gledhill BMA 215 OV-SOL Design, Installation & Servicing Instructions Download

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Design, Installation

& Servicing

Instructions

Model Numbers

BMA 215 OV-SOL
BMA 225 OV-SOL
BMA 235 OV-SOL
BMA 245 OV-SOL
BMA 265 OV-SOL
BMA 285 OV-SOL

All models comply with the water heater manufacturers

specification for integrated thermal stores

An open vented central heating

and mains pressure hot water

supply appliance with a thermal

store designed specifically for use

with solar energy

ISSUE 5: 06-08

Summary of Contents for BMA 215 OV-SOL

Page 1: ... BMA 245 OV SOL BMA 265 OV SOL BMA 285 OV SOL All models comply with the water heater manufacturers specification for integrated thermal stores An open vented central heating and mains pressure hot water supply appliance with a thermal store designed specifically for use with solar energy ISSUE 5 06 08 ...

Page 2: ...s 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 These arrangements represent a change from the situation whereby compliance with theBuildingRegulationswasa...

Page 3: ...s OV SOL model is only suitable for use with an open vented central heating system An SP model is available for sealed central heating systems The BoilerMate A Class OV SOL is not covered by section G3 of the current Building Regulations and has no special requirements with regard to Building Control The information in this manual is provided to assist generally in the selection of equipment The r...

Page 4: ...oilerMate A Class OV SOL appliance generally follows the principles of the standard BoilerMate A Class OV appliance but is fitted with a separate set of coils to allow it to maximisetheavailableamountofheatavailable from the solar panels controls This is then used to supplement both the heating and hot water systems Because this product does not require a safety discharge from a temperature and pr...

Page 5: ...ctors The built in controller 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 C flow and a 71 C return up to a maximum of 35kW can be linked to any suitable model of Boiler...

Page 6: ...from collector 30 Solar circulating pump modulating 31 Flow and temperature sensor SR 32 Expansion vessel connection solar circuit 33 Temperature sensor SZ 34 Temperature Sensor SC is supplied complete with 2 5 metres of 2 x 0 75mm2 high temperature silicon cable 35 Safety open vent 36 Cold feed expansion 37 Thermal store drain 38 Solar coil drain 39 100mm high installation base Optional Equipment...

Page 7: ...low in line with the pipe sizing calculations 2 The flow rates are based on a 35 C temperature rise and assume normal pressure and adequate flow to the appliance The actual flow rate from the appliance is automatically regulated to a maximum of 28 litres min 3 Unit is supplied on a 100mm high installation base 4 The domestic hot water outlet temperature is automatically regulated to approximately ...

Page 8: ...485 710 785 The above dimensions do not include the 100mm high installation base Minimum Cupboard Dimensions Model Height D Width E Depth F BMA 215 OV SOL 2080 660 630 BMA 225 OV SOL 2080 660 630 BMA 235 OV SOL 2025 660 630 BMA 245 OV SOL 2025 710 700 BMA 265 OV SOL 2025 740 725 BMA 285 OV SOL 1935 810 795 The above dimensions include the 100mm high installation base In the case of the 215 225 mod...

Page 9: ...s 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 A 15mm cold water supply and a 22mm warning overflow pipe will also be required for the separate feed and expansion tank Note All dimensions are...

Page 10: ...uns 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 A 15mm cold water supply and a 22mm warning overflow pipe will also be required for the separate feed and expansion tank Note All dimensions w...

Page 11: ...from channel 1 of the clock Store Shows if there is a demand for the store to be heated by a boiler primary circuit Boiler Shows if the boiler is on P CH Shows if the demand is present for central heating from channel 2 of the clock Rstat Shows if there is a demand from the room thermostat CHpump Shows if the central heating pump is on SolH Shows if there is a demand for heat from the solar circui...

Page 12: ...ich the thermal store is satisfied when being supplied with heat from the boiler is 77 C i e the off control set point of sensor S6 The solar system will start from a minimum 10 C differential between the temperature in the store SZ and the temperature at the solar panel collector SC i e the solar circulating pump only runs if the temperature as SC is at least 10 C above the temperature at SZ The ...

Page 13: ...pe code set on the controller The two must APPLIANCE CONTROL BOARD A C B Fuse T3 15L 250V 2 DIGIT ACB BOARD DISPLAY FLOW CHART Press S2 Press S2 Press S2 Press S2 Press S2 S2 S1 Press S1 Press S1 Press S1 Press S1 Appliance type Press S1 Press S1 Press S1 Press S1 Appliance type Press S1 Press S1 Press S1 Press S1 Fault code indicator block outs Press S1 Press S1 Press S1 Press S1 Fault code indic...

Page 14: ...f the selected appliance code does not match with the ID resistor fitted to the appliance then an error 33 will be displayed A table showing this and other common fault codes is shown below Fault Codes Fault code locations are numbered C0 CF andc0 cF CO cO locations hold the latest fault recorded A code of FF indicates that the fault location is empty If a sensor is faulty instead of a temperature...

Page 15: ...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 fitted in line scale inhibitor should be specified atthetimeoforderforhardnesslevelsbetween 200 and 300 ppm m...

Page 16: ...ter systems by the manufacturer and is installed fully in accordance with their recommendations It is also essential that if an alternative pipework material system is chosen the manufacturer confirms that the design criteria of the new system is at least equivalent to the use of BS EN Standard copper pipework and fittings or the pipework sizes are increased accordingly Taps Shower Fittings Aerate...

Page 17: ...e must not exceed 0 6 bar The F E cisterns must be installed at the same level and a typical arrangement is shown above If installed in a roofspace suitable insulation will need to be provided to the cisterns any pipework to protect them from damage by frost IfanyradiatorsarelocatedabovetheleveloftheBoilerMateA ClassOVSOLthesystem should be designed so that gravity circulation does not occur when ...

Page 18: ...onswithregardtopipeworksystemsinthismanualaregenerally 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 ...

Page 19: ...and must also be at least 250mm above the highest point of the system The height of the bottom of the F E cistern from the base of the store should be no greater than 6m A gravity check valve should be fitted in the boiler return pipework to prevent gravity circulationbetweentheBoilerMateA Classand the boiler during dormant periods ConnectionofBathroomRadiator Towel Rail for Summer use IfseparateS...

Page 20: ...r a high level termination from walls or on roofs is not normally considered acceptable because of the possible harm to people below A suitable solar expansion vessel will also be requiredanda15mmconnectionwithpressure gauge is provided on the top of the appliance The vessel shall be sized and the initial filling pressure established in accordance with an approved method such as set out in Appendi...

Page 21: ...lifting and fitting the solar panels collectors on the roof To prevent overheating in the summer and discharge from the pressure relief valve we suggest a saving of 50 of the energy required for the domestic hot water should be used as the target when calculating the number area of solar panels collectors required In addition to this we believe that a further 10 15 saving willbeachievedbecausetheB...

Page 22: ... two smaller appliances it may be possible to fit these at high level in the cupboardhousingtheBoilerMateA ClassOVSOL However itisnormalforthesetobe fitted elsewhere in the property such as the roofspace The 2 cisterns must be fitted at thesamelevelandabovetheapplianceinaccordancewiththedetailsshowninFigure 1 10 The location will need to provide a suitable route from the appliance for the cold fee...

Page 23: ...intopositionin the cupboard on top of the base and the front panelremovedbyunscrewingthe2screwsand liftingthedoorupandout readyforconnection ofthepipeworkandelectricalsupplies Thefeed andexpansioncisternsupportshallbeinstalled ensuring that the base is fully supported the working head of the appliance is not exceeded and the recommended access is provided for maintenance see the Technical Data sec...

Page 24: ...ry return connection to boiler 22mm compression 8 Heating return connection 22mm copper tube 9 Solar coil drain connection Rc 1 2 10 Primary flow connection from boiler 22mm copper tube 11 Thermal store drain connection Rc 1 2 12 Domestic mains cold water connection 22mm compression 13 Domestic hot water connection 22mm compression All factory made joints should be checked after installation in ca...

Page 25: ...e roof space then this and the 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 The overflow warning pipe shall have a continuous fall be fitted to discharge clear of the building and be sited so tha...

Page 26: ...ply 230VAC 50Hz 32Amps 6 0 10 0mm Twin Earth Cable PVC 10 0mm is only required when there is a high ambiant temperature and or long cable run CH1 HOT WATER CH2 CH TWO CHANNEL DIGITAL CLOCK 1 2 3 4 5 L 3 1 2 4 ISSUE No 4 APPROVED DATE MARCH 2008 DO NOT SCALE FROM THIS DRAWING COPYRIGHT OF THIS DRAWING IS RESERVED IT IS NOT TO BE REPRODUCED COPIED OR DISCLOSED TO A THIRD PARTY EITHER WHOLLY OR IN PA...

Page 27: ...estic Hot Water OUT Bottom store sensor 1K5 Resistor ID_Resistor White Middle store sensor S1 S2 SENSOR LEGEND Sc Sz Solar Collector sensor 20K Dedicated Solar Zone 20K Br Br O O Br Wh S5 S6 Br Wh Bl Br Br Bl Sr S 7 Solar Return Temp 147DI Solar Flow Rate 147DI F G Y Or Wh BL J34 J5 J30 J31 J9 1 Solar Collector Sensor fitted in the panel sensor pocket provided by manufacturer Minimum pocket size 8...

Page 28: ...d hot surfaces The supply to the BoilerMate A Class OV SOL must be protected by a type B MCB to BS EN 60898 of at least 32 amps rating Two installer supplied cables are required to connect the 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 a 3 pole isolator is positioned within 2 metres of the re...

Page 29: ...r means that frost protection is required for the boiler circuit then a frost thermostat and pipe mounted thermostat should be fitted in the normal way and wired back to the special terminal SL F provided in the appliance as shown below Br Br Blk Br Blk PIPE THERMOSTAT 4 Core 4 Core ROOM THERMOSTAT FROST THERMOSTAT Temperature setting range 3 to 20 C Set to 5 C 1 1 3 3 1 2 C 2 2 Bl Bl BoilerMate A...

Page 30: ...ARNING LABEL ANDTHEN COMMISSION THE SWITCH FACILITY Roomthermostat SL L E N Factory fitted 2 channel digital clock prewired Typical external wiring of a BoilerMate A Class OV SOL L SL_B E N E L_P N_P Boiler Wiring Terminals e g Gledhill HEBoiler Double pole Isolator Within 2 meters of appliance Permanent mains supply 230V 50Hz rated at 6 500W And fused at 32A 6 0mm Feed Cable 2 MCB 2 MCB 1 MCB 3 1...

Page 31: ... set as normal to control the hot water but channel 2 must be set to continuous operation mode Manual Isolating Valves Connection to BoilerMate OV SOL heating return pipe Connection to BoilerMate OV SOL heating flow pipe Connection to BoilerMate OV SOL elec terminals Zone 1 Programmable room thermostat Zone 2 Programmable room thermostat Zone 1 Flow Zone 2 Flow Zone 1 Return Zone 2 Return TYPICAL ...

Page 32: ...lumes Inmostcasesthequantitiesshownoppositewill be adequate for a typical installation Primary Water System Treatment When determining the quantity of inhibitor required be sure to allow for the increased volume of water in the primary circuit due to the thermal store see the Technical data section for volumes Inmostcasesthequantitiesshownoppositewill be suitable for a typical installation Failure...

Page 33: ...ges 13 14 of these instructions Either can be used The demands are shown on display 2 left hand and the resultant actions on display 1 right hand A diagram and table showing the function of each LED is shown opposite Set the BoilerMate A Class OV SOL power switch to on the dot in the right hand corner of display 2 will flash Set the hot water channel 1 on the digital clock on the front of the appl...

Page 34: ...ormal temperature before balancing the system in the usual way to achieve a temperature drop of about 10 C Set channel 2 of the digital clock and room thermostat as per manufacturer s instructions supplied and ensure that the digital clock instructions along with the user instructions for the appliance are left with the user Commissioning the Domestic Hot Water System When the store is fully up to...

Page 35: ...filling pump and pressure the system to 4 bar WATCHING THE LEVEL OF FLUID IN YOUR BOTTLE and adding more antifreeze solution if required When a pressure of 4 bar is achieved close the filling point on the fill and flush valve at the SAME time switch off the power at the RCD safety device Now leave the system under this pressure for at least 30 minutes Check the system for leaks including the roof ...

Page 36: ... clearance above the F E cistern to service the ballvalve meet the Water Regulation Requirements 5 DO ensure that any range rated boilers are set at the highest output and the boiler thermostat is set to maximum for all boilers 6 DOensurethatthebottomoftheF Ecisternisatleast250mmabovethehighest point on the radiator circuit or the highest point of the system 7 DO check that the bottom of the F E c...

Page 37: ...ice or through any of the larger plumbers merchants specialist heating spares suppliers Help and advice is also available from the Technical Helpline on 01253 474401 However all components are readily accessible and can be changed quickly and easily by the installer using common plumbing practice Note The PHE circulating pump is a Grundfos UPR 4 wire type and any replacement must be the same model...

Page 38: ... XG083 215 225 12 F E cistern ball valve Vemco FT206 All 13 1 x 6 kW switch immersion heater Wardtec XB468 All 14 Bottom store sensor Tasseron GT198 All 15 Middle store sensor Tasseron GT198 All 16 Top OHT store sensor Tasseron GT199 All 17 Main PCB controller Argus Vision XB442 All 18 Front panel digital display membrane R H Technical XB473 All 19 Front panel display wiring harness R H Technical ...

Page 39: ...Page 39 SERVICING SHORT PARTS LIST 1 2 3 4 28 5 6 14 15 7 9 8 10 11 12 13 17 18 19 24 23 22 20 25 27 29 34 35 33 32 31 30 36 16 21 26 ...

Page 40: ... that the store is charging to at least 77 C Check that the hot water plate heat exchanger pump stops and starts when the hot water tap is opened and closed Check that the space heating and hot water load is not greater than the boiler output and that the BoilerMate A Class OV SOL model is suitable for the type of dwelling If all the above checks are satisfactory then it is possible that the perfo...

Page 41: ...ood House 40 New Road Stourbridge West Midlands DY8 1PA Telephone 01384 442611 Fax 01384 442612 Water Savings Water Related Costs Can Be Reduced By Good Plumbing Practice TAPS MIXERS SHOWERS Unregulated 25 30 l m Regulated 10 12 l m Over 20 l m 5 6 or 8 l m 2 tap half open Fitted with regulator Unregulated 4 Fixing Options For Taps Mixers 1 MK Range Combined Regulators Aerator forscrewingontoTaps ...

Page 42: ...otal 10 15 APPENDIX APPENDIX B Two sets of manifolds are available as an optional extra Each set comprises a separate hot and cold water manifold Both are provided with a 22mm inlet connection located centrally All outlet connections are 15mm compression The centre to centre dimension of each branch is 55mm 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 ...

Page 43: ...the sink should be branched off the cold water main prior to the treatment device instead of the cold water manifold Anyotherisolating controlvalvesandbackflow protection devices should be provided as necessary to comply with the Water Regulations An optional location where cupboard space is tight Table 1 Maximum equivalent pipe length in 15mm copper Inlet pressure bar Maximum equivalent length of...

Page 44: ...Page 44 APPENDIX APPENDIX C ...

Page 45: ...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 aware of the weight and of ...

Page 46: ...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 charge during the first year after delivery by us ii thereafter at a charge of one tenth of the then current list price and any copper price supplement and delivery charge during the second year after del...

Page 47: ...ject to of 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 until property in the goods supplied hereunder passes to the Purchaser in accordance with paragraph 2 above i the Purchaser shall hold the goods in a fiduciary capacity for us and shall store ...

Page 48: ...Thecodeofpracticefortheinstallation commissioning servicingofcentralheatingsystems ...

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