction with the Installation and Servicing Instructions issued by the manufacturers of the heat source e.g. the boiler used. Any water distribution and central heating installation must comply with the relevant recommendations of the current version of the Regulations and British Standards listed below:- Gas Safety Regulations Building Regulations...
  • Page 4 fl ow rates without the need for temperature and pressure relief safety valves or expansion vessels. This is achieved by passing the mains water Gledhill are part of the ‘Benchmark’ scheme and through a plate heat exchanger. The outlet temperature of the domestic hot water is a separate commissioning/service log book is maintained by a printed circuit board (A.C.B.), which controls the speed of the pump...

  • Page 5: Technical Data

    1.0 DESIGN 1.2 TECHNICAL DATA Model BMA 125 OV BMA 145 OV BMA 185 OV BMA 215 OV BMA 225 OV Weight (empty) Weight (full) DHW Pump Grundfos UPR 15/50 Grundfos UPR 15/50 Grundfos UPR 15/50 Grundfos UPR 15/50 Grundfos UPR 15/50 Heating Pump Grundfos UPS 15/50 Grundfos UPS 15/50...

  • Page 6: Issue 8

    1.0 DESIGN 1.2 TECHNICAL DATA Standard Equipment The standard confi guration of the BoilerMate A-Class OV is shown opposite. The Appliance Control Board (A.C.B.), mounted inside the appliance, controls the operation of the complete system. The A.C.B. is pre-wired to a terminal strip where all electrical connections terminate.
  • Page 7 1.0 DESIGN 1.2 TECHNICAL DATA APPLIANCE DIMENSIONS MODEL Height Width Depth BMA 125 OV 960mm 530mm 595mm BMA 145 OV 1000mm 530mm 595mm BMA 185 OV 1040mm 530mm 595mm BMA 215 OV 1145mm 530mm 595mm BMA 225 OV 1300mm 530mm 595mm Note: The Appliance dimensions above do not allow for the100mm high installation base...
  • 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 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_1 T_overh_2 check and set its identity and interrogate it for...
  • Page 10 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 11: System Details

    1.0 DESIGN 1.3 SYSTEM DETAILS To comply with this requirement the hardness Hot and Cold Water System of the mains water should be checked by the installer and if necessary the optional factory General fi tted in-line scale inhibitor should be specifi ed at the time of order for hardness levels between A schematic layout of the hot and cold water services in a typical small dwelling is 200 and 300 ppm (mg/l).
  • Page 12 1.0 DESIGN 1.3 SYSTEM DETAILS Hot and Cold Water System Pipe Sizing / Materials However, if it is proposed to use a ‘whole body’ To achieve even distribution of the available supply of hot and cold water, it is or similar shower with a number of high 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.
  • Page 13 1.0 DESIGN 1.3 SYSTEM DETAILS Heating System General A schematic layout of the heating system in a typical small dwelling is shown opposite. The flow and return from the boiler must always run directly to the BoilerMate A-Class and the flow should rise continuously to facilitate venting.
  • Page 14 1.0 DESIGN 1.3 SYSTEM DETAILS Heating System It is also essential that if an alternative pipework Pipe Sizing/Materials material/system is chosen the manufacturer confirms that the design criteria of the new The primary pipework connecting the boiler and the thermal store should be sized system is at least equivalent to the use of BS/EN to achieve a maximum of 8°C rise across the boiler or the maximum temperature Standard copper pipework and fi...
  • Page 15 1.0 DESIGN 1.3 SYSTEM DETAILS Heating System Boiler sited above the BoilerMate Any boiler used must be fi tted with an overheat thermostat i.e. it must be suitable for use in a sealed system. The F & E cistern must be fi tted at a height which will provide the minimum head required for the boiler and must be at least 250mm above the highest point of the system.
  • Page 16 1.0 DESIGN 1.3 SYSTEM DETAILS Heating System Connection of Bathroom Radiator/ Towel-Rail for Summer use If a pumped circuit is required for the bathroom radiator/towel rail, the fl ow pipework can be teed anywhere into the primary fl ow between the boiler and the BoilerMate.
  • 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 ‘Switch’ The BoilerMate A-Class 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 19: Installation

    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 20: 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 21 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 22 2.0 INSTALLATION 2.2 INSTALLATION Central Heating WIRE COLOUR LEGEND SENSOR LEGEND S1 & S2 Store overheat sensors Blue Cold Water IN Brown Domestic Hot Water OUT Black Bottom store sensor Middle store sensor Orange 1K5 Resistor (White) Yellow ID_RESISTOR White Green / Yellow Grey GRASSLIN CLOCK...
  • Page 23 2.0 INSTALLATION 2.2 INSTALLATION FRONT PANEL S1 & S2 White Covering Flat Ribbon Cable Red LED Push Button 'MODE' Switch Green Neon Illuminated ON / OFF Switch SCALE INHIBITOR Rocker Switch terminal conections (1) Connection only used if Modulating Pump is fitted ('SWITCH' ON / OFF) (Heating SL-H) (Boiler ON / OFF)
  • Page 24 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) should be used if it is intended to install the F &...
  • Page 25 2.0 INSTALLATION 2.2 INSTALLATION Electrical Connection - Standard Appliance The BoilerMate A-Class OV 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 26 2.0 INSTALLATION 2.2 INSTALLATION The BoilerMate A-Class incorporates a pump overrun for the boiler pump and terminal L2 on the terminal strip (as shown on page 23) should only be used if the boiler requires a permanent live for another purpose. The boiler manufacturers wiring instructions should be read in conjunction with this manual.
  • Page 27 2.0 INSTALLATION 2.2 INSTALLATION WARNING Electrical Power Supplies - BoilerMate : THE BOILERMATE A-CLASS IS FITTED WITH AN ELECTRIC A-Class with Switch. 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’...
  • Page 28 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 29 2.0 INSTALLATION 2.2 INSTALLATION Multi-Zone Wiring Diagram Page 29...

  • Page 30: Commissioning

    2.0 INSTALLATION 2.3 COMMISSIONING Open the incoming stop valve and fill the domestic mains cold and hot water When using either cleansing or corrosion systems. inhibitor chemical, the manufacturers instructions must be followed. Fill the whole of the primary heating system with potable water through the feed and expansion cistern.
  • Page 31 2.0 INSTALLATION 2.3 COMMISSIONING (a) Check that the BoilerMate front panel mode Once the system is fi nally fi lled turn down the servicing valve for the ballvalve rocker is in the ‘normal’ position. Put the hot in the F & E cistern to the point where the warning/overfl ow will cope with the water control rocker in the constant position discharge arising from a ballvalve failure.
  • Page 32 (e) Handover appliance and room thermostat user instructions and put the completed discharges in a conspicuous external position. “Benchmark” logbook and the appliance instruction manual in the pocket on the inside of the appliance front panel. 10. DO check the pump settings (f ) DON’T place any clothing or other combustible materials against or on top of this...
  • Page 33 2.0 INSTALLATION 2.3 COMMISSIONING 10. DO ensure that the bypass valve for the heating system (if fi tted) is set correctly. 11. DON’T use a combined feed and vent on BoilerMate installations. 12. DON’T use a BoilerMate on a sealed primary i.e.

  • Page 34: Servicing

    3.0 SERVICING 3.1 ANNUAL SERVICING No annual servicing of the BoilerMate A-Class 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 specifi...

  • Page 35: Short Parts List

    3.0 SERVICING 3.3 SPARE PARTS 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 Vemco GT133 PHE pump isolating valve - outlet Vemco GT135 CW inlet Y-line strainer...

  • Page 36: Fault Finding

    Wh e n re q u e s t i n g a v i s i t f ro m t h e and re-check hot water performance. manufacturer the installer must have the completed ‘Benchmark’ commissioning/ service record sheet to hand to enable help to be provided.

  • Page 37: 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 Fitted with regulator Unregulated SHOWERS 4 FIXING OPTIONS FOR TAPS & MIXERS 1.

  • Page 38: Appendix B

    APPENDIX B MANIFOLDS Two sets of manifolds are available as an Manifold type: 1 - Stock Code MIP 050 optional extra. Each set comprises a separate (one bathroom, one en suite shower room, one cloakroom, one kitchen) hot and cold water manifold. Both are Flow regulator Terminal fi...
  • Page 39 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 40 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 41: Appendix C

    The levels of water hardness may be measured using a water hardness test kit. BUILDING REGULATIONS Completion of the BENCHMARK log book requires that the ‘competent person’ undertaking the installation and commissioning provide information relating to Cleaning, Inhibitor and Scale Protection.

  • Page 42: Appendix D

    APPENDIX D MANUAL HANDLING OF APPLIANCE PRODUCTS e. Taking the lead for team lifts- As Description more than one person is required for these products ensure that one Manual handling means any transporting or supporting of a load (including lifting, person is taking the lead.

  • Page 43: Terms & Conditions

    (vi) The benchmark log book is completed after each sold between the date of receipt of order and the date of receipt of payment in full; and annual service.
  • Page 44 of three years from the date of delivery Gledhill will replace, free of charge, any plate heat exchanger fitted in recovering any such goods the property in which the appliance as original equipment in which scale formation occurs that materially reduces the effectiveness has remained in us under paragraph (2) above.

This manual is also suitable for:

Boilermate ov seriesBoilermate bma 185 ovBoilermate bma 145 ovBoilermate bma 215 ovBoilermate bma 225 ov

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