gledhill BMA 120 SP, Design, Installation And Servicing Instructions

Page 1: ...INS 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: ...l 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 Similar arrangements 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 ...

Page 3: ...sted 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 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 ...

Page 4: ...s 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 Any sealed system automatic boiler designed to operate on an 820 C flow and a 710 C 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...

Page 5: ...7 The expansion vessel sizes have been calculated to be adequate for typical steel panel mini bore heating systems The designer installer MUST check that these are adequate as part of normal design procedures and specify an extra expansion vessel if 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 ...

Page 6: ...ture 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 A seven day digital clock programmer to control the space heating in conjunction with a room thermostat A no clock multi zone option Hot and cold wate...

Page 7: ...o 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 A B C 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 ...

Page 8: ...ude 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 ea...

Page 9: ... 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: ...r 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 notreleasethebuttonbutholditfor10seconds Thedisplaywillchangefrom c to A Atthisstage the push button S2 can be released The a...

Page 11: ...ns 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 S...

Page 12: ...adetotreatthefeed water to water heaters and the hot water circuit of combination boilers to reduce the rate of accumulation of lime scale 1 0 DESIGN To comply with this requirement the hardness of the mains water should be checked by the installer and if necessary the optional factory fitted in line scale inhibitor should be specified atthetimeoforderforhardnesslevelsbetween 200 and 300 ppm mg l ...

Page 13: ...ems 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...

Page 14: ...ng circuit pipework For example At 24 litres min primary flow rate the pressure loss through the SysteMate 2000 model SM210 coil and fittings is 2 1m W G 21kPa The maximum pump head available at 24 litres min and setting 3 is 3 2m H2 O 32kPa therefore 1 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 nee...

Page 15: ...tions 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 re...

Page 16: ...We recommend any radiators towelrailsonthiscircuitareprovided withT R V sandthatthetotalheatoutputofthe 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 and the store is being heated Itisimportantthattheflowratesthroughthese radiators is adjusted to the minimum required at the lockshield valves on the radiator...

Page 17: ...gandhotwaterfromeachappliancemustserveseparatezones 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 they are adequate for the system that has been installed If necessary an extra pump should be fitted ...

Page 18: ...chnical 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 If the system volume is greater than that shown in the table at the selected operating conditions the...

Page 19: ...witch 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 and the hot 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 b...

Page 20: ...f the cupboard and door will need to take this into account No ventilationisnormallyrequiredtothecupboard Asuitablelocationwillbeneededfortheseparatefeedandexpansioncistern Thiswill often be at high level in the cupboard housingtheBoilerMateA 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 expans...

Page 21: ...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 th...

Page 22: ...1 MCB 3 16A 6A 16A L N N O SL W SL B SL R L1 L2 L3 E E SL H SL F N N N E E PE IH 2 5 mm Solid Core 2 N IH 2 5 mm SID Silicon 2 2 5 mm SID Silicon 2 R R L IH L IH VAL N VAL L1 VAL L2 VAL SL Zone Valve Br Wh Bl Gr Or B A AB 2 5 mm SIF Silicon 2 R R RELAY R1 0 1 230 240Vac 50Hz Br Br 2 8 6 4 2 x 3kW Heating Elements 2 5 mm SID Silicon 2 2 5 mm SID Silicon 2 5 mm SID Silicon 2 2 2 5 mm SIF Silicon 2 2...

Page 23: ...ing Flat Ribbon Cable 1 Connection only used if Modulating Pump is fitted 1 1 SWITCH ON OFF Boiler ON OFF Heating SL H Hot Water SL W Frost Protection SL F Room Stat SL R DHW Pump Boiler Pump 1b 1a 1 Bl Br B Bl G Y Bl R Or Wh B J34 J28 J29 J5 J3 J30 J31 J9 1 1 Br Br B B R Or R Or B Y 0 5 mm Tri Rated 2 8 7 6 5 A B C D E DRG NAME DRG SIZE JOB NAME TITLE BOILERMATE A Class SP with Clock Factory Stan...

Page 24: ...ow G Domestic hot water H Incoming mains cold water I Drain valve is not provided with the appliance J Primary flow for pumped summer towel rail circuit see page 16 Note The safety open vent and cold feed expansion must be connected to the F E cistern using the pipework assembly provided Do not alter or connect any pressure relief device to the vent pipe of this water heater All factory made joint...

Page 25: ...6 metres above the base of the BoilerMate A Class appliance Obviously if installed in the roof space the feed and expansion cistern and any pipework will need to be adequately insulated to protect against frost damage Combined feed and open vent pipe arrangements must not be used No valves should be fitted in the safety open vent which must be a minimum of 22mm copper pipe or equivalent Iftheautom...

Page 26: ...ot surfaces The supply to the BoilerMate A Class must be protected by a type B MCB to BS EN 60898 of at least 32 amps rating Two installer supplied flex cables are required to connect external room thermostat and boiler These cables must each be 4 core and at least 1mm2 or above in size For maintenance purposes it is essential that an all pole isolator is positioned within 2 metres of the remote b...

Page 27: ...adjusted to a suitable setting When the location of the boiler means that frost protection is required for the boiler circuit only a frost thermostat and pipe mounted thermostat should be fitted in the normal way and wired back to the special terminal provided in the appliance as shown below MCB 2 MCB 1 MCB 3 16A 6A 16A L N N SL B SL R L1 L2 L3 E E SL H SL F N N N E E PE IH N IH L IH L IH VAL N VA...

Page 28: ...Y TESTED COMMISSIONED AFTER THE GAS BOILER HAS BEEN COMMISSIONED MOVE MCB S 1 AND 2 TO THE ON POSITION WHICH WILL BREAK THE WARNING LABEL AND THEN COMMISSION THE SWITCH FACILITY L SL_B E N E L_P N_P Boiler Wiring Terminals e g Gledhill HEBoiler Roomthermostat SL L E N Factory fitted programmer with hot water and central heating control rockers Typical external wiring of a standard BoilerMate with ...

Page 29: ...DIAGRAM Note Terminals L3 AND SL H must be linked in a no clock multi zone option MCB 2 MCB 1 MCB 3 16A 6A 16A N E SL W SL B SL R L1 L2 L3 N N N SL F N IH L IH L IH SL H E E PE IH Zone 1 Hot Water Time Control Zone 2 4 Core cable 4 Core cable 2 2 INSTALLATION 2 0 INSTALLATION Connecting the zones to the BoilerMate The space heating flow should be taken from theBoilerMateconnectionintothespacebelow...

Page 30: ...tore overheat sensors Cold Water IN Domestic Hot Water OUT Bottom Immersion Heater 2K2 Resistor Black A_02 Top Immersion Heater S1 S2 ID_RESISTOR SENSOR LEGEND BLUE Bl BROWN Br GREEN GREY GREEN YELLOW G Gr G Y WIRE COLOUR LEGEND BLACK ORANGE YELLOW WHITE RED B Or Y Wh R Black Covering Flat Ribbon Cable 1 Connection only used if Modulating Pump is fitted 1 1 24 23 13 14 RELAY R1 A1 A2 200 240Vac 50...

Page 31: ...798 BS 5449 and BS 7593 Full details of the requirements are given in PAS 33 1999 under Section 10 Commissioning When using either cleansing or corrosion inhibitor chemical the manufacturers instructions must be followed Cleansing the Primary System It is very important to ensure that the Primary system is cleaned using a suitable cleansingagentsuchasSentinelX300orFernoxSuperfloctoensurethatanyflu...

Page 32: ...ation of the control system should be checked as follows a Check that the BoilerMate front panel mode rocker is in the normal position Put the hot water control rocker in the constant position and the central heating control rocker in the off position b The boiler will not start i e there will be no 240V ac start signal at BoilerMate terminal SL B until The programmer calls for hot water heating w...

Page 33: ...s instructions supplied with the appliance and ensure that the programmer instructions along with the user instructions for the appliance are left with the user NOTE Withsealedheatingsystemsairisreleasedfromthewaterduringthefirst few weeks of operation This must be vented and the system repressurized Commissioning Domestic Hot Water System a When the store is hot open a hot water tap nearest to th...

Page 34: ...ere is adequate clearance above the appliance F E cistern to service the ballvalve DO ensure that the range rated appliancesaresetatthehighestoutput and the boiler thermostat is set to maximum for all boilers DO insulate any exposed pipework in the BoilerMate A Class SP cupboard DO plumb the overflow warning pipe if fitted in a 20mm internal diameter pipe materialwhichissuitableforusewithaheatingF...

Page 35: ...reavailablefromGledhillduring the in warranty period normally 12 months After this spares can be obtained direct from Gledhill using the Speed Spares service or throughanyofthelargerplumbersmerchants specialist heating spares suppliers Help and advice is also available from the Technical Helpline on 08449 310000 However allcomponentsarereadilyaccessible and can be changed quickly and easily by the...

Page 36: ...225 9 1 x 6 kW switch immersion heater Wardtee XB430 All 10 Main PCB controller Pijnenburg GT490 All 11 Bottom store sensor Tasseron GT198 All 12 Middle store sensor Tasseron GT198 All 13 Top OHT sensor Tasseron GT199 All 14 Front panel display R H Technical XB414 All 15 Front panel display wiring harness R H Technical XB057 All 16 Internal fuses circuit protection MCB Single Pole 16A x 2 XG175 Al...

Page 37: ... is opened and closed Check that the plate heat exchanger pump is set at maximum speed Check that the space heating and hot water load is not greater than the boiler output and that the BoilerMate A Class model is suitable for the type of dwelling If all the above checks are satisfactory then it is possible that the performance of the heat exchanger is impaired by scale In this case the hot water ...

Page 38: ...R SHOWERS 4 FIXING OPTIONS FOR TAPS MIXERS 1 MK Range Combined Regulators Aerator for screwing onto Taps Mixers with internal or external threads on their noses AntiVandal models also available 2 MR05 T Range Internal Regulators Push fit into Tap or Mixer seats Produced in three sizes 12 5mm BS1010 12mm 10mm Flangeless models also available for Taps with Low Lift washers 3 MXF Standard Range Screw...

Page 39: ...d 595mm 2 No 6mm fixing holes 18 l mm 12 l mm 9 l mm 9 l mm 9 l mm 9 l mm 12 l mm inlet 55mm 18 l mm 12 l mm 9 l mm 9 l mm 9 l mm 9 l mm 9 l mm 9 l mm 9 l mm 9 l mm 12 l mm inlet 165mm 595mm A hot B cold blank blank 18 l min 12 l min 12 l min 9 l min 9 l min 9 l min 9 l min 9 l min 12 l min 18 l min inlet 595mm C D 18 l min 12 l min 12 l min 9 l mm 9 l mm 9 l mm 9 l mm 9 l mm 9 l mm 9 l min 9 l mi...

Page 40: ...and the resistance characteristics of the pipes The examples presented below are for 15mm copper pipe in table 1 and for plastic pipework in table 2 The preferred solution where space will allow An optional location where cupboard space is tight Table 1 Maximum equivalent pipe length in 15mm copper Inlet pressure bar Maximum equivalent length of pipe m 9 l m 12 l m 18 l m 2 0 25 10 5 2 5 75 30 15 ...

Page 41: ...nk should be branched off the cold water main prior to the treatment device instead of the cold water manifold Any other isolating control valves and backflow protection devices should be provided as necessary to comply with the Water Regulations Bath Toilet cistern Hand basin Toilet cistern Hand basin Hand basin Toilet cistern Mains supply Shower DW Kitchen sink Kitchen En Suite Bathroom Check va...

Page 42: ...ld be fixed to the system in a prominent location Where a combi boiler and or a hot water storage vessel is installed in areas where the mains water can exceed 200ppm Total Hardness as defined by BS 7593 1993 Table 2 a scale reduction device should be installed in accordance with the boiler manufacturer s instructions The levels of water hardness may be measured using a water hardness test kit BUI...

Page 43: ... easy lifting at the top of the product Each appliance is supplied with a pallet which has been attached to the unit via the packaging The pallet will also allow for one or two persons to get a good hold e Taking the lead for team lifts As more than one person is required for these products ensure that one person is taking the lead This may be you so ensure that each person that is helping is made...

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