Gledhill BMA 200 SP-SOL Nota de publicación

Design, Installation

& Servicing

Instructions Addendum

These instructions must be read in conjunction with the

standard Boilermate A-Class SP Design, installation and

servicing instructions before installation

Model Numbers

BMA 200 SP-SOL

BMA 220 SP-SOL

BMA 240 SP-SOL

BMA 260 SP-SOL

BMA 280 SP-SOL

BMA 300 SP-SOL

All models comply with the water heater manufacturers

speciﬁcation for integrated thermal stores

A sealed system central heating

and mains pressure hot water

supply appliance with thermal

store designed speciﬁcally for use

with solar energy

ISSUE 5: 06-08

Page 2

Section Page

DESIGN

Introduction 3

Technical Data 5

INSTALLATION

Wiring Details 10

Typical Pipework Arrangement 12

Controls 13

Filling/Commissioning 16

Short Parts List 17

Terms & Conditions 22

ISSUE 5: 06-08

The code of practice for the installation,

commissioning & servicing of central heating systems

The Gledhill BoilerMate range is a WBS

listed product and complies with the WMA

Speciﬁcation for integrated thermal 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

The Gledhill Group’s ﬁrst priority is to give a

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.

Building Regulations and Benchmark Commissioning

The Building Regulations (England & Wales) require that the installation of a heating

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

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

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 being

replaced by a similar document in the form of a commissioning check list and a service

interval record is included with all gas appliance manuals. However, the relevant

Benchmark Logbook is still being included with all Thermal Storage products and

unvented cylinders.

Gledhill fully supports the Benchmark aims to improve the standards of installation

and commissioning of central heating systems in the UK and to encourage the regular

servicing of all central heating systems to ensure safety and efﬁciency.

Building Regulations require that the heating installation should comply with the

manufacturer’s instructions. It is therefore important that the commissioning check

list is completed by the competent installer. This check list only applies to installations

in dwellings or some related structures.

Page 3

INTRODUCTION

DESIGN

The arrangement of a typical BoilerMate A-Class

SP Solar installation is shown schematically

below. The basic unit which is covered by these

instructions incorporates the Danfoss SH - E01

solar controller.

The appliance generally follows the principles

of the standard BoilerMate A-Class SP appliance

but is fitted with a separate set of coils to

allow it to accept the maximum amount of

heat available from the solar panels/controls.

This is then used to supplement the hot water

system.

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.

The models 200 and 220 are supplied with a

single F&E cistern. All four larger models are

supplied with two F&E cisterns.The single cistern

will ﬁt within the cupboard in a typical storey

height cupboard but when two cisterns are

used, these will need to be located elsewhere.

The operation of the appliance/solar system is

controlled by a number of sensors. The location

and reference numbers of the various sensors

is shown eg 2, S6.

Sensors S1/S2, S3, S4, S5 and S6 are connected

to the appliance control PCB which operates all

the heating and hot water functions as the basic

BoilerMate appliance.

Sensors T1, T2 and T3 are connected to the

Danfoss controller and operate all the solar

functions.

Sensor T3 provides a high temperature interlock

to de-activate the solar pump at a temperature

of 90°C in the store.

Although sensors T3 and T2 are wired in to the

solar controller the cable provided for Sensor T1

(3 metres long) may require to be extended by

the installer dependant on the location of the

solar panels/appliance. (2 x 0.75mm2double

insulated cable) up to a maximum total length

of 50 metres.

A safety device (pressure relief valve) to control

the risk of over-pressure in system components

should be ﬁtted as shown on the Solar System

diagram. A termination from a safety pressure

device should minimise the risk of damage

to persons or materials. Suitable locations are

a high temperature receptacle, an internal

Schematic Diagram of Typical BoilerMate 260 SP solar system Figure 1.1

F&E cisterns

Solar

collector

Solar

circuit

Note: V1-

V2-

normally open

(powered closed)

normally closed

(spring return)

Heating

circuit

PRV

Discharge pipe

BoilerMate

A-Class SP Sol

Boiler

Hot out

S1/S2

Mains

cold in

Heating/hot

water controls

(ACB) Automatic

bypass

valve

Sealed

system kit -

available as

an optional

extra

Components fitted

within the

appliance case

Commissioning/

filling assembly Solar

Controls

Page 4

DESIGN

INTRODUCTION

gulley or else issue externally at ground level.

High level termination from walls or on roofs

could cause injury to people or animals below

if the valve were to release scalding water and

steam.

The pipe leading to the safety device and

the collector should be of rigid and non-

deformable construction,without any possibility

of restriction or disclosure by any other ﬁtted

component.

In order to meet the Building Regulations

requirement to reduce the rate of accumulation

of scale in hard water areas, it is important

that the installer checks the hardness of the

incoming water supply.

If this exceeds 200ppm (mg/l), we recommend

that the factory ﬁtted scale inhibitor is ordered

as an optional extra.

If it exceeds 300ppm (mg/l),we recommend the

use of a polyphosphate type of scale inhibitor.

This can also be ordered as an optional extra but

will need ﬁtting on site by the installer.

Note:

If the summer towel rail circuit is required, this

will need to be a separate zoned circuit from the

heating circuit complete with its own time and

temperature controls.

The standard manual ﬁll model BoilerMate A-

Class SP SOL appliance is shown.A ballvalve and

overﬂow are available as an optional extra at the

time of order.If required,these should be ﬁtted

in the plain F&E cistern in a position to suit the

individual site conditions.

Model Selection Data Table/Weights

Model Reference

BMA

200 SP

SOL

BMA

220 SP

SOL

BMA

240 SP

SOL

BMA

260 SP

SOL

BMA

280 SP

SOL

BMA

300 SP

SOL

Dwelling

type

Bedrooms 2-3 2-4 3-5 3-5 4-5 5-6

Bathrooms 1 2 2 2 2 3

En-Suite 2 1 2 3 3 3

Max Floor Area (m2) 80 100 130 170 220 280

Weight Empty (kg) 73 79 96 104 112 120

Full (kg) 233 260 313 366 411 472

Volume Total (l) 160 181 217 262 299 352

Solar (l) 82 93 109 127 148 167

Note:

It is important that the maximum ﬂoor area is not exceeded to achieve compliance

with the SAP regulations.

Page 5

BoilerMate A-Class

SP SOL

300 *250A100 *500

Maintenance

access

Figure 1.2

*Minimum access /

maintenance access

above the appliance

case.

*If the F&E cistern is

fitted with a ballvalve,

this dimension will

need to increase to

350mm to comply with

the Water Regulations.

The minimum clear

opening in front of

the appliance to be

at least the same as

the depth of the

appliance

plus 50mm.

The cupboard door

opening will need to

take into account the

various sizes of

appliances.

F&E cistern

BMA 200-220 SP SOLBMA 240-300 SP SOL

Appliance Dimensions

Model Height

(A)

Width

(B)

Depth

(C)

BMA 200-SP SOL 1330 560 620

BMA 220-SP SOL 1330 560 620

BMA 240-SP SOL 1575 560 620

BMA 260-SP SOL 1575 610 670

BMA 280-SP SOL 1575 640 700

BMA 300-SP SOL 1485 710 770

The above dimensions are for the appliance

only and do not include the 100mm high

installation base.

Minimum Cupboard Dimensions

Model Height

(D)

Width

(E)

Depth

(F)

BMA 200-SP SOL 1980 660 630

BMA 220-SP SOL 1980 660 630

BMA 240-SP SOL 2175 660 630

BMA 260-SP SOL 2175 710 680

BMA 280-SP SOL 2175 740 710

BMA 300-SP SOL 2085 810 780

The above dimensions include the 100mm

high installation base and allow space for

installation/maintenance of the appliance only.

The height shown for the 200-220 models also

allows for the installation of the F&E cistern (with

no ballvalve) as shown opposite.

Note:With the 240-300 models,additional space

will be required for two feed and expansion

cisterns (each 280mm wide x 420mm deep x

300 high).This is NOT included in the minimum

cupboard dimensions shown above. Access

and maintenance space will also be required

for these cisterns.

Options at Extra Cost

• Hot and cold water manifolds for use with

plastic pipework.

• Scale inhibitor for mains water services with

hardness levels above 200ppm (mg/l).

• Ballvalve/overﬂow connector for automatic

ﬁll model.

• Primary sealed system kit for ﬁtting near

boiler comprising:

- Expansion vessel (size varies with model)

- 15mm 3 bar pressure relief (safety) valve

- Pressure gauge and ﬁlling loop

DESIGN

TECHNICAL DATA

Page 6

Connection Details/Dimensions - 200 model

Figure 1.3

490 - Boiler Flow

525 - Heating Flow

560 - Combined Boiler/Heating Return

620 (including the door/clock)

560

520 - Domestic Hot Water

545 - Incoming Cold Supply

210

490

520

130

Connection Details/Dimensions

Diagrams opposite show the connection details

and dimensions for the BoilerMate A-Class SP

SOL appliance.

The BoilerMate A-Class SP SOL 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. A 15mm cold water

supply and a 22mm warning/overflow pipe

may also be required for the separate feed and

expansion cisterns if these are located in the

appliance cupboard.

Note: All dimensions are shown in mm and

are to the centre line of pipework/gland.

Connection Details/Dimensions - 220 model

Figure 1.4

490 - Boiler Flow

525 - Heating Flow

560 - Combined Boiler/Heating Return

620 (including the door/clock)

560

520 - Domestic Hot Water

545 - Incoming Cold Supply

210

490

520

130

DESIGN

TECHNICAL DATA

Page 7

DESIGN

TECHNICAL DATA

Connection Details/Dimensions - 240 model

Figure 1.5

490 - Boiler Flow

525 - Heating Flow

560 - Combined Boiler/Heating Return

620 (including the door/clock)

560

520 - Domestic Hot Water

545 - Incoming Cold Supply

210

490

520

130

Connection Details/Dimensions

Diagrams opposite show the connection details

and dimensions for the BoilerMate A-Class SP

SOL appliance.

The BoilerMate A-Class SP SOL 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. A 15mm cold water

supply and a 22mm warning/overflow pipe

may also be required for the separate feed and

expansion cisterns if these are located in the

appliance cupboard.

Note: All dimensions are shown in mm and

are to the centre line of pipework/gland.

Connection Details/Dimensions - 260 model

Figure 1.6

535 - Boiler Flow

595 - Heating Flow

625 - Combined Boiler/Heating Return

670 (including the door/clock)

610

600 - Domestic Hot Water

615 - Incoming Cold Supply

240

510

550

130

Page 8

Connection Details/Dimensions - 280 model

Figure 1.7

570 - Boiler Flow

605 - Heating Flow

650 - Combined Boiler/Heating Return

700 (including the door/clock)

640

605 - Domestic Hot Water

610 - Incoming Cold Supply

250

570

605

160

Connection Details/Dimensions

Diagrams opposite show the connection details

and dimensions for the BoilerMate A-Class SP

SOL appliance.

The BoilerMate A-Class SP SOL 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. A 15mm cold water

supply and a 22mm warning/overflow pipe

may also be required for the separate feed and

expansion cisterns if these are located in the

appliance cupboard.

Note: All dimensions are shown in mm and

are to the centre line of pipework/gland.

Connection Details/Dimensions - 300 model

Figure 1.8

000 - Boiler Flow

000 - Heating Flow

000 - Combined Boiler/Heating Return

770 (including the door/clock)

710

000 - Domestic Hot Water

000 - Incoming Cold Supply

000

Details to follow

in later issue

DESIGN

TECHNICAL DATA

Page 9

DESIGN

TECHNICAL DATA

Standard Equipment

The standard conﬁguration of the BoilerMate

A-Class SP SOL is shown opposite.The Appliance

Controllers mounted inside the appliance,

control the operation of the complete system.

These are pre-wired to a terminal strip where all

electrical connections terminate. It is supplied

with the following factory ﬁtted equipment:-

Switch immersion heater (2 x 3kW elements & OHT’s)

2 Grundfos UPR 15-50 (185 & 215 model) or

15-60 boiler/central heating pump

3 Overheat (top) sensor pocket (Sensor S1/S2)

4 Middle sensor pocket (Sensor S6)

5 Bottom sensor pocket (Sensor S5)

6 DHW (CW) inlet sensor, S3

7 DHW outlet sensor, S4

8 Grundfos UPR 15-50 PHE pump

9 Filter & ﬂow regulator

10 Plate heat exchanger

11 Isolating valves

12 Non return valve

13 Open vent/safety connection

14 Cold feed/expansion connection

15 CW inlet connection

16 HW outlet connection

17 Thermal store drain tapping

18 Return from PHE to store

19 Flow from store to PHE

20 Combined boiler/heating return

21 Primary ﬂow manual air vent

22 Boiler ﬂow (from boiler)

23 CH ﬂow

24 2 port valve V1 (boiler ﬂow)

25 2 port valve V2 (CH ﬂow)

26 Solar heat exchanger return connection

to solar panel

27 Solar heat exchanger ﬂow (collector)

connection from panel

28 Remote solar panel sensor (T1) & cable

29 Solar return sensor (T2)

30 Solar overheat sensor (T3)

31 Solar circuit pump UPS 15-60 (high temp.)

32 Solar controller

33 User control panel/clock

34 Appliance control board

35 Electrical DIN rail

36 Solar expansion vessel connection (ﬁtted

with pressure gauge)

37 100mm high installation base

Optional Equipment

• Hot and cold water manifolds for use with

plastic pipework (Set 1 or 2).

• Electronic scale inhibitor for mains water

services with hardness levels above

200ppm (mg/l) ﬁtted in the appliance.

• Polyphosphatescaleand corrosion inhibitor

for mains water services with hardness

levels above 300ppm (mg/l) for ﬁtting on

site by the installer.

Figure 1.9

11/12

Note 1: All the panels,pipework and other components necessary for the installation

of the remainder of the solar system can be supplied by Gledhill with the BMA SP SOL

appliance. For further details please contact the Gledhill Technical Sales Dept.

Note 2: A single feed and expansion cistern will be supplied with the BMA 200 and 220

SP SOL appliances.Two feed and expansion cisterns will be supplied for other models.

Note 3: A solar commissioning/ﬁlling assembly is provided separately for ﬁtting

vertically on site (see diagram on page 9 for more detail).

Page 10

INSTALLATION

WIRING DETAILS

‘A’ Class BoilerMate SP SOL ver 4.ai

Br Br

G/Y

B B

ID_RESISTOR

FRONT PANEL

'MODE'

Switch

Green Neon Illuminated

ON / OFF Switch

Red LED

Push Button

S1 & S2

J33

J32

J28

J29 J3

L LN NE EM M

* All wire sizes 0.5mm² unless otherwise stated

2 3 41

SPD1/2A

OPTIONAL EXTRA

IF FITTED

(PART No XB142)

SCALE INHIBITOR

BlueBl

BrownBr

Green

Grey

Green / Yellow

G/Y

WIRE COLOUR LEGEND

Black

Orange

Yellow

White

Red

Black Covering

2K2 A-ID A02

Flat Ribbon Cable

(1) Connection only used

if Modulating Pump is fitted

(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

1a 1

1a 1b

Rocker Switch

terminal conections

SOLAR CO NTROLLER

DANFOSS SH-E01

N L T1 COM T2 AL P1

P-SL

Solar Pump High Store

temperature interlock.

Capillary Thermostat set to 87 C

Cotherm GTLH0054

3 Speed

Solar Pump

T2 SOLAR

Mod

Speed

S 3

S 4

S 5

S 6

Store overheat sensors

Cold Water IN

Domestic Hot Water OUT

Bottom store sensor

2K2 Resistor (Black)

Middle store sensor

S1 & S2

ID_RESISTOR

SENSOR LEGEND

APPLIANCE ID A02

S5 & S6

Duplex Sensor must fitted into S6

pocket i.e. above both V3 & V2 valves

Duplex Sensor must be fitted in

top saftey overheat pocket

and secured

CH1

HOT

WATER

CH2

ZONE 1

TWO CHANNEL DIG ITAL CLOCK

123 4 5

G/Y

J34

J30

J31

(1)

Br Br Br

MCB 2

MCB 1

MCB 3

16A 6A

16A

Mains Supply

230VAC 50Hz 32Amps

(10.00 mm² Twin & Earth Cable PVC)

L N

SL-W

SL-B

SL-R

SL-F

N-IH

L-IH

2.5 mm SID Silicone

2 x 3kW Heating Elements

SL-H

PE-IH

2.5 mm SID Silicone

2.5 mm SID Silicon

2.5 mm SID Silicone

4.0 mm SIF Silicone

2.5 mm SIF Silicone

2.5 mm SID Silicone

Dedicated Solar Zone Sensor

Solar Collector Sensor fitted

in the panel sensor pocket

provided by manufacturer.

Minimum pocket size 8mm.

Remove link to fit room stat.

3 WAY BUS BAR

2 4

1 3

2.5 mm SID Silicone

31 2 87654

DRG. NAME

DRG. SIZE

JOB NAME

TITLE

BOILERMATE 'A' Class SP SOL ADL1

With Danfoss Solar Controller

and three 2 port valves, factory fitted

2 channel digital clock.

Electrical Schematic for :

BOILERMATE 'A' class SP SOL ADL1

Appliance fitted with 2 channel digital clock

ISSUE No : 4

APPROVED

DATE : MARCH 2008

GLEDHILL WATER STORAGE LTD.

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 PART WITHOUT OUR

WRITTEN CONSENT.

SYCAMORE TRADING ESTATE

SQUIRES GATE LANE

BLACKPOOL

LANCASHIRE

FY4 3RL

DRN. SIGN. DATE DATEAPP'D.

CH'KD.DATE

03-03-08 03-03-08

03-03-08

S. McGachie S. Gataora

S. Gataroa

Zone Valve

Normally

Open

SIGN.

VAL-N

VAL-V1

VAL-V2

VAL-SL2

Solar Sensor cable will need to

be extented to reach the panel,

0.75mm two core flex and 5 amp

2 post junction box will be required

fitted in the roof space close

to the Solar panel sensor pocket.

T1 Solar Sensor

VAL-PE

SOL-T1

VAL-N

Zone Valve

Normally

Closed

V1 HW

V2 CH

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