gledhill benchmark BoilerMate A-Class OV Series User guide
DESIGN, INSTALLATION AND
SERVICING INSTRUCTIONS
PLEASE LEAVE THESE INSTRUCTIONS IN THE POCKET PROVIDED ON
THE BACK OF THE FRONT PANEL
AN OPEN VENTED CENTRAL HEATING
AND MAINS PRESSURE HOT WATER SUPPLY
SYSTEM INCORPORATING
A THERMAL STORE
ALL MODELS COMPLY WITH THE
WATER HEATER MANUFACTURERS
SPECIFICATION FOR INTEGRATED THERMAL
STORES
TM
benchmark
The code of practice for the installation,
commissioning & servicing of central heating systems
Gas Council Approved Reference Numbers
BMA 125 OV
BMA 145 OV
BMA 185 OV
BMA 210 OV
BMA 225 OV
BoilerMate OV
A - C L A S S
Page 2
CONTENTS
Section Page
1.0 DESIGN
1.1 Introduction 3
1.2 Technical Data 5
1.3 System Details 11
2.0 INSTALLATION
2.1 Site Requirements 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 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
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.
ISSUE 3: 09/05
As part of the industry wide “Benchmark” Initiative all Gledhill BoilerMates now
include a Benchmark Installation, Commissioning and Service Record Log Book.
Please read carefully and complete all sections relevant to the appliance installation.
The details of the Log Book will be required in the event of any warranty work being
required. There is also a section to be completed after each regular service visit.
The completed Log Book and these instructions should be left in the pocket
provided on the back of the front panel.
TM
benchmark
The code of practice for the installation,
commissioning & servicing of central heating systems
Page 3
BOILERMATE A-CLASS OV
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
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.
A competent person as stated in the Gas
Safety Regulations must install the BoilerMate
heating system. The manufacturer’s notes
must not be taken as overriding statutory
obligations.
The BoilerMate A-Class is only suitable for use
with an open vented central heating system.
The BoilerMate A-Class is not covered by section
G3 of the current Building Regulations and is
therefore not notifiable 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 4
The BoilerMate A-Class OV shown schematically above is designed to provide improved
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.
An important feature of this concept 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.
To comply with the Benchmark Guidance Note for Water Treatment in heating and
hot water systems the installer should check the hardness levels of the water supply
and if necessary fit an in-line scale inhibitor/reducer to provide protection to the
whole of the domestic water system.
We recommend the use of the optional scale inhibitor to help protect the appliance
itself if the hardness level is above 280 ppm (mg/l).
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.
1.0 DESIGN
Description
1.1 INTRODUCTION
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.
Any automatic boiler designed to operate on an
820C flow and a 710C return up to a maximum
of 35kW can be linked to any suitable model of
BoilerMate A-Class and the deciding factor is the
space heating and the hot water requirements
of a dwelling. See Section 1.2 Technical Data
for further details.
The BoilerMate A-Class OV is supplied complete
with ‘Switch’ which will provide a 6kW electrical
emergency backup in case of failure of the main
heat source. See section 1.3 System Details for
further information.
Gledhill are part of the ‘Benchmark’ scheme and
a separate commissioning/service log book is
included with the product.
A 15mm connection is provided on the primary
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
1.2 TECHNICAL DATA
Notes:-
1. The BoilerMate 225 appliance is suitable for use in large properties because it produces the same ‘peak hour output’ as a typical 350-
400 litre unvented cylinder. For properties requiring the BMA 225 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. In many cases, 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. 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.
4. Unit is supplied on a 100mm high installation base.
5. The domestic hot water outlet temperature is automatically regulated to approximately 52°C at the bath flow rate of 18 litres/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 210 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 UPS 15/50 Grundfos UPS 15/50 Grundfos UPS 15/50 Grundfos UPS 15/60 Grundfos UPS 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 10 meters 10 meters 10 meters 10 meters 10 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 Dwelling Types
Bedrooms 1-3 2-3 2-4 3-5 4-6
Bathrooms 1 1 2 1 2 1 3 4
En-suite shower 1 2 1 4 2 4 2 0
Page 6
1.2 TECHNICAL 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-mechanical clock and hot water
and space heating control rockers.
6. Plate heat exchanger
7. DHWS 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
* A seven day digital clock/programmer
to control the space heating (in
conjunction with a room thermostat)
* A kit to site the clock/programmer
remotely.
* A no clock/multi-zone option.
* Hot and cold water manifolds for use
with plastic pipework.
* Modulating type (UPR) pump for the
boiler/space heating circuits.
* Scale inhibitor for water services
with hardness levels above 280ppm
(mg/l)
1.0 DESIGN
Electro-mechanical clock
programmer
Digital clock programmer
Page 7
BOILERMATE A-CLASS OV
1.0 DESIGN
1.2 TECHNICAL DATA
Note: The Appliance dimensions above do not allow for
the100mm high installation base
The following table of minimum cupboard dimensions only
allow the minimum space required for the appliance (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.
If a Multi-Zone appliance is used an additional 150mm must
be added to the above heights to accomodate the space
required for the zone equipment.
APPLIANCE DIMENSIONS
MODEL Height Width Depth
A B C
BMA 125 OV 960mm 530mm 595mm
BMA 145 OV 1000mm 530mm 595mm
BMA 185 OV 1040mm 530mm 595mm
BMA 210 OV 1145mm 530mm 595mm
BMA 225 OV 1300mm 530mm 595mm
MINIMUM CUPBOARD DIMENSIONS
MODEL Height Width Depth
D E F
BMA 125 OV 1710mm 630mm 600mm
BMA 145 OV 1750mm 630mm 600mm
BMA 185 OV 1790mm 630mm 600mm
BMA 210 OV 1895mm 630mm 600mm
BMA 225 OV 2050mm 630mm 600mm
Page 8
1.0 DESIGN
1.2 TECHNICAL DATA
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Page 9
BOILERMATE A-CLASS OV
1.2 TECHNICAL DATA
Appliance Control Board
The appliance control board (shown opposite)
has a 2 digit display and 2 push buttons 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.
The 2 digit display is controlled by 2 buttons S1
and S2 The flow chart of display modes is shown
below. 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 - see page 29 for
details.
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 01 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.
If the selected appliance code does not match
with the ID resistor fitted to the appliance, then,
an error ‘33’ will be displayed.
1.0 DESIGN
Page 10
1.2 TECHNICAL DATA
1.0 DESIGN
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 flash alternately on
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
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.
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 T Tank bottom 5 & 13 Bottom of store in dry pocket for store charging
S6 T Tank 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 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 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 A-Class 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.
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 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.
To comply with the Benchmark Guidance Note for Water Treatment in Heating and
Hot Water Systems the installer should check the hardness level of the water supply
and if necessary fit an in-line scale inhibitor/reducer to provide protection to the
whole of the domestic water system. See Appendix C for a copy of the relevant part
of the Benchmark Guidance Note.
1.0 DESIGN
The standard appliance is suitable for hardness
levels up to 280 ppm without the use of a scale
inhibitor. For hardness levels above 280ppm
(mg/l) we would recommend that the appliance
is ordered with the optional factory fitted scale
inhibitor.
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, 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 12
1.3 SYSTEM DETAILS
Hot and Cold Water System
Pipe Sizing / Materials
To achieve even distribution of the available supply of hot and cold water, it is
important in any mains pressure system, that the piping in a dwelling should be
sized in accordance with BS 6700. This is particularly important in a large property
with more than one bathroom.
However, the following rule of thumb guide lines should be adequate for most
smaller property types as long as water pressures are within the recommended
range of 2-3 bar.
1. A 15mm copper or equivalent external service may be sufficient for a small
1bathroom dwelling (depending upon the flow rate available), but the minimum
recommended size for new dwellings is 22mm (25mm MDPE). For the BMA 225
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
particularly relevant where the water pressures are above the recommended
water pressure range of 2-3 bar, or the dwelling is 3 storey. Details of suitable
flow regulators are provided in Appendix A.
Note: If manifolds (available as an optional extra) are being used suitable flow
regulators are automatically provided in the manifold and do not need to be
provided at each outlet - See Appendix B for further details.
All the recommendations with regard to pipework systems in this manual are
generally based on the use of BS/EN Standard copper pipework and fittings.
However, we are happy that plastic pipework systems can be used in place of copper
internally as long as the chosen system is recommended for use on domestic hot
and cold water systems by the manufacturer and is installed fully in accordance
with their recommendations.
It is also essential that if an alternative pipework material/system is chosen the
manufacturer confirms that the design criteria of the new system is at least equivalent
to the use of BS/EN Standard copper pipework and fittings.
Taps/Shower Fittings
Aerated taps are recommended to prevent splashing.
Any type of shower mixing valve can be used as long as both the hot and cold
supplies are mains fed. However, all mains pressure systems are subject to
dynamic changes particularly when other hot and cold taps/showers are opened
and closed, 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
expensive than a manual shower we strongly recommend the use of thermostatic
showers with this appliance. These must be used in 3 storey properties where
the impact on pressure/temperature of opening another tap in the system is
greater than normal.
The shower head provided must also be suitable for mains pressure supplies.
1.0 DESIGN
However, if it is proposed to use a ‘whole body’
or similar shower with a number of high flow/
pressure outlets please discuss with the Gledhill
technical department.
The hot water supply to a shower-mixing valve
should be fed wherever practical directly 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.
The supply of hot and cold mains water directly
to a bidet is permitted provided that it is of the
over-rim flushing type and that a type ‘A’ air
gap is incorporated.
Hot and Cold Water System.
If the length of the hot water draw off
pipework is excessive the delivery time may
be unacceptable before hot water is available
at the tap, you may wish to consider using trace
heating to the hot water pipework such as the
Raychem HWAT system. Please consult Gledhill
Technical Department for further details.
It is important that the cold water pipework
is adequately separated/protected from any
heating/hot water pipework to ensure that
the water remains cold and of drinking water
quality.
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
from the BoilerMate A-Class and is piped in the
conventional manner.
The BoilerMate A-Class is only suitable for an
open vented system.
The F & E cistern can be fitted remotely up to
10m above the base of the BoilerMate A-Class
i.e. the maximum static pressure in the store
must not exceed 1 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
recommended that a check valve, or valves, are
fitted on the vertical flow pipes.
The water level in the F & E cistern should be
at least 250mm above the highest point on
the system including the radiators and must
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.
It is not necessary to provide a boiler bypass on
the primary circuit (i.e. between the boiler and
the thermal store.)
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
rise specified by the boiler manufacturer, whichever is smaller, but in any instance 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.
The heating circuit operates on the normal primary boiler temperatures i.e. 82°C flow
and 71°C return. Therefore any traditional hot water radiators or convectors can be
used with this system and no special over-sizing of the heat emitters is necessary.
All the recommendations with regard to pipework systems in this manual are generally
based on the use of BS/EN Standard copper pipework and fittings.
However, we are happy that plastic pipework systems can be used in place of
copper internally as long as the chosen system is recommended for use on domestic
heating systems by the manufacturer and is installed fully in accordance with their
recommendations. We always recommend the use of barrier pipe for these systems.
Heating System
It is also essential that if an alternative pipework
material/system is chosen the manufacturer
confirms that the design criteria of the new
system is at least equivalent to the use of BS/EN
Standard copper pipework and fittings.
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
BoilerMate A-Class rises continuously. No valve
shall be fitted in the primary flow or open vent.
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
Any boiler used must be fitted with an overheat
thermostat i.e. it must be suitable for use in
a sealed system.
The F & E cistern must be fitted 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.
The height of the water level in the F & E cistern
from the base of the store should be no greater
than 10m.
A gravity check valve should be fitted in the
boiler return pipework to prevent gravity
circulation between the BoilerMate A-Class and
the boiler during dormant periods.
An automatic air vent will be required on the
flow adjacent to the boiler and depending
upon the pipe layout a manual air vent may also
be required on the return adjacent to the boiler
- 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.
The height of the water level in the F & E cistern
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
Page 16
1.0 DESIGN
1.3 SYSTEM DETAILS
Connection of Bathroom Radiator/
Towel-Rail for Summer use
If a pumped circuit is required for the bathroom
radiator/towel rail, the flow pipework can be
teed anywhere into the primary flow between
the boiler and the BoilerMate. The return
pipework can be connected into the 15mm
copper blanked connection provided adjacent
to the boiler pump. We recommend any
radiators/towel rails on this circuit are provided
with T.R.V.’s and that the total heat output of the
radiators/towel rails is not more than the figure
quoted in the table on page 5.
The radiators will only get hot when the
boiler is firing.
It is important that the flow rates through these
radiators is adjusted to the minimum required
at the lockshield valves on the radiators. If this
is not done the performance of the BoilerMate
will be adversely affected.
The height of the water level in the F & E cistern
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
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.
The heating and hot water from each appliance must serve separate zones/bathrooms
within the property.
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.
Both primary pumps and the primary pipework sizes should be checked to ensure
that they are adequate for the system that has been installed.
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 Gledhill Technical helpline.
1.0 DESIGN
Page 18
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.
Full details of the electrical requirements are
provided in Section 2.1 Site Requirements and
2.2 Installation.
‘Switch’ will be activated by moving the mode
rocker located on the front control panel into
the ‘switch’ position (see diagram opposite).
This replaces the function of the external boiler
with the internal electric emergency boiler.
The programming of space heating and store
charging is still controlled by the clock and the
hot water and central heating control rockers.
For emergency hot water only put the mode
rocker into ‘Switch’ position, the hot water
control rocker in the constant position and the
central heating rocker to off.
For emergency hot water and heating put
the mode rocker into ‘Switch’ position, the hot
water and central heating control rockers in
the constant position and the central heating
rocker to off.
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
rocker to the normal position and reset the hot
water and central heating control rockers to the
required position.
During Switch operation the central heating
can be operated in a timed mode if required
by setting the central heating control rocker
to timed and the clock/programmer to suit the
1.0 DESIGN
Put Mode Rocker to ‘Switch’ position
Select HW Only Select HW & CH
Page 19
BOILERMATE A-CLASS OV
Electrical Supply requirements for BoilerMate A-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.
Installation and maintenance access is needed to the front of the appliance and
above the 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 of pipes under the appliance from any direction as long as the
appliance is installed on the installation base provided. If the installation base is not
used extra space may be needed to allow connection to the pipework and the whole
of the base area should be continuously supported on a material which will not easily
deteriorate if exposed to moisture.
The floor of the cupboard needs to be level and even and capable of supporting
the weight of the appliance when full. Details of the weight when full is provided
in section 1.2 Technical Data.
The appliance is designed to operate as quietly as practicable. However, some noise
(from pumps etc) is inevitable in any heating system. This will be most noticeable
in cupboards formed on bulkheads, or at the mid span of a suspended floor. In these
cases the situation can be improved by placing the appliance on a suitable sound
deadening material (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
ventilation is normally required to the cupboard.
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
as the open safety vent pipe. The location will also need to provide a suitable route
and discharge position for the warning/overflow pipe and the ballvalve supply from the
mains cold water system.
An electrical supply must be available which is
correctly earthed, polarized and in accordance
with the latest edition of the IEE requirements for
electrical Installations BS 7671.
The electrical mains supply needs to be
230V/50Hz.
Connection must be made using a double-pole
linked isolator with a contact separation of
3mm in both poles which is located within 1m
of the appliance. The supply must only serve
the appliance.
The minimum breaking capacity of the main
isolator cable sizes/lengths at 230V shall follow
the recommendations in the table shown
opposite.
If the boiler incorporates a frost thermostat an
extra 3 core 3 amp supply cable will be required
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
supply of 230 VAC using
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
2.0 INSTALLATION
HANDLING
When lifting the unit work with someone of similar build
and height if possible.
Choose one person to call the signals.
Lift from the hips at the same time, then raise the unit to
the desired level.
Move smoothly in unison.
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.
The appliance is supplied shrink wrapped on a
timber installation base. Carrying handles are
also provided in the back of the casing.
The feed and expansion cistern complete with
ballvalve, cold feed/expansion and overflow/
warning fittings are provided in a separate
box. If flexible connections have been ordered
these will also be inside the feed and expansion
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 placed in position.
The appliance can then be lifted into position
in the cupboard on top of the base and the
front panel removed by unscrewing the 2
screws and lifting the door up and out, ready
for connection of the pipework and electrical
supplies. The feed and expansion cistern
support shall be installed ensuring that the
base is fully supported 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: Although the above guidance is provided
any manual handling/lifting operations will
need to comply with the requirements of
the Manual Handling Operations Regulations
issued by the H.S.E.
The appliance can be moved using a sack truck
on the rear face although care should be taken
and the route should be even.
In apartment buildings containing a number
of storeys we would recommend that the
appliances are moved vertically in a mechanical
lift.
If it is proposed to use a crane expert advice
should be obtained regarding the need for
slings, lifting beams etc.
A specific manual handling assessment is shown in Appendix D
at the rear of this manual.
This manual suits for next models
5
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