gledhill benchmark BMA 125 OV, Design, Installation And Servicing Instructions

Page 1: ...PRESSURE HOT WATER SUPPLY SYSTEM INCORPORATING A THERMAL STORE ALL MODELS COMPLY WITH THE WATER HEATER MANUFACTURERS SPECIFICATION FOR INTEGRATED THERMAL STORES TM benchmark Thecodeofpracticefortheinstallation commissioning servicingofcentralheatingsystems 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: ...nts 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 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 care...

Page 3: ...ystem TheBoilerMateA Classisnotcoveredbysection 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 desig...

Page 4: ...self 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...

Page 5: ... 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 G...

Page 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 heat...

Page 7: ...he 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 ...

Page 8: ...Page 8 1 0 DESIGN 1 2 TECHNICAL DATA ...

Page 9: ...h 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 resistorvaluesfortheB...

Page 10: ...n 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...

Page 11: ... 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 hardnes...

Page 12: ...anufacturer 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 ...

Page 13: ...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 ThewaterlevelintheF Ecisternshouldbe at least 250mm above the highest point on thesystemincludingtheradiatorsandmust be high enough to provide the minimum head required by the bo...

Page 14: ...ework 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 confirm...

Page 15: ...oilerMateA Classand the boiler during dormant periods An automatic air vent will be required on the flow adjacent to the boiler and depending uponthepipelayoutamanualairventmayalso berequiredonthereturnadjacenttotheboiler see boiler installation insructions Boiler sited with dipped flow and return pipes to the BoilerMate Any boiler must be fitted with an overheat thermostat i e it must be approved...

Page 16: ...e table on page 5 The radiators will only get hot when the boiler is firing Itisimportantthattheflowratesthroughthese 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 a...

Page 17: ...rimary pump Theheatingandhotwaterfromeachappliancemustserve separatezones 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 Boile...

Page 18: ...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 situatio...

Page 19: ...adening material i e carpet underlay or similar Cupboard temperatures will normally be higher than in a conventional system and the design of the cupboard and door will need to take this into account No ventilationisnormallyrequiredtothecupboard A suitable location will be needed for the separate feed and expansion cistern This will often be at high level in the cupboard housing the BoilerMate A C...

Page 20: ...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 sup...

Page 21: ...return F Central heating flow G Domestic hot water H Incoming mains cold water I Drain valve is not provided with the appliance J Primary return for pumped summer towel rail circuit Note The safety open vent and cold feed expansion should be connected to the F E cistern using the pipework assembly provided All factory made joints should be checked after installation in case they have been loosened ...

Page 22: ...D PART No XB142 2 x 3kW Heating Elements S 3 S 4 S 5 S 6 Store overheat sensors Cold Water IN Domestic Hot Water OUT Bottom Immersion Heater 1K5 Resistor White Top Immersion Heater S1 S2 ID_RESISTOR SENSOR LEGEND BLUE Bl BROWN Br GREEN YELLOW G Y WIRE COLOUR LEGEND BLACK ORANGE YELLOW WHITE RED B Or Y Wh R 2 DOUBLE POLE CHANGE OVER SWITCHES WITH CENTRE OFF FACTORY FITTED CLOCK STANDARD OPTION 24 2...

Page 23: ... J31 J9 L L L N N N E E E M M M All wire sizes 0 5mm unless otherwise stated SCALE INHIBITOR White Covering Flat Ribbon Cable 1 Connection only used if Modulating Pump is fitted 1 1 SWITCH ON OFF Boiler ON OFF Heating S L Hot Water S L Room Stat S L DHW Pump Heating Pump Boiler Pump G Y Or Wh BL Bl Br R J33 J32 J34 J28 J29 J5 J3 J30 J31 J9 1 1 8 7 6 5 A B C D E DRG NAME DRG SIZE JOB NAME TITLE BOI...

Page 24: ...nce Obviously any pipework in the roof space and the feed and expansion cistern 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 The overflow warning pipe shall have a continuous fall be fitted to discharge cl...

Page 25: ...etres from the appliance Make the connections as shown opposite The appliance is provided with a link between terminals SL_R and L2 on the terminal connections This must be removed if a room thermostat is fitted see opposite Clamp the cables in the grips provided below theterminalconnectionsandensureallcables are routed to avoid hot surfaces Note The appliance is provided with a 4 0mm earth cable f...

Page 26: ...weather the programmer should be set to constant during the time required and the room thermostat adjusted to a suitable setting When the location of the boiler means that frost protection is required the boiler specified should incorporate its own integral frost thermostat Important When the boiler has an integral frost thermostat fitted it will be necessary for the primary pump to be powered from ...

Page 27: ...TALLER PLEASE NOTE THE 2 x 16A MCB s MCB1 and MCB2 FOR THE SWITCH ELECTRIC BACKUP SYSTEM ARE SUPPLIED SET IN OFF POSITION THE GAS BOILER CAN BE COMMISSIONED WITHOUT SWITCHING THESE ON IT IS IMPORTANT THAT THE GAS BOILER IS COMMISSIONED BEFORE TESTING OR USING EMERGENCY SWITCH FACILITY AFTER THE GAS BOILER HAS BEEN COMMISSIONED CUT AND REMOVE THE PLASTIC TIE AND MOVE THE MCB S TO ON POSITION TO COM...

Page 28: ...porting the weight of the appliance when full Details of the weight when full is provided in section 1 2 Technical Data 1 COM 2 OFF 3 ON E L N E SL L1 L E N AS 1 COM 2 OFF 3 ON E L N E SL L1 L E N AS E 2 2 INSTALLATION 2 0 INSTALLATION Connecting the zones to the BoilerMate The space heating flow should be taken from theBoilerMateconnectionintothespacebelow the platform The flow can now be split int...

Page 29: ...ts 2 x auto reset OHT set at 95 0 5 o C 1 5m long 2 5mm 2 high temp flying cables CT 3 6 2 5 1 4 3 6 2 5 1 4 J5 3 6 2 5 1 4 3 6 2 5 1 4 4 8 3 7 2 6 1 5 4 8 3 7 2 6 1 5 J28 4 8 3 7 2 6 1 5 E N L M DHW Pump J34 4 8 3 7 2 6 1 5 E N L M Boiler Pump J32 J3 5 10 4 9 3 8 2 7 1 6 J30 Main PCB 2 4 1 3 J29 2 4 1 3 J29 J28 8 HW calling orange J5 3 L J3 6 L Earth to Panel brown Red Electric backup g y g y blu...

Page 30: ...s shown opposite will be adequate for up to a typical 3 4 bedroom property Primary Water System Treatment Although the BoilerMate has no special water treatment requirements the radiators and other parts of the circuit will benefit from the application of a scale and corrosion inhibitor such as Sentinel X100 or a Protector such as Fernox MB1 When determining the quantity of inhibitor required be su...

Page 31: ...rking However it is a warning of limited alternative control functionality b The boiler will not start i e there will be no 240V ac start signal at BoilerMate terminal SL B until The heating programmer calls for hot water heating which will bring display segmentV1 1 on and Store sensors are calling for heat which will bring display segments H1 1 and H1 2 on see opposite c Set the boiler thermostat...

Page 32: ...central heating pump and this will be indicated by display segment H2 2 being lit c Wait until the heating circuit has reached its normal temperature before balancing the system in the usual way to achieve a temperature drop of about 10o C d Set the programmer and room thermostat as per manufacturer s instructions supplied with the appliance and ensure that the programmer instructions along with t...

Page 33: ... T use pipe smaller than 28mm between the boiler and the BoilerMate when the boiler rating exceeds 20kW about 68 000 Btu h 14 DON Tusedippedflowandreturnbetween theboilerandtheBoilerMateunlesstheboileris fittedwithanoverheatthermostat Ifnecessary check with the suppliers of the boiler 15 DON T operate the switch backup facility until the system is fully fitted vented and commissioned 16 DON T place ...

Page 34: ... 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 01253 474401 However allcomponentsarereadilyaccessible and can be changed quickly and easily by the installer using common plumbing practice Note The PHE pump is a Grundfos UPR 4 wi...

Page 35: ...utlet XB122 210 225 9 Central heating pump isolating valves Vemco Inlet XB121 125 145 185 Vemco Outlet XB121 125 145 185 Vemco Inlet Outlet XB122 210 225 10 1 x 6 kW switch immersion heater Backer XB084 All 11 Main PCB controller Pijnenburg GT490 All 12 Bottom store sensor Tasseron GT198 All 13 Middle store sensor Tasseron GT198 All 14 Top OHT sensor Duplex GT199 All 15 Front panel display R H Tec...

Page 36: ...rts when the hot water tap 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 I...

Page 37: ...PTIONS FOR 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 Ran...

Page 38: ... g n i t t i f l a n i m r e T s t e l t u o d l o f i n a m r e t a w t o H y t i t n a u Q s t e l t u o d l o f i n a m r e t a w d l o C y t i t n a u Q 8 1 p a t h t a B 1 1 8 n i s a b d n a H 3 3 0 1 k n i s n e h c t i K 1 1 8 n r e t s i c t e l i o T e n o N 3 8 r e w o h S 1 1 8 e n i h c a m g n i h s a W 1 1 8 r e h s a w h s i D e n o N 1 l a t o T 7 1 1 595mm 2 No 6mm fixing holes 1...

Page 39: ...lastic pipework in table 2 r e p p o c m m 5 1 n i h t g n e l e p i p t n e l a v i u q e m u m i x a M 1 e l b a T e r u s s e r p t e l n I r a b m e p i p f o h t n e l t n e l a v i u q e m u m i x a M m l 8 m l 0 1 m l 8 1 0 2 3 3 3 1 5 5 2 0 1 1 5 4 7 1 0 3 0 0 2 0 8 0 3 e p i p c i t s a l p n i s h t g n e l e p i p t n e l a v i u q e m u m i x a M 2 e l b a T e r u s s e r p t e l n I r...

Page 40: ... 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 valve NOT REQU...

Page 41: ... label should 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 t...

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