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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 fl uctuating 
demands for heating and hot water.  

Because this product does not require a safety discharge from a temperature and 
pressure relief valve, any installations will be easy to incorporate into the building and 
will not suffer from the problems associated with using PVCu soil stacks to take the 
discharge from unvented cylinders.

An important feature of this concept is that hot water can be supplied directly from 
the mains at conventional fl ow 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.

The Building Regulations L1A: New dwellings/L1B: Existing dwellings and the 
requirements set out in the Domestic Heating Compliance Guide specify that “where 
the mains water hardness exceeds 200ppm provision should be made to treat the 
feed water to water heaters and the hot water circuit of combination boilers to reduce 
the rate of accumulation of lime scale”.

To comply with this requirement the hardness of the mains water should be checked 
by the installer and if necessary the optional factory fi tted electronic in-line scale 
inhibitor should be specifi ed at the time of order for hardness levels between 200 
and 300 ppm (mg/l).

Where the water is very hard ie 300ppm (mg/l) and above the  optional polyphosphate 
type, inhibitor should be specifi ed at the time of order.  However, this will need to be 

1.0 DESIGN

Description

1.1 INTRODUCTION

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fi tted 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.  

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 
82

0

C fl ow and a 71

0

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 
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.

The heat losses from thermal stores should not 
be directly compared with heat losses 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 refl ect the 
different ways that the hot water and heating 
operates.

For further information please request a copy 
of the SAP 2005 Data Sheet which provides 
the information required to produce SAP 
calculations for all Gledhill Thermal Storage 
products.

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 diffi culties as well as incurring 
extra costs.

Summary of Contents for BoilerMate BMA 125 OV

Page 1: ...MPLY WITH THE WATER HEATER MANUFACTURERS SPECIFICATION FOR INTEGRATED THERMAL STORES TM benchmark Thecodeofpracticefortheinstallation commissioning servicingofcentralheatingsystems Gas Council Approve...

Page 2: ...rom 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 a...

Page 3: ...otifiable to Building Control The BoilerMate A Class OV is not intended for use by persons including children with reduced physical sensory or mental capabilities or lack of experience or knowledge un...

Page 4: ...ORE AUTOMATIC BYPASS VALVE 4 2 15 2 UNLESS THE HEATING SYSTEM INCORPORATES MECHANICAL THERMOSTATIC CONTROL VALVES E G 4 2 6gS TO ALL RADIATORS OR PORT ZONE VALVES 0RIMARY FLOW 0RIMARY RETURN LASS OILE...

Page 5: ...rature 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...

Page 6: ...rature 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 separ...

Page 7: ...tional 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 1000...

Page 8: ...k 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 a...

Page 9: ...troller 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 Wh...

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 W...

Page 11: ...thefeed 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 wa...

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 manufacturerconfirmsthatthedesigncriteria...

Page 13: ...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 thesystemincludingtheradiatorsandmus...

Page 14: ...ernally 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...

Page 15: ...and depending uponthepipelayoutamanualairventmayalso berequiredonthereturnadjacenttotheboiler see boiler installation insructions Boiler sited with dipped flow and return pipes to the BoilerMate Any...

Page 16: ...ge 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...

Page 17: ...rooms 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 Bothprimarypumpsandtheprima...

Page 18: ...ot 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 waterandcentralheatingco...

Page 19: ...tures 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 locatio...

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 b...

Page 21: ...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 must be connected t...

Page 22: ...Mains Supply 230VAC 50Hz 32Amps 6 0 10 0 mm Twin Earth Cable PVC 10 0mm is only required when there is a high ambiant temperature and or long cable run N L N E E SL W SL B SL R L1 L2 L3 N N N SL F N I...

Page 23: ...CALE INHIBITOR Y White Covering 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 D...

Page 24: ...d more than 6 meters above the base of the BoilerMate A Class appliance Obviously any pipework in the roof space and the feed and expansion cistern will need to be adequately insulated to protect agai...

Page 25: ...ll cables are routed to avoid hot 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 requi...

Page 26: ...t 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...

Page 27: ...AS BOILER HAS BEEN FULLY 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...

Page 28: ...ection is made to the heating return on the BoilerMate Atypicalwayofprovidingheatingandhotwater time control is shown below However other methods can be used such as using a 3 channel programmer if re...

Page 29: ...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 B...

Page 30: ...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 t...

Page 31: ...e 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...

Page 32: ...The BoilerMate controller will now Turn on the 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 bef...

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 theboilerandtheBoilerMateunlesstheboiler...

Page 34: ...mGledhillusingthe SpeedSpares service or throughanyofthelargerplumbersmerchants specialist heating spares suppliers Help and advice is also available from the Technical Helpline on 08449 310000 Howeve...

Page 35: ...tlet XB122 210 225 8 1 x 6 kW switch immersion heater Wardtec XB468 125 145 185 XB469 215 XB470 225 9 Main PCB controller Argus Vision GT490 All 10 Bottom store sensor Tasseron GT198 All 11 Middle sto...

Page 36: ...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...

Page 37: ...OPTIONS 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 availa...

Page 38: ...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...

Page 39: ...formation 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 a...

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...

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 defin...

Page 42: ...ng 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 Takin...

Page 43: ...r in materials or workmanship we will either repair or supply replacement at our option with the closest substitute in the case of any obsolete product to any address in Great Britain i free of all ch...

Page 44: ...any other contract between the Purchaser and us which at the time of payment of the full price of the goods sold under this contract have been delivered to the Purchaser but not paid for in full c unt...

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