gledhill BMA 120 SP User guide

DESIGN, INSTALLATION AND
SERVICING INSTRUCTIONS
TEL: [phone]
www.gledhill-boilermate.co.uk
AN SEALED 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
BOILERMATE A CLASS SP
Gas Council Approved Reference Numbers
89-317-14 / BMA 120 SP
89-317-15 / BMA 140 SP
89-317-16 / BMA 180 SP
89-317-17 / BMA 200 SP
89-317-18 / BMA 220 SP

Page 2
CONTENTS
Section Page
1.0 DESIGN
1.1 Introduction 3
1.2 Technical Data 5
1.3 SystemDetails 13
2.0 INSTALLATION
2.1 SiteRequirements 20
2.2 Installation 21
2.3 Commissioning 31
3.0 SERVICING
3.1 Annual Servicing 35
3.2 Changing Components 35
3.3 Short Parts List 36
3.4 Fault Finding 37
Appendix A 38
Appendix B 39
Appendix C 42
Appendix D 43
Terms & Conditions 44
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 6:06-08
TM
benchmark
The code of practice for the installation,
commissioning & servicing of central heating systems
Building Regulations and Benchmark Commissioning
TheBuildingRegulations(England&Wales)requirethattheinstallationofaheating
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
SchemeasanoptiontonotifyingtheLocalAuthoritydirectly. Similararrangements
will follow for Scotland and will apply in Northern Ireland from 1st January 06.
CORGI operates a Self Certification Scheme for gas heating appliances.
Thesearrangementsrepresentachangefromthesituationwherebycompliancewith
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
beingreplacedbyasimilardocumentintheformof acommissioningchecklistand
a service interval record is included with all gas appliance manuals. However, the
relevantBenchmarkLogbookisstillbeingincludedwithallThermalStorageproducts
and unvented cylinders.
Gledhillfullysupports theBenchmarkaimstoimprovethestandardsof installation
andcommissioningofcentralheatingsystemsintheUKandtoencouragetheregular
servicing of all central heating systems to ensure safety and efficiency.
Building Regulations require that the heating installation should comply with the
manufacturer’sinstructions. Itisthereforeimportantthatthecommissioningcheck
listiscompletedbythecompetentinstaller.Thischecklistonlyappliestoinstallations
in dwellings or some related structures.

Page 3
BOILERMATE A-CLASS SP
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.
Anywaterdistributionandcentralheatinginstallationmustcomplywiththerelevant
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 suitably competent person as stated in the Gas Safety Regulations must install the
BoilerMateandcarryoutanysubsequentmaintenance/repairs.Infact,thefrontpanel
is secured by 2 screws and should only be removed by a competent trades person.
The manufacturer’s notes must not be taken as overriding statutory obligations.
TheBoilerMateA-ClassSPisonlysuitableforusewithasealedprimarycentralheating
system.
TheBoilerMateA-ClassisnotcoveredbysectionG3ofthecurrentBuildingRegulations
and is therefore not notifiable to Building Control.
TheBoilerMateA-ClassSPisnotintendedforusebypersons(includingchildren)with
reducedphysical,sensory ormentalcapabilities,orlackofexperienceor knowledge,
unlesstheyhavebeengivensupervisionorinstructionconcerninguseoftheappliance
by a person responsible for their safety.
Children should be supervised to ensure that they do not play with the appliance.
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 and Warranty Terms, which
are set out at the rear of this manual.
IntheinterestofcontinuouslyimprovingtheBoilerMaterange,GledhillWaterStorage
Ltdreservetherighttomodifytheproductwithoutnotice,andinthesecircumstances
thisdocument,whichisaccurateatthetimeofprinting,shouldbedisregarded. Itwill
however be updated as soon as possible after the change has occurred.
Description
TheBoilerMateA-ClassSPshownschematically
onpage4isdesignedtoprovidesealedsystem
spaceheatingandmainspressurehotwaterat
highflowrateswhencoupledtoanyremotely
sited, condensing or non condensing, boiler
suitable for sealed heating systems, as long
as they comply with the recommendations
contained in the rest of this manual.
The BoilerMate A-Class is an indirectly heated
hot water only thermal store and is supplied
withthefactoryfittedcontrolsandequipment
shown in Section 1.2 Technical Data. The
indirect heatexchangeris highly efficient and
designedtoprovideextremelyquickhotwater
recovery as well as back-up space heating
when using‘Switch’.
Because the F & E cistern is only used to fill
the thermal store the standard appliance
is supplied as a manual fill model, i,e,
without a ballvalve and overflow, which
makes it particularly suitable for use in
flats/apartments. Aballvalveand overflow
fittingcanbesuppliedasanoptionalextraif
requiredtoprovideanautomaticfillmodel.
Because this product does not require a safety
discharge from a temperature and pressure
relief valve, any installations will be easy to
incorporateintothebuildingandwillnotsuffer
fromtheproblemsassociatedwith usingPVCu
soilstackstotakethedischargefromunvented
cylinders.
An important feature of this concept is that
hot water can be supplied directly from the
mains at conventional flow rates without the
needfortemperatureandpressurereliefsafety
valves or expansion vessels. This is achieved
by passing the mains water through a plate
heatexchanger.Theoutlettemperatureofthe
domestichotwaterismaintainedbyaprinted
circuitboard(A.C.B.),whichcontrolsthespeed
ofthepumpcirculatingtheprimarywaterfrom
the store through the plate heat exchanger.

Page 4
1.0 DESIGN
1.1 INTRODUCTION
Remote
F&E
Cistern
BM
A-Class
SP
Boiler
Cold feed
Open Vent
Heating Circuit
Hot Out
Mains Cold In
Components fitted
within appliance case
Expansion Vessel
Pressure Gauge/Filling Loop
Pressure Gauge Relief/Safety Valve
Optional
sealed system
kit
3 port divertor valve
Automatic
bypass valve
Summer use towel
rail blanked connection
The Building Regulations L1A: New dwellings/L1B: Existing dwellings and the
requirementssetoutintheDomesticHeatingComplianceGuidespecifythat“where
themainswaterhardnessexceeds200ppmprovisionshouldbemadetotreatthefeed
watertowaterheatersandthehotwatercircuitofcombinationboilerstoreducethe
rate of accumulation of lime scale”.
Tocomplywiththisrequirementthehardnessofthemainswatershouldbecheckedby
theinstallerandifnecessarytheoptionalfactoryfittedin-linescaleinhibitorshouldbe
specified at the time of order for hardness levels between 200 and 300 ppm (mg/l).
Wherethewaterisveryhardie300ppm(mg/l)andabovethe optionalpolyphosphate
type,inhibitorshouldbespecified at thetimeoforder. However,this willneedtobe
fitted by the installer at a suitable point in the cold water supply to the appliance.
If scale should ever become a problem the plate heat exchanger is easily isolated and
quickly replaced with a service exchange unit which can be obtained at a nominal
cost from Gledhill.
TheA.C.B.alsoincorporatesthefacilitytooperatetheprimarypumpforafewseconds
every few days when the heating is not being used (to reduce the likelihood of the
pumps sticking) as well as providing a primary pump overrun facility for the boiler.
Anysealedsystemautomatic boiler designed tooperateon an 820C flow and a 710C
return up to a maximum of 35kW can be linked to any suitable model of BoilerMate
A-Classandthedecidingfactoristhe spaceheating andthehot waterrequirements
of a dwelling. See Section 1.2 Technical Data for further details.
The BoilerMate A-Class 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.
Theheatlossesfromthermalstoresshouldnotbedirectlycomparedwithheatlosses
from unvented or vented cylinders because
they are treated differently in SAP. The SAP
calculator takes account of the type of store
and various correction factors are included to
reflectthedifferentwaysthatthehotwaterand
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 SP is a SYSTEM
appliance and only requires a basic boiler
without a pump. If a system boiler is
chosen this will present wiring/operational
difficulties as well as incurring extra cost

Page 5
BOILERMATE A-CLASS SP
1.2TECHNICAL DATA
Notes:-
1. TheBoilerMate225applianceissuitableforuseinlargepropertiesbecauseitproducesthesame‘peakhouroutput’asatypical350-
400litreunventedcylinder. Forpropertiesrequiringthe BMA 220theincomingmain shouldbea minimum of32mmMDPEwith
apressureof not lessthan2bar dynamic andanadequateflow inlinewiththe pipe sizingcalculations. Inmanycases,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.
6. The designer/installer MUST calculate the suitability of the standard pump as part of normal design procedures.
7. The expansion vessel sizes have been calculated to be adequate for typical steel panel mini bore heating systems. The designer/
installerMUSTcheckthattheseareadequateaspartofnormaldesignproceduresandspecifyanextraexpansionvesselif
required.
1.0 DESIGN
Model BMA 120 SP BMA 140 SP BMA 180 SP BMA 200 SP BMA 220 SP
Weight (empty) 49.4 kg 51.8 kg 54.2 kg 56.5 kg 60.8 kg
Weight (full) 174.4 kg 191.3 kg 201.2 kg 220.5 kg 245.8 kg
DHW Pump Grundfos UPR 15/50 Grundfos UPR 15/50 Grundfos UPR 15/50 Grundfos UPR 15/50 Grundfos UPR 15/50
Boiler/Heating 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 flow
(for summer use
bathroom towel rail)
15mm 15mm 15mm 15mm 15mm
Maximum summer
towel rail load 0.5kW 0.75kW 1.00kW 1.25 kW 1.5 kW
Maximum pressure
heating circuit 3 bar 3 bar 3 bar 3 bar 3 bar
Volume of primary
coil 4.9 litres 4.9 litres 5.5 litres 5.5 litres 6.1 litres
Expansion vessel size 12 lts 12 lts 12 lts 25 lts 25 lts
Drain connection R ½” R ½” R ½” R ½” R ½”
Maximum Head
Thermal Store 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 11.25 kW 15 kW 18.75 kW 22.5 kW 26.25 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 SP 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/heating pump
2. Domestic hot water primary (plate
heat exchanger) pump - modulating
3. 3 port control valve
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 for filling
the thermal store complete with 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.
* Scaleinhibitorformainswaterservices
with hardness levels above 200ppm
(mg/l)
* Ballvalve/overflow connector for
automatic fill model.
* Primarysealedsystemkitforfittingnear
boiler comprising:
Expansionvessel(sizevarieswithmodel
of appliance)
15mm 3 bar pressure relief (safety) valve
Pressure gauge and filling loop.
1.0 DESIGN
Electro-mechanical clock
programmer
Digital clock programmer
2
3
1
4 5
6
7
8
9
10
11
13
12 (F & E Tank
not shown)

Page 7
BOILERMATE A-CLASS SP
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.
If the standard manual fill model is chosen the height can be
reduced by 100mm.
If the appliance is to be connected to a multi-zone heating
then an additional 150mm must be added to the above
heights to accomodate the space required for the zone
equipment eg valves.
APPLIANCE DIMENSIONS
MODEL Height Width Depth
ABC
BMA 120 SP 960mm 530mm 595mm
BMA 140 SP 1000mm 530mm 595mm
BMA 180 SP 1040mm 530mm 595mm
BMA 200 SP 1145mm 530mm 595mm
BMA 220 SP 1300mm 530mm 595mm
MINIMUM CUPBOARD DIMENSIONS
MODEL Height Width Depth
DEF
BMA 120 SP 1710mm 630mm 600mm
BMA 140 SP 1750mm 630mm 600mm
BMA 180 SP 1790mm 630mm 600mm
BMA 200 SP 1895mm 630mm 600mm
BMA 220 SP 2050mm 630mm 600mm
"
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Page 8
1.0 DESIGN
1.2 TECHNICAL DATA
65
65
115 190
PRIMARY FLOW 475
CYLINDER DRAIN
PRIMARY RETURN TO BOILER
COLD FEED
DOMESTIC HOT WATER
CENTRAL HEATING FLOW 560
TOWEL RAIL FLOW
CENTRAL HEATING RETURN
560
550
220 230
115
50
150
210
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. With the standard
appliance (supplied without a ballvalve and overflow) a 15mm valved mains cold branch
should be provided along with a temporary hose connection incorporating a double check
valve to allow the cistern to be easily topped up when necessary (the temporary hose
connection must be disconnected once the appliance is filled). With the automatic fill
model a15mm cold water supply and a 22mm warning/overflow pipe will be required for
the separate feed and expansion tank.
C
L
Cut out area
in base

Page 9
BOILERMATE A-CLASS SP
1.2 TECHNICAL DATA
1.0 DESIGN
0RIMARYHEATEXCHANGERIECOILPRESSURE
LOSSOF"OILER-ATE!#LASS
???????????
(EATINGCIRCUITPRESSURELOSSOF"OILER-ATE!#LASS
??????????????
LITRESSEC

LITRESSEC
PERFORMANCE GRAPHS OF GRUNDFOS PUMPS
GRUNDFOS 15/50 GRUNDFOS 15/60

Page 10
1.2 TECHNICAL DATA
Appliance Control Board
Theappliancecontrol board(shownopposite)
hasa2digitdisplayand 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.
The2digitdisplayiscontrolledby2buttonsS1
andS2Theflowchartofdisplaymodesisshown
below. Generally,eachpressofbuttonS2cycles
thedisplayfrom toptobottomandeachpress
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 SP 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/applianceto 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.ThecontrollercodesandtheIDresistor
values for the BoilerMate SP are 02 and 2K2
respectively. The procedure for checking and
setting the appliance code on the controller is
described below.
•Theapplianceselectionmenu(A0...A9)onthe
controlleris hidden.It isonlypossibleto getto
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 A02.
Presstheresetbutton, 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
# # # #&
C C C C&
! ! ! !
&AULTCODEINDICATION
"LOCKOUTS
!PPLIANCE4YPE
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
0RESS3
0RESS3
0RESS3
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1.0 DESIGN

Page 11
BOILERMATE A-CLASS SP
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/cOlocations holdthelatestfault 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 75 - 77
S3 DHW in 35
S4 DHW out 55
S5 Bottom store sensor on 60
S6 Bottom store sensor off 68
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 12
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-Classwill operateatmains pressuresaslow as1bar and
ashighas5baralthoughtherecommendedrangeis2-3bar. Thesepressuresarethe
minimumdynamicpressuresatthecoldconnectiontothe 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.
Ifyouencounter asituation wherethe water pressureisadequate butflowrates are
poor please contact our technical helpline for details of an effective solution.
Note: EachBoilerMateA-Classis fittedwitha strainerandflowregulatoronthe cold
mainssupplyconnection. If the supplypressureisless 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.
Nocheckvalve orsimilardeviceshouldbefitted on the cold watersupplybranchto
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 complywiththisrequirement thehardness
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).
Wherethewaterisvery hardie300ppm(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
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
aa a
a
aa a
CHC HC 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

Page 13
BOILERMATE A-CLASS SP
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
recommendedsizefor new dwellingsis22mm(25mmMDPE). FortheBMA225
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(availableas anoptional extra)arebeing 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,ifit isproposedtousea‘whole body’
or similar shower with a number of high flow/
pressureoutletspleasediscusswiththeGledhill
technical department.
Thehotwatersupplytoashower-mixingvalve
shouldbefedwhereverpractical 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.
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 hotwaterpipework suchasthe
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 14
1.0 DESIGN
1.3 SYSTEM DETAILS
Remote
F&E
Cistern
BM
A-Class
SP
Boiler
Cold feed
Open Vent
Heating Circuit
Hot Out
Mains Cold In
Components fitted
within appliance case
Expansion Vessel
Pressure Gauge/Filling Loop
Pressure Gauge Relief/Safety Valve
Optional
sealed system
kit
3 port divertor valve
Automatic
bypass valve
Summer use towel
rail blanked connection
Heating System
General
A schematic layout of the heating system in a typical small dwelling is shown
above.
TheflowandreturnfromtheboilermustalwaysrundirectlytotheBoilerMateA-Class
SP 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.
TheBoilerMateA-ClassSPis only suitable forasealedheating systemand therefore
boiler/heating pipework can run at a higher level than the store.
ItisrecommendedthattheF& Ecisternfortheapplianceisfitted athighlevelinthe
samecupboardastheBoilerMate. However,itcanbefittedremotelyupto6mabove
thebaseof theBoilerMateA-Classi.e.themaximum staticpressureinthe storemust
not exceed 0.6 bar.
TheperformanceofthesystempumpandthepressurelossesthroughtheSysteMate
2000primarycoilcircuitareshownin1.2TechnicalData. Thenettpumpheadavailable
fortheheatingcircuitcanbedeterminedfromthesefiguresandthisnettpumphead
should be used for sizing the heating circuit pipework.
For example: At 24 litres/min primary flow rate, the pressure loss through the
SysteMate2000 model SM210 (coilandfittings)is 2.1mW.G. (21kPa). Themaximum
pumpheadavailableat24litres/minandsetting3is 3.2mH2O(32kPa),therefore1.1m
W.G.(11kPa) is available for the boiler circuit.
With sealed heating systems air is released during the first few weeks of operation.
This will need to be vented and the system re-pressurised.
If the automatic model is being used the overflow/warning pipe should be installed
in a material suitable for a heating system feed and expansion cistern in accordance
with BS 5449.
Anautomaticbypassisfittedon theBoilerMate
A-ClassSPtocompensateforpressure(i.e.flow)
ratechangesintheheatingcircuite.g.whenthe
thermostaticradiatorvalvesclose. Thesystem
does not require any other bypass valves but
a bypass radiator used in conjunction with a
room thermostat can be used if required to
provide a boiler interlock. The bypass valve
must be set by the installer to suit the system
ie to provide minimum flow required for the
boiler when allTRV’s are closed.
There shall be no permanent connection to
the mains water supply for filling the system,
even through a non-return valve without
the approval of the Local Water Authority.
An approved filling loop is required with
the BoilerMate A-Class (available as part of
an optional extra kit) which this should be
disconnectedaftercommissioningthesystem.
This should be located adjacent to the boiler
along with a suitable expansion vessel gauge
andpressurerelief valve(alsoavailableaspart
of the optional extra kit) as shown above.

Page 15
BOILERMATE A-CLASS SP
1.0 DESIGN
1.3 SYSTEM DETAILS
Heating System
Pipe Sizing/Materials
The BoilerMate A-Class SP is designed to be installed with any condensing or non
condensing boiler which is suitable for a sealed heating system (i.e.fitted with an
overheat thermostat) and is capable of delivering hot water at a minimum of 80oC.
The primary pipework connecting the boiler and the thermal store should be sized
to achieve a maximum of 11°C rise across the boiler or the maximum temperature
risespecifiedbythe boiler manufacturer,whicheverissmaller,but in anyinstanceit
should not be less than 22mm copper tube.
If theboilerisacondensingtypetheboilermustbeset to operateatanormal82oC
flow 71oC return system.
Note: There should be no valves in the pipework connecting the boiler to the
BoilerMate A-Class SP and between the boiler and the pressure safety relief valve.
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.
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.
Itisalsoessentialthatifanalternativepipework
material/system is chosen the manufacturer
confirms that the design criteria of the new
systemis atleastequivalenttotheuseofBS/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 SP
The size of the primary pipework connecting
theboilertotheBoilerMateA-Classmustnotbe
less than 22mm (or that specified by the boiler
manufacturer).
Allowance for Domestic
HotWater
Model (kW)
BMA 120 SP 2
BMA 140 SP 3
BMA 180 SP 3
BMA 200 SP 3.5
BMA 220 SP 4
Boiler
Expansion
Vesse l
Remote F & E
Cistern
Boiler Return
Boiler Flow
Pressure relief (safety) valve
Filling loop
Pressure gauge
BoilerMate
A-Class SP

Page 16
1.0 DESIGN
1.3 SYSTEM DETAILS
Boiler sited above the BoilerMate or with
dipped flow and return pipes
An automatic air vent will be required on the
flow adjacent to the boiler and depending
upon the pipe layout an automatic or manual
air vent will also be required on the return
adjacent to the boiler.
The pressure relief (safety valve) must be
located on the flow immediately adjacent to
the boiler.
Heating System
Connection of Bathroom Radiator/Towel
- Rail for Summer use
If a pumped circuit is required for a bathroom
radiator/towel rail, the flow pipework can be
connected into the 15mm copper blanked
connection provided. 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 and the store is being
heated.
Itisimportantthattheflowratesthroughthese
radiatorsisadjustedtotheminimum required
atthe lockshieldvalvesontheradiators. Ifthis
isnotdonetheperformanceoftheBoilerMate
A-Class SP will be adversely affected.
Heating System
Remote
F & E cistern
Boiler
Expansion
Vessel
AAV
AAV
Boiler
Flow
Boiler
Return
AAV - Automatic air vent
GCV - Gravity check valve
Pressure relief (safety) valve
Filling loop
Pressure gauge
BoilerMate
A-Class SP
2EMOTE
&%CISTERN
%XPANSION
6ESSEL
"OILER
"ATHROOM4OWEL
2ADIATOR
0RESSURERELIEFSAFETYVALVE
&ILLINGLOOP
0RESSUREGAUGE
#(&
#(2
"2
"&

Page 17
BOILERMATE A-CLASS SP
1.0 DESIGN
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
common primary return (to boiler) - see diagram below.
Theheatingandhotwaterfromeachappliancemustserveseparatezones/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.
Bothprimarypumpsandtheprimarypipeworksizesshouldbecheckedtoensurethat
theyareadequateforthesystemthat hasbeen installed. Ifnecessaryan extrapump
should be fitted on the common primary return pipework - see diagram below.
1.3 SYSTEM DETAILS
Heating System
"-
!#LASS
30
"OILER
(EATING#IRCUIT
(EATING#IRCUIT
"-
!#LASS
30
&ITEXTRAPUMP
IFREQUIRED
3INGLECHECK
VALVE
3INGLECHECK
VALVE

Page 18
1.0 DESIGN
1.3 SYSTEM DETAILS
Heating System
ExpansionVessel Requirements
TheBoilerMate expansionvesselispre-chargedto1.0bar.Themaximumwatercontent
of the heating system (boiler + radiators + connecting pipework + primary coil but
NOT store volume) must not be greater than those shown in the table below.
A figure of 4.5 litres/kW of installed radiator capacity can be used for a preliminary
assessment of the water content of the heating system.
Thevaluespresentedinthetablearebasedonamaximumboilerflowtemperatureof
93oC. Theexpansionvessel must besuitabletoaccommodate thechangeinvolume
of the water in the system when heated from 10oC to 110oC as specified in BS 5449:
1990 clause 16.2.
Theprimaryheatingcoilandpipeworkvolumesareshowninthetablein1.2Technical
Data.
Innormalcircumstancesaninitialvesselandsystemchargepressureof1barissuitable
for most domestic purposes.
The minimum system pressure should not be less than the static head plus 0.5 bar
i.e.the height of the highest point in the system above the expansion vessel plus a
margin of 0.5 bar.
Ifthesystemvolumeisgreaterthanthatshowninthetableattheselectedoperating
conditions then an additional expansion vessel must be fitted.
12 LitreVessel i.e.BMA 120/140/180
Maximum Recommended Heating SystemVolumes
Safety valve setting (bar) 3.0
Vessel charge pressure (bar) 0.5 1.0 1.5
Initial system pressure (bar) 0.5 1.0 1.5 1.0 1.5 2.0 1.5 2.0
Maximum permitted system
volume (litres) 140 80 40 110 60 27 70 35
25 LitreVessel i.e.BMA 200/220
Maximum Recommended Heating SystemVolumes
Safety valve setting (bar) 3.0
Vessel charge pressure (bar) 0.5 1.0 1.5
Initial system pressure (bar) 0.5 1.0 1.5 1.0 1.5 2.0 1.5 2.0
Maximum permitted system
volume (litres) 270 160 85 200 115 50 140 65

Page 19
BOILERMATE A-CLASS SP
1.3 SYSTEM DETAILS
‘Switch’
The BoilerMate A-Class SP is supplied with
‘Switch’ which provides a 6kW electrical
emergencybackupinthecaseoffailureofthe
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
providedinSection2.1SiteRequirementsand
2.2 Installation.
‘Switch’will be activated bymovingthemode
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
moderockerinto‘Switch’position and 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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.ORMAL
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/VERHEATSAFETYTRIP
@3WITCH/N
053("544/. 4ORESETAPPLIANCE
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.ORMAL @3WITCH
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4IMED
Put Mode Rocker to‘Switch’position
Select HW Only Select HW & CH

Page 20
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 1.2Technical 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. SeeTechnical Data section for further details.
The minimum dimensions contained in section 1.2 Technical Data allow for the
passage/connection of pipesundertheappliancefromany direction as long as the
applianceisinstalled ontheinstallationbase provided.Ifthe installationbaseisnot
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,or at themidspanof asuspendedfloor. 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.
Asuitablelocationwillbeneededfortheseparatefeedandexpansioncistern.Thiswill
oftenbeathighlevelinthecupboardhousingtheBoilerMateA-Class. Thedimensions
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
safetyventpipe.Thelocationwillalsoneedtoprovideasuitablerouteanddischarge
positionforthewarning/overflowpipeandtheballvalvesupplyfromthemainscoldwater
system if the automatic fill version appliance is being fitted.
Note: Thestandardapplianceissuppliedwith acisternbutwithouta ballvalve
and overflow connector.
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
isolator and cable sizes/lengths at 230V shall
followtherecommendationsinthetableshown
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
supplyof230VACusing
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