Benchmark BoilerMate BMA 125 OV User guide

DESIGN,INSTALLATION AND
SERVICING INSTRUCTIONS
AN OPENVENTED CENTRAL HEATING
AND MAINS PRESSURE HOTWATER SUPPLY
SYSTEM INCORPORATING
ATHERMAL STORE
ALL MODELS COMPLYWITHTHE
WATER HEATER MANUFACTURERS
SPECIFICATION FOR INTEGRATEDTHERMAL
STORES
TM
benchmark
The code of practice for the installation,
commissioning & servicing of central heating systems
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
BoilerMate OV
A - C L A S S
ISSUE 8:06-08

Page 2
CONTENTS
Section Page
1.0 DESIGN
1.1 Introduction 3
1.2 Technical Data 5
1.3 SystemDetails 11
2.0 INSTALLATION
2.1 SiteRequirements 19
2.2 Installation 20
2.3 Commissioning 30
3.0 SERVICING
3.1 Annual Servicing 34
3.2 Changing Components 34
3.3 Short Parts List 35
3.4 Fault Finding 36
Appendix A 37
Appendix B 38
Appendix C 41
Appendix D 42
Terms & Conditions 43
The Gledhill BoilerMate range is a WBS
listed product and complies with theWMA
Specificationforintegratedthermal 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
TheGledhillGroup’sfirstpriorityistogivea
high quality service to our customers.
Quality is built into every Gledhill product
and we hope you get satisfactory service
from Gledhill.
If not please let us know.
ISSUE 8:06-08
TM
benchmark
The code of practice for the installation,
commissioning & servicing of central heating systems
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.
Similararrangements willfollowfor Scotlandand willapply in Northern Ireland
from 1st January 06.
CORGI operates a Self Certification Scheme for gas heating appliances.
Thesearrangementsrepresentachangefromthesituationwherebycompliance
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
beingreplacedbyasimilar documentinthe formofacommissioningcheck list
andaserviceintervalrecordisincludedwithallgasappliancemanuals. However,
therelevantBenchmarkLogbookisstillbeingincludedwithallThermalStorage
products and unvented cylinders.
GledhillfullysupportstheBenchmarkaimstoimprovethestandardsofinstallation
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
themanufacturer’sinstructions. Itisthereforeimportantthatthecommissioning
checklistiscompletedbythecompetentinstaller. Thischecklistonlyappliesto
installations in dwellings or some related structures.

Page 3
BOILERMATE A-CLASS OV
1.0 DESIGN
1.1 INTRODUCTION
These instructions should be read in
conjunctionwiththeInstallationandServicingInstructionsissuedbythe
manufacturers of the heat source e.g. the boiler used.
Anywaterdistributionandcentralheatinginstallationmustcomplywith
the relevant recommendations of the current version of the Regulations
and British Standards listed below:-
Gas Safety Regulations
Building Regulations
I.E.E. Requirements for Electrical Installations
Water Regulations
British Standards
BS6798, BS5449, BS5546, BS5440:1, BS5440:2, CP331:3, BS6700, BS5258,
BS7593 and BS7671.
AsuitablycompetentpersonasstatedintheGasSafetyRegulationsmust
installtheBoilerMateandcarryoutanysubsequentmaintenance/repairs.
Infactthefrontpanelissecuredby2screwsandshouldonlyberemoved
by a competent trades person. The manufacturer’s notes must not be
taken as overriding statutory obligations.
TheBoilerMateA-Classisonlysuitableforusewithanopenventedcentral
heating system.
TheBoilerMateA-ClassisnotcoveredbysectionG3ofthecurrentBuilding
Regulations and is therefore not notifiable to Building Control.
The BoilerMate A-Class OV is not intended for use by persons (including
children) with reduced physical,sensory or mental capabilities,or lack of
experience or knowledge, unless they have been given supervision or
instruction concerning use of the appliance by a person responsible for
their safety.
Children should be supervised to ensure that they do not play with the
appliance.
Theinformationinthismanualisprovidedtoassistgenerallyintheselection
ofequipment. Theresponsibilityfortheselectionandspecificationofthe
equipmentmusthoweverremainthatofthecustomerandanyDesigners
or Consultants concerned with the design and installation.
PleaseNote: Wedonotthereforeacceptanyresponsibilityformattersof
design,selectionorspecificationorfortheeffectivenessofaninstallation
containingoneofourproductsunlesswehavebeenspecificallyrequested
to do so.
AllgoodsaresoldsubjecttoourConditionsofSale,whicharesetout
at the rear of this manual.
In the interest of continuously improving the BoilerMate range, Gledhill
WaterStorageLtdreservetherighttomodifytheproductwithoutnotice,
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 4
TheBoilerMateA-ClassOVshownschematicallyaboveisdesignedtoprovideimproved
space heating and mains pressure hot water when coupled to any remotely sited
condensing or non condensing boiler.
The principle of a BoilerMate A-Class 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.
Because this product does not require a safety discharge from a temperature and
pressurereliefvalve,anyinstallationswill be easyto incorporateintothebuildingand
will not suffer from the problems associated with using PVCu soil stacks to take the
dischargefromunventedcylinders.
An important feature of this concept is that hot water can be supplied directly from
themainsatconventionalflowrateswithouttheneedfortemperatureandpressure
reliefsafetyvalves orexpansion vessels. Thisis achievedby passingthe mains water
throughaplateheatexchanger. Theoutlettemperatureofthedomestichotwateris
maintainedbyaprintedcircuitboard(A.C.B.),whichcontrolsthespeedofthepump
circulating the primary water from the store through the plate heat exchanger.
The Building Regulations L1A: New dwellings/L1B: Existing dwellings and the
requirementssetoutintheDomesticHeatingComplianceGuidespecifythat“where
the mains water hardness exceeds 200ppm provision should be made to treat the
feedwatertowaterheatersandthehotwatercircuitofcombinationboilerstoreduce
the rate of accumulation of lime scale”.
Tocomplywiththisrequirementthehardnessofthemainswatershouldbechecked
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).
Wherethewaterisveryhardie300ppm(mg/l)andabovethe optionalpolyphosphate
type,inhibitorshould be specifiedatthe timeoforder. However,thiswill needtobe
1.0 DESIGN
Description
1.1 INTRODUCTION
2EMOTE
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fitted by the installer at a suitable point in the
cold water supply to the appliance.
Ifscaleshouldeverbecomeaproblemtheplate
heat exchanger is easily isolated and quickly
replacedwithaserviceexchangeunitwhichcan
be obtained at a nominal cost from Gledhill.
The A.C.B. 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.
Anyautomaticboilerdesignedtooperateonan
820Cflowanda710Creturnuptoa maximum
of35kWcanbelinkedtoanysuitablemodelof
BoilerMateA-Classandthedecidingfactoristhe
spaceheatingandthe hotwaterrequirements
of a dwelling. See Section 1.2 Technical Data
for further details.
TheBoilerMateA-ClassOVissuppliedcomplete
with‘Switch’whichwillprovidea6kWelectrical
emergencybackupincaseoffailureofthemain
heatsource. Seesection1.3 SystemDetails for
further information.
Theheatlossesfromthermalstoresshouldnot
be directly compared with heat losses from
unventedorventedcylindersbecausetheyare
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.
Gledhillarepartofthe‘Benchmark’schemeand
a separate commissioning/service log book is
included with the product.
A15mmconnectionisprovidedontheprimary
return on all units to allow for the provision
of a pumped summer use towel rail circuit if
required (see page 16 for further details)
Note
The BoilerMate OV 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
BOILERMATE A-CLASS OV
1.2TECHNICAL DATA
Notes:-
1. TheBoilerMate225applianceissuitableforuseinlargepropertiesbecauseitproducesthesame‘peakhouroutput’asatypical350-
400litre unventedcylinder. For properties requiringtheBMA 225the incomingmain shouldbe aminimum of 32mmMDPE with
apressureof not lessthan 2bar dynamicand anadequate flowin linewith thepipe sizingcalculations. In manycases,properties
of this size will benefit from having 2 smaller sized appliances located adjacent to the areas of peak hot water use. This will allow
2 heating zones to be provided and remove the need to provide trace heating on the hot water system.
2. A plastic feed and expansion cistern will be supplied separately including ballvalve,float and overflow fitting.
3. Theflowratesarebasedona35°Ctemperatureriseandassumenormalpressureandadequateflowtotheappliance.Theactual
flow rate from the appliance is automatically regulated to a maximum of 28 litres/min.
4. Unit is supplied on a 100mm high installation base.
5. Thedomestichotwateroutlettemperatureisautomaticallyregulatedtoapproximately52°Catthebathflowrateof18litres/min
recommended by BS 6700. The temperature is not user adjustable.
1.0 DESIGN
Model BMA 125 OV BMA 145 OV BMA 185 OV BMA 215 OV BMA 225 OV
Weight (empty) 45 47 50 51 56
Weight (full) 177 187 197 215 244
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 Grundfos UPS 15/50 Grundfos UPS 15/60 Grundfos UPS 15/60
Boiler Pump Grundfos UPR 15/50 Grundfos UPR 15/50 Grundfos UPR 15/50 Grundfos UPR 15/60 Grundfos UPR 15/60
Primary/heating
pipe connections 22mm 22mm 22mm 28mm 28mm
MCW & DHW pipe
connections 22mm 22mm 22mm 22mm 22mm
Cold feed/expansion
connection 22mm 22mm 22mm 22mm 22mm
Safety open vent
connection 22mm 22mm 22mm 22mm 22mm
Primary return
(for summer use
bathroom towel rail)
15mm 15mm 15mm 15mm 15mm
Maximum summer
towel rail load 0.15kW 0.75kW 1.00kW 1.25 kW 1.5 kW
Drain connection R ½” R ½” R ½” R ½” R ½”
Maximum Head 6 meters 6 meters 6 meters 6 meters 6 meters
Hot water flow rate
(l/m) up to 35 35 35 35 35
Max heating system
size 12 kW 17 kW 20 kW 25 kW 30 kW
‘Switch’ 6 kW 6 kW 6 kW 6 kW 6 kW
Typical DwellingTypes
Bedrooms 1-3 2-3 2-4 3-5 4-6
Bathrooms 1 1 2 1 2 1 2
En-suite shower 1 2 1 4 2 4 3

Page 6
1.2TECHNICAL DATA
Standard Equipment
The standard configuration 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. It is supplied with the following
factory fitted equipment:-
1. Boiler pump
2. Domestic hot water primary (plate
heat exchanger) pump - modulating
3. Space heating pump
4. Appliance control board (A.C.B.)
5. Electro-mechanicalclockforhotwaterand
space heating time control.
6. Plate heat exchanger
7. DHW temperature sensor
8. Cold water inlet sensor
9. Store temperature sensors
10. Overheat sensor
11. Y type strainer/flow regulator
12. A feed and expansion cistern complete
with ballvalve,overflow fitting and cold
feed/open vent pipework assembly is
supplied separately.
13. ‘Switch’elements (2 x 3 kW)
Optional Equipment
* Asevendaydigitalclock/programmer
to control the space heating (in
conjunction with a room thermostat)
* A no clock/multi-zone option.
* Hotandcoldwatermanifoldsforuse
with plastic pipework.
* Modulatingtype(UPR)pumpforthe
space heating circuit.
* Electronicscaleinhibitorformainswater
services
with hardness levels above
200ppm(mg/l) - fitted in the appliance.
* Polyphosphate scale and corrosion
inhibitor for mains water services with
hardness levels above 300 ppm (mg/l)
for fitting on site by the installer.
1.0 DESIGN
Electro-mechanical clock
programmer
Digital clock programmer
1
2
3
45
6
7
8
9
10
11
13

Page 7
BOILERMATE A-CLASS OV
1.0 DESIGN
1.2TECHNICAL DATA
Note: The Appliance dimensions above do not allow for
the100mm high installation base
The following table of minimum cupboard dimensions only
allowtheminimumspacerequiredfortheappliance(including
the F & E cistern) and any extra space required for shelving etc
in the case of airing cupboards etc must be added.
Note: The above dimensions are based on the Appliance and
the F & E cistern being in the same cupboard.
IfaMulti-Zoneapplianceisusedan additional 150mmmust
be added to the above heights to accomodate the space
required for the zone equipment.
APPLIANCE DIMENSIONS
MODEL Height Width Depth
ABC
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
MINIMUM CUPBOARD DIMENSIONS
MODEL Height Width Depth
DEF
BMA 125 OV 1710mm 630mm 600mm
BMA 145 OV 1750mm 630mm 600mm
BMA 185 OV 1790mm 630mm 600mm
BMA 215 OV 1895mm 630mm 600mm
BMA 225 OV 2050mm 630mm 600mm
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Page 8
1.0 DESIGN
1.2 TECHNICAL DATA
65
65
95 185
BOILER RETURN 475
BOILER FLOW
COLD FEED
DOMESTIC HOT WATER
CENTRAL HEATING FLOW 560
TOWEL RAIL RETURN 560
CENTRAL HEATING RETURN
560
550
220
155
220
120
55
145
205
22
15
OPEN VENT
530
COLD FEED
All dimensions in mm - to centre line of pipework
The BoilerMate A-Class units are supplied on an installation base to allow the pipe runs to
connect to the appliance from any direction. It is easier if all pipes protrude vertically in the
cut out area shown. Compression or push fit connections can be used. All pipe positions
are approximate and subject to a tolerance of +/-20mm in any direction. A 15mm cold
water supply and a 22mm warning/overflow pipe will also be required for the separate
feed and expansion tank.
C
L
Cut out area
in base

Page 9
BOILERMATE A-CLASS OV
1.2 TECHNICAL DATA
Appliance Control Board
Theappliance controlboard (shownopposite)
hasa 2 digit displayand 2 pushbuttons which
are used to check the status of the appliance,
check and set its identity and interrogate it for
the current faults and the fault history.
The2digitdisplayiscontrolledby2buttonsS1
andS2Theflowchartofdisplaymodesisshown
below. Generally,eachpressofbuttonS2cycles
thedisplayfrom toptobottom and eachpress
of button S1 cycles the display functions from
left to right.
ThebuttonS2isalsousedtoresettheappliance
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
Inthestandard/normalmodethe2digitdisplay
indicates the status of the appliance inputs
and outputs by switching on the appropriate
segments of the display - see page 29 for
details.
ApplianceType 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
thecontroller/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
resistorvaluesfortheBoilerMateare01and1K5
respectively. The procedure for checking and
setting the appliance code on the controller is
described below.
•Theapplianceselectionmenu(A0...A9)onthe
controllerishidden.It is onlypossible togetto
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
notreleasethebuttonbutholditfor10seconds.
Thedisplaywillchangefrom‘c’to‘A’.Atthisstage
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.
Pressthe resetbutton, S2,toacceptthesetting.
If the selected appliance code does not match
withtheIDresistorfittedtotheappliance,then,
an error‘33’will be displayed.
Tank_middle
16
8
9
1
T_overh_2
T_dhw_in
ID_resistor
T_overh_1
Tank_bot
T_dhw_out
Push button
Ext_led_k
Ext_se_1 PC Connector
Reset
button Enter
button
Main processor
FLIP jumper
J9 J31
J30
SEND_TO_GAS
VSS
GASV_IN
220_0
WD_RECEIVE
VSS
SAFETY
220_1
J29
DIV_OUT_2
220-0
DIV_OUT_1
220_0
EL_HEAT_OUT
BOIL_HEAT_DEM
OVERHEAT
220_0
BOIL_HEAT_DEM
CH_P_MOD
CH_P_L CH_P_L
CH_P_PE
BOIL_P_PE
BOILER_P_MOD
BOIL_P_L BOIL_P_N
DHW_P_PE
DHW_P_MOD
DHW_P_L DHW_P_N
220_1
220_PE
220_0
220_PE
220_1
220_0
CH_ON_IN
220_0
220_1
SWL_IN
DHW_ON_IN
220_INPUT
J3
J33
J32
J34
J28
J5
S2 S1
APPLIANCE CONTROL BOARD
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3 3 3 3
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0RESS3 0RESS3 0RESS3 0RESS3
0RESS3 0RESS3 0RESS3 0RESS3
0RESS3 0RESS3 0RESS3 0RESS3
0RESS3 0RESS3 0RESS3 0RESS3
0RESS3 0RESS3 0RESS3 0RESS3
0RESS3
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1.0 DESIGN

Page 10
1.2 TECHNICAL DATA
1.0 DESIGN
SensorTempature 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
temperatureatthatsensorflashalternatelyon
the display when selected.
Control Set Points
The sensor control set points are shown
opposite. PLEASE NOTE THAT THE DISPLAY
S1 - S6 IS NOT THE SAME AS THE SENSOR
REFERENCE.
Fault Codes
Fault code locations are numbered C0 - CF
andc0 - cF.
CO/cOlocationshold thelatestfault recorded.
A code of FF indicates that the fault location
is empty.
If a sensor is faulty instead of a temperature
it will show E1 if open circuit and E2 if short
circuit.
Sensors used in BoilerMate A-Class
Sensor Sensor Connector J9 pins Location
S1 T Overheat 1 6 & 14 Top of store in dry pocket (S1 & S2 are in single housing)
S2 T Overheat 2 2 & 10
S3 T DHW in 3 & 11 In cold water inlet pipe (Wet i.e.direct)
S4 T DHW out 4 & 12 In hot water outlet pipe (Wet i.e.direct)
S5 TTank bottom 5 & 13 Bottom of store in dry pocket for store charging
S6 TTank middle 1 & 9 Middle of store in dry pocket for store charging
Sensor Control Set Points
Display Sensor Temp
S1 Middle store sensor on 68
S2 Middle store sensor off 77
S3 DHW in 35
S4 DHW out 55
S5 Bottom store sensor on 60
S6 Bottom store sensor off 70
Common Fault Codes
Code Code
10 Overheat error 45 S1 overheat 1 shorted
30 Phase error 48 I.D.resistor shorted
33 Appliance selection 49 S4 sensor shorted
37 S1 overheat 1 open 50 S5 sensor shorted
40 I.D.resistor open 51 S6 sensor shorted
41 S4 sensor open 52 S2 overheat 2 shorted
42 S5 sensor open
43 S6 sensor open
44 S2 overheat 2 open
Any other code displayed should be checked against the full chart

Page 11
BOILERMATE A-CLASS OV
1.3 SYSTEM DETAILS
Hot and ColdWater System
General
A schematic layout of the hot and cold water services in a typical small dwelling is
shownbelow. BoilerMateA-Class willoperateat mainspressuresas low as1 barand
ashighas5baralthoughtherecommendedrangeis2-3bar. Thesepressuresarethe
minimumdynamicpressuresat thecoldconnectiontothe BoilerMateA-Classat the
timeofthemaximumcalculatedsimultaneousdemand. Ifthemanifolds(availableas
anoptionalextra)arebeingusedtheinletpressuretothemanifoldmustbeaminimum
of 2 bar. Particular consideration should also be given to available pressures in the
caseof3storeyproperties. Itisalsoimportanttocheckthatallotherequipmentand
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.
Ifyou encounterasituation where thewater pressure isadequate but flowratesare
poor please contact our technical helpline for details of an effective solution.
Note: EachBoilerMate A-Classis fittedwitha strainerand flowregulatoronthe cold
mainssupply connection. Ifthe supply pressureis less than 2 bar orif 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.
Nocheck valveor similar deviceshould be fittedon the coldwater supplybranch to
the BoilerMate A-Class.
The Building Regulations L1A: New dwellings/L1B: Existing dwellings and the
requirementssetoutintheDomesticHeatingComplianceGuidespecifythat“where
themainswaterhardnessexceeds200ppmprovisionshouldbemadetotreatthefeed
watertowaterheatersandthehotwatercircuitofcombinationboilerstoreducethe
rate of accumulation of lime scale”.
1.0 DESIGN
To complywith this requirementthe hardness
of the mains water should be checked by the
installer and if necessary the optional factory
fittedin-linescaleinhibitorshouldbespecified
atthetimeoforderforhardnesslevelsbetween
200 and 300 ppm (mg/l).
Wherethewaterisveryhardie300ppm(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
theinstalleratasuitablepointinthecoldwater
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
A-Class is directly related to the adequacy
of the cold water supply to the dwelling.
This must be capable of providing for those
services,whichcouldberequiredtobesupplied
simultaneously, and this maximum demand
shouldbecalculatedusingproceduresdefined
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.
Pressure limiting valve NOT
REQUIRED at pressures
below 5 bar unless any
components have a lower
maximum working
pressure.
Second
dwelling
M.C.W.S
supply pipe.
Sink
Open vent
Warning/overflow
pipe
Cold feed/
expansion
Hand
basin
WC - fitted
with BS1212
ballvalve
Bath
BM A-Class
Optional
polyphosphate
scale inhibitor - NOT
REQUIRED
unless the hardness
level exceeds
300ppm (mg/l)
Shower.
H
a a a
a
a a a
C H C H C C
S.V.
Check valve NOT REQUIRED unless
chemical water treatment unit is fitted.
'a' - flow regulator recommended for better
balance of hot and cold water supplies.
Double check valve NOT REQUIRED unless supply
pipe services more than one dwelling.
Typical hot and cold water distribution
F&E Cistern
Cold mains
supply

Page 12
1.3 SYSTEM DETAILS
Hot and ColdWater 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
1bathroomdwelling(dependingupontheflowrateavailable),buttheminimum
recommendedsize fornew dwellingsis 22mm(25mm MDPE). Forthe BMA225
model we recommend a 28mm (32mm MDPE) supply pipe.
2. The internal cold feed from the main incoming stop tap to the BoilerMate
should be run in 22mm pipe. The cold main and hot draw-off should also
be run in 22mm as far as the branch to the bath tap.
3. The 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.
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
particularlyrelevantwherethewaterpressuresareabovetherecommended
waterpressurerangeof2-3bar,orthedwellingis3storey. Detailsofsuitable
flow regulators are provided in Appendix A.
Note: Ifmanifolds (availableasanoptional extra) are being usedsuitable 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,wearehappythatplasticpipeworksystemscanbeusedinplaceofcopper
internally as long as the chosen system is recommended for use on domestic hot
and cold water systems by the manufacturer and is installed fully in accordance
with their recommendations.
It is also essential that if an alternative pipework material/system is chosen the
manufacturerconfirmsthatthedesigncriteriaofthenewsystemisatleastequivalent
to the use of BS/EN Standard copper pipework and fittings.
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
dynamicchangesparticularlywhenotherhotandcoldtaps/showersareopened
and closed,which will cause changes in the water temperature at mixed water
outlets such as showers. For this reason and because these are now no more
expensivethanamanualshowerwestronglyrecommendtheuseofthermostatic
showers with this appliance. These must be used in 3 storey properties where
the impact on pressure/temperature of opening another tap in the system is
greater than normal.
The shower head provided must also be suitable for mains pressure supplies.
1.0 DESIGN
However,ifitisproposedtousea‘wholebody’
or similar shower with a number of high flow/
pressureoutletspleasediscusswiththeGledhill
technical department.
Thehotwatersupplytoashower-mixingvalve
shouldbe fed whereverpracticaldirectly from
the BoilerMate A-Class 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 back-syphonage
protection in accordance with the Water
Regulations.
Thesupplyofhotandcoldmainswaterdirectly
toabidetispermittedprovidedthatitisofthe
over-rim flushing type and that a type ‘A’ air
gap is incorporated.
Hot and ColdWater System.
If the length of the hot water draw off
pipework is excessive the delivery time may
be unacceptable before hot water is available
atthetap,youmaywishtoconsiderusingtrace
heatingtothe hotwater pipeworksuchas the
RaychemHWATsystem. PleaseconsultGledhill
Technical Department for further details.
It is important that the cold water pipework
is adequately separated/protected from any
heating/hot water pipework to ensure that
the water remains cold and of drinking water
quality.

Page 13
BOILERMATE A-CLASS OV
1.0 DESIGN
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. The heating circuit is taken
fromtheBoilerMateA-Classandispipedinthe
conventional manner.
The BoilerMate A-Class is only suitable for an
open vented system.
The F & E cistern can be fitted remotely up to
6 m above the base of the BoilerMate A-Class
i.e. the maximum static pressure in the store
must not exceed 0.6 bar.
If any radiators are located above the level
of the BoilerMate A-Class 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
recommendedthatacheckvalve,orvalves,are
fitted on the vertical flowpipes.
ThewaterlevelintheF&Ecisternshouldbe
at least 250mm above the highest point on
thesystemincludingtheradiatorsandmust
be high enough to provide the minimum
head required by the boiler being used.
1.3 SYSTEM DETAILS
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.
Itisnotnecessarytoprovideaboilerbypasson
theprimarycircuit (i.e.betweentheboilerand
the thermal store.)
2EMOTE
&%TANK
&ULLBOREAUTOMATICBYPASSVALVE./42%15)2%$
UNLESSTHEHEATINGSYSTEMINCORPORATES
MECHANICALTHERMOSTATICCONTROLVALVESEG
426gSTOALLRADIATORSORPORTZONEVALVES
0RIMARYFLOW
0RIMARY
RETURN
"-
!#LASS
"OILER
7ARNINGOVERFLOW
PIPE
#OLDFEED
-AINSCOLD
WATER
/PEN6ENT

Page 14
1.0 DESIGN
1.3 SYSTEM DETAILS
Pipe Sizing/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
risespecified bythe boiler manufacturer,whicheveris smaller,but inanyinstance it
should not be less than 22mm copper tube.
Note: There should be no valves in the pipework connecting the boiler to the
BoilerMate A-Class.
Theheatingcircuitoperatesonthenormalprimaryboilertemperaturesi.e.82°Cflow
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.
Alltherecommendationswithregardtopipeworksystemsinthismanualaregenerally
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
copperinternallyaslongasthechosensystemisrecommendedforuseondomestic
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.
Heating System
Itisalsoessentialthatifanalternativepipework
material/system is chosen the manufacturer
confirms that the design criteria of the new
systemisatleastequivalenttotheuseofBS/EN
Standard copper pipework and fittings.
Boiler Size
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.
Boiler Sited Below BoilerMate A-Class
Any temperature controlled boiler can be
used when the flow pipe from the boiler to the
BoilerMateA-Class rises continuously. No valve
shall be fitted in the primary flow or open vent.
&%#ISTERN
&%#ISTERN
0RIMARYFLOW
0RIMARYFLOW
0RIMARYRETURN
0RIMARYRETURN
"-!#LASS
"-!#LASS
"OILER
"OILER
Allowance for
domestic hot water
Model (kw)
BM125 3
BM145 3
BM185 4
BM210 5
BM225 6

Page 15
BOILERMATE A-CLASS OV
1.0 DESIGN
1.3 SYSTEM DETAILS
Anyboilerusedmustbefittedwithanoverheat
thermostat i.e. it must be suitable for use in
a sealed system.
The F & E cistern must be fitted at a height
whichwillprovidetheminimumheadrequired
for the boiler and must be at least 250mm
above the highest point of the system.
TheheightofthewaterlevelintheF&Ecistern
fromthebaseofthestoreshouldbenogreater
than 6m.
A gravity check valve should be fitted in the
boiler return pipework to prevent gravity
circulationbetweentheBoilerMateA-Classand
the boiler during dormant periods.
An automatic air vent will be required on the
flow adjacent to the boiler and depending
uponthepipelayoutamanualairventmayalso
berequiredonthereturnadjacenttotheboiler
- see boiler installation insructions.
Boiler sited with dipped flow and return
pipes to the BoilerMate
Any boiler must be fitted with an overheat
thermostat i.e.it must be approved for use in
a sealed system.
An automatic air vent will be required on the
flow and return connections adjacent to the
boiler.
TheheightofthewaterlevelintheF&Ecistern
must provide the minimum head required by
the boiler and must be at least 250mm above
the highest point of the system.
Boiler sited above the BoilerMate
Heating System
&%#ISTERN
&%#ISTERN
0RIMARYFLOW
0RIMARYFLOW
0RIMARYRETURN
0RIMARYRETURN
"OILER
"OILER
!6
#6
!6!UTOMATICAIRVENT
#6'RAVITYCHECKVALVE
"-!#LASS
"-!#LASS
&%#ISTERN
&%#ISTERN
0RIMARYFLOW
0RIMARYFLOW
0RIMARYRETURN
0RIMARYRETURN
"-!#LASS
"-!#LASS
"OILER
"OILER
!6 !6
!6!UTOMATICAIRVENT

Page 16
1.0 DESIGN
1.3 SYSTEM DETAILS
Connection of Bathroom Radiator/
Towel-Rail for Summer use
Ifapumpedcircuitisrequiredforthebathroom
radiator/towel rail, the flow pipework can be
teedanywhereinto theprimary flowbetween
the boiler and the BoilerMate. The return
pipework can be connected into the 15mm
copperblankedconnectionprovidedadjacent
to the boiler pump. We recommend any
radiators/towelrailsonthiscircuitareprovided
withT.R.V.’sandthatthetotalheatoutputofthe
radiators/towelrailsisnotmorethanthefigure
quoted in the table on page 5.
The radiators will only get hot when the
boiler is firing.
Itisimportantthattheflowratesthroughthese
radiatorsis adjusted tothe minimumrequired
atthelockshield valvesontheradiators. Ifthis
isnotdonetheperformanceoftheBoilerMate
will be adversely affected.
TheheightofthewaterlevelintheF&Ecistern
must provide the minimum head required by
the boiler and must be at least 250mm higher
than the highest point of the system.
Alternatively, if full time control is required
of the Summer/Towel rail circuits these can
be piped as a separate zone from the main
heating circuit with their own zone valve and
programmable room thermostat as shown
in Section 2.2 Installation, Zoned Heating
Systems.
Heating System
&%#ISTERN
"-!#LASS
"OILER
2ADIATOR

Page 17
BOILERMATE A-CLASS OV
1.3 SYSTEM DETAILS
Heating System
Method of connecting two BoilerMates to one heat source.
If the primary flow and return pipework continuously rises from the boiler to the
BoilerMate the recommended method for connecting two BoilerMates to one heat
source is to fit the BoilerMates as normal but to provide a single check valve on the
branch immediately after each primary pump - see diagram below.
Theheatingandhotwaterfromeachappliancemustserveseparatezones/bathrooms
withintheproperty.
The electrical supplies from each appliance to the boiler will need twinning so that
the boiler will operate on a call from either/both appliances.
Bothprimarypumpsandtheprimarypipeworksizesshouldbecheckedtoensurethat
theyareadequateforthesystemthathasbeeninstalled. Ifnecessaryan extrapump
should be fitted on the common primary return pipework - see diagram below.
The BoilerMate A-Class appliances will not be suitable if the primary pipework
dips or the boiler is located above the BoilerMate.
For further details please ring the GledhillTechnical helpline.
1.0 DESIGN
Boiler
Single check valve
Heating circuit
Fit extra pump if required
BoilerMate
OV
BoilerMate
OV

Page 18
1.3 SYSTEM DETAILS
‘Switch’
TheBoilerMateA-Classissuppliedwith ‘Switch’
which provides a 6kW electrical emergency
back up in the case of failure of the main heat
source i.e.gas boiler.
ThismustNOTbeusedtoprovidehotwater
onlyinsummerifthemainsystemisworking
correctly.
Full details of the electrical requirements are
providedinSection2.1SiteRequirementsand
2.2 Installation.
‘Switch’will beactivatedby movingthe mode
rocker located on the front control panel into
the ‘switch’ position (see diagram opposite).
Thisreplacesthefunctionoftheexternalboiler
with the internal electric emergency boiler.
The programming of space heating and store
chargingisstillcontrolledbytheclockandthe
hot water and central heating control rockers.
For emergency hot water only put the mode
rocker into ‘Switch’ position, the hot water
controlrockerintheconstantpositionandthe
central heating rocker to off.
For emergency hot water and heating put the
moderocker into‘Switch’positionand thehot
waterandcentralheatingcontrolrockersinthe
constant position.
In this situation the store will charge and the
space heating will be available at all times.
Once the fault has been resolved return to
normal boiler operation by moving the mode
rockertothenormalpositionandresetthehot
waterandcentralheatingcontrolrockerstothe
required position.
During Switch operation the central heating
can be operated in a timed mode if required
by setting the central heating control rocker
totimedandtheclock/programmertosuitthe
times required.
1.0 DESIGN
"OILER-ATE!#,!33
/&&
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-%$)5-&,!3().'
2!0)$&,!3().'
/.
.ORMAL
@3WITCHFAILURE
@3WITCHBACKUPSELECTED
/VERHEATSAFETYTRIP
@3WITCH/N
053("544/. 4ORESETAPPLIANCE
-/$% #ONTROLCIRCUIT
POWERSUPPLY
.ORMAL @3WITCH
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#ENTRAL(EATING
(OT7ATER
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/&&
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#ONSTANT
(7#(/&&
4IMED
Put Mode Rocker to‘Switch’position
Select HW Only Select HW & CH

Page 19
BOILERMATE A-CLASS OV
Electrical Supply requirements for BoilerMateA-Class
2.0 INSTALLATION
2.1 SITE REQUIREMENTS
The appliance is designed to be installed in an airing/cylinder cupboard and the
relevant minimum dimensions are provided in section 1.2 Technical Data.
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.
Installationandmaintenanceaccessisneeded to the front of the appliance and
abovethe F & E cistern. See Technical Data section for further details.
The minimum dimensions contained in section 1.2 Technical Data allow for the
passage/connection ofpipes under the appliancefrom anydirection as longas the
applianceisinstalled onthe installationbase provided.Ifthe installation baseis not
usedextraspacemaybeneededtoallowconnectiontothepipeworkandthewhole
ofthebaseareashouldbecontinuouslysupportedonamaterialwhichwillnoteasily
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 section 1.2 Technical Data.
Theapplianceisdesignedtooperateasquietlyaspracticable. However,somenoise
(from pumps etc) is inevitable in any heating system. This will be most noticeable
in cupboards formed on bulkheads,orat themid spanof asuspended floor. In these
cases the situation can be improved by placing the appliance on a suitable sound
deadening material (i.e.carpet underlay or similar).
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
ventilationisnormallyrequiredtothecupboard.
A suitable location will be needed for the separate feed and expansion cistern.
This will often be at high level in the cupboard housing the BoilerMate A-Class. The
dimensions and clearances are provided in section 1.2 Technical Data. The location
will need to provide a suitable route for the cold feed and expansion pipe as well
asthe open safetyvent pipe. Thelocation willalso need toprovide asuitable route
anddischargepositionforthewarning/overflowpipeandtheballvalvesupplyfromthe
mainscoldwatersystem.
An electrical supply must be available which is
correctly earthed,polarized and in accordance
withthelatesteditionoftheIEErequirementsfor
electricalInstallationsBS7671.
The electrical mains supply needs to be
230V/50Hz.
A means for disconnection from the supply
mains having a contact separation in all
poles that provides full disconnection under
over voltage category III conditions must be
incorporated in the fixed wiring in accordance
with the wiring rules. This shall be located
within 1m of the appliance and only serve the
appliance.
The minimum breaking capacity of the main
isolatorcablesizes/lengthsat230Vshall follow
the recommendations in the table shown
opposite.
If the boiler incorporates a frost thermostat an
extra3core3ampsupplycablewillberequired
between the boiler and the BoilerMate to
provide a supply to the boiler pump - see 2.2
Electrical Connection for further details.
Nominal
full load
current
Min rating of
the isolator Cable size
Max.recommended
cable run-based on
not exceeding 4% of
the nominal voltage
supplyof 230VACusing
a type B breaker
28.5 Amps 32 Amps 6 mm244 metres
Recommended circuit
protection device - based on
0.4 second disconnection
time
32 A type B circuit breaker to BS EN
60898
or 32A type B RCBO to BSEN 61009

Page 20
2.2 INSTALLATION
2.0INSTALLATION
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.
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. If these have been followed
installation is very simple and much quicker
than any other system.
Theapplianceissuppliedshrinkwrappedona
timber installation base. Carrying handles are
also provided in the back of the casing.
Thefeedandexpansioncisterncompletewith
ballvalve, cold feed/expansion and overflow/
warning fittings are provided in a separate
box.Ifflexibleconnectionshavebeenordered
thesewillalsobeinsidethefeedandexpansion
cistern.
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)and placedinposition.
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 and the working
head of the appliance is not exceeded and
the recommended access is provided for
maintenance - see section 1.2 Technical Data.
For further information on manual handling
See Appendix D.
Note:Althoughtheaboveguidanceisprovided
any manual handling/lifting operations will
need to comply with the requirements of
the Manual Handling Operations Regulations
issued by the H.S.E.
Theappliancecanbemovedusingasacktruck
ontherearfacealthoughcareshouldbetaken
and the route should be even.
In apartment buildings containing a number
of storeys we would recommend that the
appliancesaremovedverticallyinamechanical
lift.
If it is proposed to use a crane expert advice
should be obtained regarding the need for
slings,lifting beams etc.
A specific manual handling assessment is shown in Appendix D
at the rear of this manual.