Gledhill Boilermate 2 Design Installation and Servicing Instructions

BoilerMate 2

For Gledhill BoilerMate 2 Parts and Spares click on the following links: Gledhill BoilerMate 2 Parts And Spares

A central heating and mains pressure hot water supply system incorporating a thermal store.

Design, Installation and Servicing Instructions

LL MODELS COMPLY WITH THE BRITISH GAS SPECIFICATION FOR INTEGRATED THERMAL STORES.

CONTENTS

GLEDHILL BOILERMATE SPECIFICATION

Section  Details
01 DESCRIPTION
02 SYSTEM DESIGN
03 INSTA LLATION
04 COMMISSION ING
05 PROBLEM SOLVING
06 SERVICING
07 APPENDICES
PERFORM ANCE SPECIFICATIONS
SHORT PA RTS LIST
SALE & WARRANTYTERMS


These instructions should be read in conjunction with the installation/servicing instructions issued by the manufacturer of the heat source being used. Any installation must be in accordance with the relevant requirements of the Gas Safety Regulations, Local Building Regulations, I.E.E. Wiring Regulations and Byelaws of the Local Water Undertaking. It should be read in accordance with the relevant recommendations of the following:

BS 6798; BS 5449; BS 5546;
BS 5440:1; BS 5440:2; CP 331 :3;
BS 6700; BS 5258 and BS 7593: 1992.

It must be installed by a competent person as stated in
the Gas Safety Regulations.
Manufacturers notes must NOT be taken as over-riding
statutory obligations

BoilerMate is not covered by section G.3 of the 1985 Building Regulations and is therefore not notifiable to the Building Control Office.

Although the secondary supply (domestic) is at mains pressure, it is not necessary to fit an expansion chamber, pressure or temperature relief valve. BoilerMate is only suitable for use with a vented primary system.

This information is provided to assist generally in the selection of equipment

Responsibility for selection and specification of our equipment must however remain that of our customer and any experts or consultants concerned with the installation (s).

PLEASE NOTE: THAT WE DO NOT THEREFORE ACCEPT ANY RESPONSIBILITY FOR MATTERS OF DESIGN SELECTION OR SPECIFICATION, FOR THE EFFECTIVENESS OF AN INSTALLATION OR UNIT CONTAINING ONE OF OUR PRODUCTS.

All goods are sold subject to our Conditions of Sale which are set out at the rear of this specification. 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 booklet, which is accurate at the time of printing, should be disregarded.

A UK - WFBS LISTED PRODUCT DEVELOPED IN CONJUNCTION WITH BRITISH GAS PLC GAS COUNCIL NO. 89-317-02

BRITISH PATENT NOS. 1358166, 2136099
BRITISH PATENT APPL/CATIONS
PUBLISHED UNDER NOS. 2136099,
2153503,2153504,8516025

DESCRIPTION

Introduction

 The BoilerMate is used to provide improved space heating as well as a mains pressure hot water supply system for use with any boiler sited remotely. A report by the Cranfield Institute of T echnology found that heat storage systems give a potential for energy savings of between 5% and 15%. A boiler of any output up to a maximumof100,000BTUcanbe linked toany suitable model of BoilerMate and the deciding factor is the hot water requirement (see Model Selection Data, page 5). The principle of BoilerMate is to separate the heat generator (e.g. the boiler) from heat emitters by a thermal store, which evens out the fluctuating demands for heating and hot water. Thus by storing energy produced when demand is low and discharging it when demand is high (i.e. during warm-up or when hot water is drawn off) a smaller boiler can be used. An important feature of this design is that hot water can be supplied directly from the mains at conventional flow rates without the need for temperature and pressure safety relief valves or expansion vessels.

TERMAL STORE

The thermal store contains primary water which is maintained at a temperature close to the boiler flow temperature in winter. The store temperature can be reduced in the summer-time by the user by means of the store temperature control on the front panel of the BoilerMate. It is efficiently insulated with rockwool insulation in a galvanised steel case to minimize standing losses.

DOMESTIC HOT WATER

COLD SUPPLY

BoilerMate models are designed to be fed directly from mains. They fulfil the requirements of Water Byelaw91, and therefore do not require a check valve to be fitted to the supply pipe. The performance of the BoilerMate is directly related to the adequacy of the cold supply to the dwelling. This must be capable of providing for those services which could be required simultaneously and the maximum demand should be calculated. BoilerMate will operate at pressures as low as 1 bar which must be available when local demand is at its maximum, but the preferred range is between 2 and 3. 5 bar. Between 1 and 2 bar simultaneous demand capability will be affected and a low resistance model (140, 180, 200, 220 or 125) should be specified.

Asa general guideline, although a 15mm external service may be sufficient for the smaller dwelling with one bathroom, a 22mm service is preferred (25mm MOPE) and should be the minimum for larger dwellings.

If a water meter is fitted in the service pipe, it should have a nominal rating to match the anticipated maximum simultaneous hot and cold water demand, calculated in accordance with BS 6700. This could be 50 liters per minute in some properties.

 If the incoming static mains water pressure exceeds 3.5 bar at any point in the 24 hour cycle then a pressure limiting valve set at 3.5 bar should be fitted downstream of the stop tap where the cold supply enters the property. Units must be fitted strictly in accordance with the requirements of the Local Water Undertaking who should be consulted prior to installation. In the event of any difficulty please contact us as the manufacturer. Equipment used in the system should be suitable for a working pressure of 1 Obar.

SAFETY FITTINGS

It is not necessary to fit the control and safety equipment normally associated with mains pressure supply since the unit contains its own patented expansion chamber which is sealed for life. In the event of failure of this chamber, the system will relieve at the toilet ball valve provided:

1. It is plumbed in accordance with Figure 1.

2. The property contains at least one ballvalve which complies with BS 1212 Part 2 or 3 pattern open to the system expansion.

3. BoilerMate is WBS listed. A non-return valve is NOT required. Should ancillary equipment fitted in the supply, to these appliances require a non-return valve then this valve must be fitted directly after the branch to the drinking water tap (kitchen sink). "A check valve must never be fitted to the final cold inlet branch to the BoilerMate.

DOMESTIC FLOW RATE

Provided that the pipe sizing is adequate, the hot flow at the tap is determined by the local mains pressure, but should be up to 20 litres/min on Models 115 and 120, up to 26 litres/min on Models 140 and 125, up to 28 litres/ min on Model 180, up to 30 litres/min on Model 200 and up to 35 litres/min on Model 220 according to the temperature set by the user and the amount of cold water blended in.

EXTERNAL EXPANSION VESSEL

This is not necessary with BoilerMate.
USE IN HARD WATER AREAS

The patented design of the heat exchange module is such that the turbulence through the coil slows down the formation of scale in even the hardest water conditions, at normal operating pressures. Where the water can be considered hard, it is recommended that an effective proprietary in-line scale inhibitor is installed. It is important that where the supply to the BoilerMate is in 22mm the in-line descaler is also 22mm. In practice the servicing requirements can be considered similar to those needed for instanteous or 'combi' appliances. The installation of the scale inhibitor should be in accordance with the manufacturers instructions and with the Water Byelaws.

Alternatively, periodic on-site descaling can be conveniently carried out using a special valve obtainable from ourselves. See Page 23 for full instructions. The advice of a specialist Water Treatment Company should be sought if in doubt.

 DESCRIPTION

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BoilerMate is supplied as standard with an electromechanical clock to control the space heating (see Figure 2). A seven day digital clock is available as an alternative (see Figure 3). The clock/programmer, together with a room thermostat, if fitted, controls the heating system pump. If required a kit is available to site the clock/programmer remotely or a no clock option is available for use with any 2 channel clock (see page 27). The boiler is controlled by the store thermostat.

STORE THERMOSTAT
Store thermostat is the principal control mechanism and the correct type is therefore important. This will be supplied as part of the control package.

 DESCRIPTION

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DELAY TIMER

A delay timer is pre-wired into the BoilerMate wiring loom. The delay timer is activated by the switched live from terminal 7 and the link between terminals 4 and 8. This aids system economy by removing all the hot water from the boiler each time it shuts down.

PUMP DRIVE P.C.B.

This is pre-wired into the BoilerMate wiring loom. Its purpose is to prevent the heating pump from becoming seized during the summer period. It does this by automatically switching the pump on for a few seconds approximately every 40 hours.

ELECTRICAL IMMERSION HEATER

If an electric immersion heater is fitted it must:
a. be set to operate at 80 °C

b. be wired to its own power source by a 13amp fuse and not through the cylinder terminal block or time clock which should be protected with a 3 amp fuse.

DESCRIPTION 

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NOTES:

1. All BoilerMates meet the requirements of the British Gas Specification for Integrated Thermal Stores.
** Cat SC2
••• Cat SC3

2. Models 140, 180, 200, 220 and 125 have low resistance, high flow rate heat exchangers. They are particularly suited to areas where the water pressure is lower than normal.

3. The flow rates shown are with the Brawa-mix valve set to give 35 °C rise and assume normal pressure and an adequate flow to the appliance.

4. All units are supplied complete with an integral feed and expansion tank. This is easily removed from any circular model and repositioned remotely up to 6m above the base of the store if necessary. It will fit in any space greater than 500rnm high by 500rnm square, which includes the necessary allowance for ballvalve servicing. 5

5. Please ask for details if the BoilerMate is for use with a central boiler (CB) installation.

6. Any pattern of BoilerMate can be specified 'ET' for use with dual boilers (see page 9).

7. With integrated thermal storage, it is important to recognize that hot water and heating loads can b e supplied simultaneously.

 SYSTEM DESIGN

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METHOD OF SIZING

The efficiency of this system is such that special design criteria apply when calculating the boiler size. It is only necessary to calculate the heating requirements in accordance with BS 5449 and add the following allowances for hot water which are approximately half the traditional allowances.

Up to 1 bathroom & shower - 1 .5kW
Up to 2 bathrooms & 2 showers - 3.0 kW
Up to 3 bathrooms & 2 showers - 4.0 kW

The primary pipes should be sized to achieve a 6 ° C temperature rise across the boiler, but in any case should be not less than 22mm.

BOILER SITED BELOW BOILERMATE

Any boiler can be used when the flow to the BoilerMate rises continuously without valves. No part of the flow should contain a valve, as this forms the open vent should the boiler thermostat fail. The recommended control system to give the most energy efficient operation is shown in Figure 7.

 

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BOILERMATE is supplied as a factory fitted and prewired package consisting of:

a. Pump between boiler and thermal store.
b. Pump for radiator circuit.
c. Store thermostat.
d. Central heating timer.
e. Junction box.
f. Thermostatic mixing valve.
g. Boiler pump delay timer P.C.B.
h. Pump drive P.C.B.

SYSTEM DESIGN

SYSTEM S WITH DIPPED FLOW & RETURN AND BOILERS WITH OVERHEAT THERMOSTAT If the flow and return between the boiler and the thermal store (BoilerMate) are dipped the boiler should be fitted with an overheat thermostat. In these circumstances manual air vents should be fitted as in Figure 8. In situations where headroom is restricted (eg. in a flat) the boiler manufacturer's instructions with regard to minimum head must be followed. In the case of the Baxi Solo 2, however, the boiler may be installed in accordance with Figure SA. The F&E cistern may be left attached to the store, and the whole BoilerMate raised on a stillage.

Refer to Figure 6 for water levels

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Figure 9 shows an alternative layout using a BoilerMate with the F & E cistern remotely situated.

If the boiler is higher than the BoilerMate (as in Figure 9) a gravity check valve is necessary as shown to prevent gravity circulation from the BollerMate to the boiler during dormant periods.

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SYSTEMS WITH DIPPED FLOW & RETURN AND BOILERS WITHOUT OVERHEAT THERMOSTAT

Whereas boiler of at type which does notate an overheat thermostat is fitted so that the flow and return between the boiler and the thermal store are dipped, special criteria apply. In order to comply with British Standards, the expansion pipe must rise continuously from the boiler. See Figure 10 overleaf.

Plastic Pipework

This appliance is suitable for use with plastic pipework as long as the material is recommended for the purpose by the manufacturer and is installed fully in accordance with their recommendations. We recommend the use of barrier pipe, which will mean the system can have BritishGas service cover in regions offering this service.

SYSTEM DESIGN

Figure 1 O illustrates a method of coupling a back boiler without an overheat switch to a BoilerMate in a situation with limited headroom (eg. in a flat). The cold feed is connected to the expansion tapping, and the expansion pipe is run directly from the boiler. The pump is moved to the boiler flow to avoid pumping over. The flow and return pipes are increased to 28mm to minimise the pressure reduction at the boiler when the pump is running.

If an electric immersion heater is fitted into a BoilerMate plumbed in this way it should be of a type fitted with a thermal cut-out(eg. Redding model 30/ 302201). The cold feed tapping should be plugged. In these circumstances, the open vent from the boiler to the feed and expansion tank should be a minimum of 22mm diameter copper tube or equivalent and should rise continuously from the boiler to discharge above the feed and expansion cistern. The feed pipe should not be less than 15mm copper tube or equivalent.

GENERAL NOTES

If summer heating of a bathroom radiator or towel rail is required, then it must be piped in accordance with Figure 11. This involves moving the boiler pump so that the radiator return can be teed in upstream of the pump. Any other way would degrade the flow temperature into the BoilerMate, and is incorrect. It must be remembered that the heating of such a radiator will be intermittent i.e. it will only heat up whilst the boiler is actually firing. The radiator lock shield valve should be throttled down so that it does not draw an excessive flow out of the flow to the BoilerMate.

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Figure 7 is controlled by the heating circuit pump through the action of the room thermostat and time clock. For fuel economy and best boiler performance, the system should be designed so that gravity circulation does not take place in the heating system when the pump is not running. It is often necessary to fit a check valve to be certain of preventing this. If the boiler is fitted at a higher level than the BoilerMate it may be necessary to fit a gravity check valve on the primary circuit to prevent reverse circulation during dormant periods. All units come complete with their own feed and expansion tank. The water level in this tank should be at least 250mm above the highest point on the radiator circuit. The F & E cistern may be detached from any circular model and fitted remotely up to 6m above the base of the thermal store. The overflow/warning pipe should be installed in a material suitable for Feed and Expansion cisterns in accordance with BS 5449. A by-pass is not needed in the circuit between boiler and thermal store as the latter performs this function. 

A METHOD OF COUPLING GAS & SOLID FUEL BOILERS TO BOILERMATE

Many of our customers would like their solid fuel open fire or boiler to make a useful contribution to their automatic gas-fired central heating system. Unit( now, this has required a whole array of controls, and installers have been deterred, either by the cost, or the complexity, or both. Where BoilerMate is used as the heart of the system there is no problem. BoilerMate is the neutral point of the installation and can therefore accept heat from more than one source without upsetting the other. The heat from the secondary source can be fed to the BoilerMate either by gravity or pumped circulation.

SYSTEM DESIGN

If it is required to use heat from a solid fuel boiler then this must be piped in conjunction with a gas (or other automatic) boiler, so as to ensure that the store will be maintained at full temperature.

Figure 12 is a suggested method of doing this. The high limit thermostat on the solid fuel boiler flow pipe should be wired across BoilerMate terminals 4 and 10. It should close on temperature rise, and be set to (say) 9D°C. This will then switch on the heating pump, thus dispersing the excess heat into the radiators.

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To order BoilerMate for dual boiler use specify model 'ET'. Price and delivery will be confirmed by our Technical Sales Office.

TAPS & VALVES

Hot and cold taps and mixing valves used with the unit must be suitable for operating at 1 O bar pressure. Aerated taps are recommended to prevent splashing.

PIPE SIZING

To achieve even distribution of the available supply, it is important in any mains pressure system that piping in the dwelling should be sized in accordance with BS 6700 particularly in large or multi bath roomed properties, however the rule of thumb guidelines following this paragraph should be adequate for most typical domestic property types.

1. A 15mm external service may be sufficient for the smaller 1 bathroom dwelling ( depending on the flow rate available), but the minimum size for larger dwellings is 22mm (25mm MOPE).

2. The internal cold feed from the stop tap to the BoilerMate should be run in 22mm tubing. The hot draw off should also be run in 22mm as far as the branch to the bath tap.

3. The tee-offs to basins/sinks should be in 10mm: the tee-offs to the bath and showers should be in 15mm.

4. Tee-offs to taps in existing property which are in 15mm should be restricted to balance flow to each outlet.

5. Best results are achieved by fitting appropriate flow regulators to each hot and cold outlet (see page 28).

6. Any surface pipework in the BoilerMate cupboard should be insulated to reduce standing losses and cupboard temperatures.

SHOWERS

Either thermostatic or manual showers and mixer valves can be used as long as both hot and cold are mains fed, however thermostatic valves will provide better control. The hot water supply to a shower mixing valve should be fed directly from the BoilerMate and where practical should be the first draw-off point on the hot circuit. The cold supply to a shower mixing valve should be fed directly from the rising main via an independent branch.

Showers· Fixed Head Type:
No anti-syphonage arrangements are necessary.
Showers· Loose or Flexible Head Type:

If a loose head shower with flexible hose is to be used over a bath, the hose must be fixed so that the head cannot fall closer than 25mm ( as specified in Byelaw 16 of the Water Supply Byelaws) above the top edge of the bath in order that the head is prevented from being immersed in bath water, or the shower must incorporate or be fitted with an anti-syphon age device at point of flexible hose connection.

BIDETS

The supply of hot and cold mains water direct to bidet is permitted provided that this bidet is of the over-rim flushing type and that a type 'A' air gap is incorporated. It must not include either an ascending spray or provision to attach a hand spray.

SYSTEM DESIGN

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INSTALLATION

IMPORTANT NOTES a) It is important that the appliance is installed on a level and even floor or if raised above the base should be continuously supported. If the support is timber, it shall be marine ply, type C4 chipboard to B.S.5669 or other material which will not deteriorate if exposed to moisture. Details of the appliance weight when full is provided in Table 1.1 of technical specifications.

NOTE:

1. INSTALLERS ARE ADVISED THAT COMBINED FEED AND VENT PIPES MUST NOT BE USED IN BOILERMATE INSTALLATIONS.

2. IT IS RECOMMENDED IN ACCORDANCE WITH APPROVED DOCUMENT L OF THE BUILDING REGULATIONS THAT SURFACE PIPEWORK IN THE BOILERMATE CUPBOARD BE INSULATED TO REDUCE STANDING LOSSES AND TO PREVENT UNNECESSARILY HIGH CUPBOARD TEMPERATURES.MORE HEAT IS LOST FROM THE FIRST METRE OF PIPEWORK THAN FROM THE STORE.

3. NOT WITHSTANDING THE ABOVE,CUPBOARD TEMPERATURES ARE NORMALLY HIGHER THAN IN A CONVENTIONAL SYSTEM AND THE DESIGN OFBOTHTHECUPBOARD ANDTHEDOORSHOULD TAKE THIS INTO ACCOUNT.

PLUMBING CONNECTIONS

NB: The water connections on a BoilerMate are reversed when compared with a conventional system ie: the heating flow and return are taken directly from the thermal store and the domestic water is taken to and from the coil.

COMBINED FEED & EXPANSION CISTERN

a. It is most important to adjust the fitted ballvalves whilst the system is cold to give a water level of 50mm above the feed outlet to the primary system to allow adequate room tor expansion (this is marked by a corrugation in the wall of the tank).

b. Sufficient space should be left above the unit to allow access to the ballvalve for servicing and adjustment.

c. A 22mm compression fitting is provided as standard in the feed and expansion cistern for the overflow/ warning pipe, which should be no less than 20mm internal diameter.

This should be fitted to discharge clear of the building and be situated so that any overflow can be easily observed. The warning pipe should be installed in either high temperature uPVC or copper and should not have any other connections to it.

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All BoilerMates are tor vented primary systems only. A sealed system primary unit is not available.

PLUMBING CONNECTIONS

Make all water connections in accordance with the labelling on the thermal store and associated pipework. If the incoming static mains water pressure exceeds3.5 bar at any point in the 24 hour cycle then a pressure limiting valve set at 3. 5 bar should be fitted downstream of the stop tap where the cold supply enters the property. If a boiler is fitted above the thermal store, a gravity check valve should be incorporated in the connecting pipework leading from the BoilerMate to the boiler, ie the boiler return.

All factory made joints should be checked after installation in case they have loosened during transit.

 INSTALLATION

The system operates on the normal primary flow temperature of the boiler and any traditional hot water radiator or convector can be used with the system.

A Brawa-Mix valve is fitted for the control of domestic hot water by the user. The DHW flow rates shown on pages 2 and 5 are for water raised through 35°C. To increase or decrease the temperature rotate the valve head as shown in Figure 14.

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This should always be set to maximum to give the best hot water service and to achieve the highest efficiency by reducing boiler cycling.

Where a range rated boiler is used it should always be set at the highest output. System efficiency will not be impaired, while the recovery rate is improved.

The pumps in the control package must be set in the following way:

a. The pump (lower) between boiler and BoilerMate should be set to as high a level as possible consistent with low noise levels so that the temperature difference across the boiler is approximately 6°C.

b. The pump on the heating circuit must be set by the installer to give a temperature difference across the radiator circuit of 1 1 °C in the usual way.

INSTALLATION

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BoilerMate installation is easier and quicker than conventional vented systems because there is no secondary feed tank to bother with.

1. lnspect the position in which BoilerMate is to be fitted and check that the internal depth is at least 600mm and the width 700mm for models 120 and 140 and 750mm for models 180, 200 and 220. 2. Planthe pipe connections. Each fitting on BoilerMate has its own label. You need to connect the following pipes:

a. Pumped flow and return pipes, from the body of the BoilerMate to the boiler. b. Pumped flow and return pipes from the body of the BoilerMate to the radiators.
c. Cold mains water supply connections to the inlet side of the domestic hot water heating coil and to the ballvalve in the F & E cistern.
d. Domestic hot water supply pipe from the delivery of the DHW mixing valve to the taps.
e. Overflow warning pipe from the F & E cistern to discharge in a conspicuous position externally.

3. If you are fitting the cistern remotely, check the route of the 22mm diameter open safety vent pipe and of the 15mm diameter feed and expansion pipe from the BoilerMate to cistern position. Also check the route of the overflow warning pipe. All the BoilerMate connections are clearly labelled.

When you have decided where the pipes are to run, check the space required for them inside the BoilerMate compartment.

4. Decide at what stage in your installation work you are going to fit the BoilerMate. We would suggest that in most cases the BoilerMate should be fitted first and pipes run from it to the boiler, radiators and domestic hot water supply system subsequently in that order.

5. Remember that a by-pass is not needed for any boiler as the thermal store acts as the by-pass itself.

6. Carry out the rest of the installation work, ie boiler, radiators and hot water supply pipework. Connect the cold water supply pipework.

7. Fill the BoilerMate, radiators, boiler and pipe work with water through the F & E cistern. Adjust the ballvalve so that when cold there is just enough water in the cistern to float the ball. Flush the system out, fill again and vent.

8. Fill the domestic hot water heating coil with water and establish a flow through to the taps etc. Check that flow through all hot and cold watertaps etc. is stopped when the mains water stop valve is closed.

9. The system now requires to be electrically connected.

10. The system is now ready to be commissioned.

INSTALLATION

See Figure 16

Because BoilerMate is pre-wired to a central control panel, plumbers are well able to complete the electrical installation provided they adhere strictly to the IEE Regulations. Do not attempt the electrical work unless you are competent to carry it out to the above standards.

Connection to the electrical supply must allow complete electrical isolation by installing a fused double pole switch having 3mm separation on both sides. The isolating switch must only serve the heating and hot water system, together with its controls"

TO WIRE THE BOILERMATE

Before commencing, ensure that the power source to which it is intended to connect the system is isolated.

1. Remove thermostat knob and pointer.

2. Remove white cover plate ( 4 screws) and connector block cover (pull off).

3. From a 3 amp fused and switched connection unit bring a live, neutral and earth to the BoilerMate connector block.

Live to terminal 1.
Neutral to terminal 2.
Earth to terminal 3.

4. Leave in link 1 joining BoilerMate terminals 4 and 8.

5. Take a live from BoilerMate terminal 7 to boiler switched live input.

6. Take a neutral from BoilerMate terminal 5 to boiler neutral.

7. Take an earth from BoilerMate terminal 6 to boiler earth.

8. If the boiler needs a permanent live other than for a pump over-run, then this should be taken from terminal 4.

9. The link between 9 and 1 O should be removed If a room thermostat is to be fitted.

10. If a Maxol 600, a Maxol Morocco or a Maxol Microturbo 40 is used refer to Appendix 3, Page 27.

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11. If a Baxi Solo 2 is used, then its integral frost thermostat should be ignored. If frost protection is required, then a separate frost thermostat should be wired across terminals 4 and 7 on the BoilerMate terminal block, and set to 5° C.

When using the Baxi Solo 2 boiler a permanent live supply should not be provided from the BoilerMate terminal block. Instead a link should be provided from the 'L' to the "S/L" terminal on the boiler. ln the few situation ns where boilers do require permanent live it is most important that extra care is taken in the wiring of the permanent and switched live supplies. If adequate separation is not provided the switched live circuit can be affected resulting in the neon and boiler pump running permanently.

 

 

 

INSTALLATION

When the wiring is completed, replace the front panel and the store thermostat knob and pointer. Set the pointer to the maximum temperature.

TO WIRE IN A ROOM THERMOSTAT TO BOILERMATE

1. Remove link 2 joining BoilerMate terminals 9 and 1 o.

2. From BoilerMate terminal 9 take a live to the live connection on room thermostat.

3. From room thermostat switched live connection take a live to BoilerMate terminal 10.

4. Connect BoilerMate terminal 11 to room thermostat neutral.

5. Connect BoilerMate terminal 12 to room thermostat earth (if required).

FROST PROTECTION

Where frost protection is required for the boiler only, a frost thermostat should be wired across terminals 4 and 7. Where frost protection is required for the whole house, or where a base temperature is required during cold weather, a frost thermostat should be wired across terminals 4 and 9. Ensure that this thermostat is set to + 1 or +2°C, and the room thermostat set down to the required temperature. If a Baxi Solo 2 is used, see paragraph 11 on previous page. An alternative to fitting a frost thermostat would be to set the programmer to constant during the cold weather period.

DELAY TIMER

A delay timer is pre-wired into the BoilerMate wiring loom. The delay timer is activated by the switched live from terminal 7 and the link between 4 and 8. This aids system economy by removing all the hot water from the boiler each time it shuts down.

COMMISSIONING

It is essential that the system functions properly for optimum performance. To achieve this, the system should be commissioned in accordance. with good practice and generally in accordance with the requirements of BS 6798, BS 5449 and BS 7593: 1992. Ensure that the float is correctly adjusted to close the ballvalve at the water level line inside the F&E cistern. Fill the system and flush cold.

Refill the system.

Add a cleanser such as Sentinel X300 to ensure that flux residues and installation debris are removed from the system. When determining the quantity of cleanser required, be sure to allow for the increased volume of water in the primary circuit due to the thermal store.

Commission the boiler.

If the boiler is range rated, then adjust to the maximum heat input. Set the pump between boiler and BoilerMate (lower mounted pump) to give a high flow rate. A temperature difference across the boiler of say 6°C is near the optimum. In practice, the highest pump setting that does not produce system noise gives the best BoilerMate performance but the temperature difference should not be above 10°C. To ensure full cleansing, circulation to all parts of the system should continue for a minimum of 1 hour. Flush the system hot having checked that there is no overflow when the system is up to temperature. Refill the system.

Although the standard BoilerMate has no special water treatment requirements, the radiators and other parts of the circuit will benefit from the application of a corrosion and scale inhibitor, such as Sentinel X100, a multimetal corrosion and scale inhibitor manufactured by BetzDearborn. 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. Set boiler thermostat to maximum.

With the central heating system off, let the system heat up (with a 30,000 Btu boiler 1.5 hours approximately). Turn on the space heating system and adjust the space heating pump speed to give a temperature difference of 11°C. Check that the space heating system controls are functioning correctly ie: CLOCK AND ROOM THERMOSTAT. Switch off space heating system. Ensure that the store thermostat is set to maximum.

Ensure that the boiler thermostat is set to maximum. Establish that the temperature difference between the flow and return at the boiler is not more than 10°C, and preferably (say) 6°C. If it is more than 10°C, and the pipes are sized correctly. then there is some restriction in the primary flow or return pipe. Check that in accordance with good practice, air vents have been fitted at high points. Increase the pump setting if necessary. Check for obstructions in the pipework.

FINAL SETTING OF STORE THERMOSTAT

Ensure that the heating clock is set to " off ". Retire the boiler by running a little water, wait for the boiler to switch off. If the commissioning light is still lit at this stage then immediately turn the temperature control down slowly until the commissioning light at the bottom of the panel goes out. Turn the control finger one more hole down and insert a plastic peg immediately above it and push home hard to prevent accidental 'decommissioning'. Spare pegs are stored at the top of the panel.

IMPORTANT DO's AND DON'T

DO Check the incoming mains water pressure. If it exceeds 3.5 bar at any point in the 24-hour cycle then a pressure limiting valve set at 3.5 bar should be fitted where the cold supply enters the property, see page 3.

DO Check that all connections are in accordance with the labelling on the thermal store.

DO Adjust the ballvalve so that there is just enough water in the F&E cistern to float the ball when cold.

DO Make sure there is adequate clearance above the F&E cistern to service the valve.

DO Ensure that rang e-rated appliance sare setat the highest output and the boiler thermostat is set to maximum for all boilers.

DO Ensure that the water level in the expansion cistern is at least 250mm above the highest point on the radiator circuit.

DO Insulate any exposed pipework in the BoilerMate cupboard.

DO Plumb the overflow warning pipe in 20mm minimum internal diameter tubing to discharge in a conspicuous external position, using high temperature uPVC or copper.

 PROBLEM SOLVING

Any faults in the system design and malfunctions of system components will generate customer complaints. These complaints can be grouped into the following three main categories:

The system is noisy.
Hot water service is unsatisfactory.
Space heating is unsatisfactory.

CAUSES OF NOISY SYSTEM

a. Noisy pump operation: Check speed setting - if necessary, reduce pump speed. Cavitation . on account of insufficient static head on suction side (see System Design).

b. Noisy boiler operation: Check the water flow through the boiler by measuring the temperature differential across it whilst the boiler is on full gas rate. If the flow is satisfactory, contact the boiler manufacturer.

c. Noisy when hot water tap is opened: Water hammer - Loose pipework and/or tap washers.

CAUSES OF UNSATIFACTORY HOT WATER SERVICES 

a. Check boiler thermostat - this should be set at maximum.

b. Check that the boiler flow temperature is adequate.

c. Check thermostatic mixing valve - if necessary, adjust to deliver hotter or cooler water as needed.

d. Check that the space heating load is not greater than the boiler output.

e. l f a radiator sifted across the primary flow and return for summer use, check that this is correctly connected (see Figure 11, Page 8).

 CAUSES OF UNSATIFACTORY  SPACE HEATING

a. Check boiler thermostat. This should be set at maximum.

b. Check operation and setting of room thermostat.

c. If some rooms are not being heated properly, then increase the pump speed and if necessary balance the system.

d. If radiators get warm when heating is off, then install gravity check valve in the heating circuit.

OVERFLOW FROM FEED & EXANSION CISTERN

a. Check that the controlled level of the cistern is no higher than the swaged indentation. Adjust if necessary.

b. If a replacement ballvalve is required, this should be obtained only from Gledhill Water Storage Ltd.

 PROBLEM SOLVING

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 PROBLEM SOLVING

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 PROBLEM SOLVING

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 PROBLEM SOLVING

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SERVICING

In situations where scale inhibitors have not been fitted and the hot water service has deteriorated a BoilerMate can be descaled very easily with equipment available from Gledhill.

You can now do the whole job easily and efficiently on site - and do it under the hour.

The operation is carried by a VORTEX DECALOMAT-3 Descaling Unit which removes the scale chemically. By simply replacing the thermostatic mixing valve on the hot water outlet with the special adaptor valve supplied, descaling solution is pumped through the secondary coil (see Figure 19). After approximately 45 minutes the job is done and the mixer valve is put back in place. The solution is made up of 2kg of either Sentinel ScaleCleen or Fernox DS-3 descaling powder dissolved in 20 litres of water (preferably warm but not exceeding 700C). The powders are manufactured with a colour indicator which changes as the active ingredients are used up.

TO DE-SCALE BOILERMATE USING DECALOMAT-3

1. Before descaling turn the boiler off and run the hot water tap until the thermal store is below 40° C.

2. Turn off mains water supply at stop tap supplying the BoilerMate.

3. Open a hot tap on the hot water system.

4. Break the three unions securing the oventrop MV to the BoilerMate and remove the oventrop MV making sure a container is in place to collect spillage.

5. Attach the adaptor to the BoilerMate - two unions and washers.

6. Close all hot taps on the DHW system.

To charge Decalomat-3

7. Unscrew the large cap adjacent to the carrying handle.

8. Make sure that the hoses are connected together with the brass nipple.

9. Partly fill the Decalomat-3 with 20 litres of Sentinel Scale Cleen solution or Fernox DS-3solution (the solution should be 2kg of powder dissolved in water).

NOTE: This solution is ACIDIC and MUST be handled with CARE. It is a wise precaution to do the mixing, filling and emptying outside the premises ..

Observe the manufacturers handling instructions.

10. Replace the filling cap on the Decalomat-3.

11. Break the joint between the hose (keeping both hoses above the level of the Decalomat-3) retaining the brass joining piece.

12. Attach the hoses to the adaptor (ensure that the unions are finger tight on the 3/4" BSP male connectors to the adaptor).

13. Loosen the filling cap on the Decalomat - 3 to allow carbon dioxide formed in the descaling process to escape.

14. Plug in the Decalomat-3 to a 240V 50 Hz electric supply. The pump in the Decalomat will now circulate the coloured descaling solution through the heat exchanger coil of the BoilerMate. Depending on the degree of scale formation within the coil, the following may be observed:

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SERVICING

WITH SENTINEL SCALECLEEN

1. The red solution will be observed in one of the transparent plastic tubes, foam and an orange/yellow liquid may be seen in the other tube.

2. Flow of the red liquid may initially be intermittent due to:
a). Gas formation in the coil as the Sentinel ScaleCleen attacks the scale.
b). Degree of blockage - this stage may exist tor about half an hour.

3. Continous flow will begin with the red Sentinel ScaleCleen solution in one pipe and a foaming solution in the other.

4. It after some time, the color in both pipes has turned to yellow (no gas bubbles are observed), the Sentinel ScaleCleen is now exhausted and requires changing.

5. When the solution in both uses remains redo orange and no gas bubbles are observed, the coil has been descaled

 WITH FERNOX DS-3

1. The yellow solution will be observed in one of the transparent plastic tubes, foam and a greenish blue liquid may be seen in the other tube.

2. Flow of the yellow liquid may initially be intermittent due to: a). Gas formation in the coil as the Fernox DS-3 attacks the scale. b). Degree of blockage - this stage may exist tor about half an hour.

3. Conti nous flow will begin with the yellow Fernox DS- 3 solution in one pipe and a teaming solution in the other.

4. If after some time, the color in both pipes has turned to green (no gas bubbles are observed), the Fernox DS- 3 is now exhausted and requires changing.

5. When the solution in both tubes is still yellow and no gas bubbles are observed, the coil has been descaled.

TO REMOVE DECALOMAT-3

1. Unplug Decalomat - 3 from electrical supply.

2. Tighten the filling cap on the Decalomat - 3.

3. Remove the two hoses from the adaptor.

4. Join hoses with brass connector piece.

5. Remove adaptor.

6. Replace Oventrop mixing valve - ensuring that it is the correct way round.

7. Open a hot tap - preferably to a porcelain sink.

8. Turn on the mains water supply to BoilerMate.

9. Allow the system to flush via the open hot tap for some minutes, then flush out system at each hot tap.

 APPENDIX 1

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REMOTE FIXING OF THE GRAS SLIN DIGITAL PROGRAMMED TIMER OR THE ELECTROMECHANICAL CLOCKTIMER

A Remote Fixing Kit is available for this purpose, consisting of:

1. Backplate - complete with terminal strip. 2. Clock cover (surface mounting) complete with 2 No. retaining screws.
3. Terminal strip cover.
4. Opaque dust cover.

Procedure
(This work must be carried out by a qualifled person)

First switch off the power to the BoilerMate. Remove the transparent dust cover from the clock. Remove the flush mounted clock by turning the two plastic screws 1/4 turn anti-clockwise. The clock may now be withdrawn. Remove the spade connectors from the clock terminals.

Remove the clock wires from the main terminal strip of the BoilerMate. These are from terminals 1, 2and 9and are shown as broken lines on the wiring diagram. Mount the backplate in the required remote position, using 3 No.6 gauge round head screws. Connect the backplate to the main BoilerMate terminal. Refer to the wiring diagram. Do not forget to link terminals 1 and 3 of the backplate.

Remove the clock module from its flush mounting casing. This casing, together with the opaque dust cover can now be used to blank off the hole in the BoilerMate front panel. Mount the clock module onto the backplate, using the two locating pins. Press the clock home to engage its terminals into the terminal block. Slide the terminal strip cover into position. (Note that knock-outs are provided for surface wiring).

Fit the clock cover (surface mounting) and secure with the two screws provided. Switch on the power and check out. Programme the clock to required heating cycle. Fit transparent dust cover.

APPENDIX 2

The most effective service from a thermal storage system is when the boiler is on demand for twenty four hours. In special circumstances the system can be wired to isolate the boiler overnight by reference Figure 21.

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APPENDIX 2

If the BoilerMate is supplied as a no clock option the remote programmer/clock should be wired as follows:-

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APPENDIX 3

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APPENDIX 4

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TO TEST THE PUMP DRIVE:-

TURN OFF THE POWER TO THE SYSTEM. SWITCH CLOCK TO PERMANENT' OFF'. REMOVE TEST LINK FROM PUMP DRIVE P.C.8. TURN ON POWER (WITH CLOCK STILL' OFF'). HEATING CIRCUIT PUMP WILL CYCLE AT 10 SECOND INTERVALS. TURN OFF POWER AND REPLACE TEST LINK. TURN ONPOWER AND SETCLOCKAS REQUIRED.

NOTE:

FAILURE OF THE PUMP DRIVE WILL NOT AFFECT THE NORMAL FUNCTIONING OF THE PUMP UNDER THE CONTROL OF THE CLOCK AND THE ROOM THERMOSTAT.

PRIMARY PUMP NOT RUNNING

IF TERMINALS 1, 2, 4 ARE LIVE THE PUMP NEEDS CHECKING.

IFTERMINALS2AND4 ARE LIVE THE N THE DELAY TIMER IS FAUL TY AND NEEDS CHANGING. QUICKFIX IF YOU HAVE NO SPARE TEMPORARILY LINK 1 AND4.

PRIMARY PUMP RUNS CONTINUOUSLY (NEON EXTINGUISHED)

IF TERMINALS 1 AND 4 ARE LIVE AND THE PUMP CONTINUES TO RUN EVEN THOUGH POWER HAS BEEN OFF, ON 2, FOR MORE THAN 5 MINUTES: DELAY TIMER FAULTY

HEATING PUMP WILL NOT RUN

CHECK LIVE IN AT TERMINAL 1.
CHECK ROOMSTAT AND CLOCK ARE ON.

1. IS 9 LIVE? DIAGNOSIS IF NOT , THEN CLOCK IS FAULTY. QU/CKFIX LINK TERMINALS 1 AND 9 AND USE ROOM ST AT TO TURN HEATING ON AND OFF.

2. IS 10 DEAD? (AND 9 LIVE) DIAGNOSIS ROOM STAT IS FAULTY. QU/CKFIX LINK 9 AND 10 AND USE CLOCK TO CONTROL THE HEATING.

3. IS 10 LIVE? DIAGNOSIS NEED TO REPLACE THE HEATING PUMP.

APPENDIX 5

WATER RELATED COSTS CAN BE REDUCED BY GOOD PLUMBING PRACTICE.

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Vast quantities of water are needlessly run off to waste due to Taps, Mixers and Showers discharging flow rates far in excess of the rates required for them to perform their duties. The contrasting flow rates shown on this leaflet clearly illustrate the savings that can be made whilst still providing a good performance. British made AQUAFLOW REGULATORS provide constant flow rates by automatically compensating for supply pressure changes between 1 bar & 1 O bars. To facilitate installation into the wide range of plumbing equipment which is encountered in the U.K, FOUR FIXING OPTIONS are available:-

OPTIONS FOR SHOWERS

 1. MXF "DW" RANGE - For fitting behind Fixed Shower Heads or onto Flexible Hoses for Hand showers (preferably onto the inlet end when lightweight hoses are used).

2. COMPRESSION FITTING RANGE. "In Line" regulators as in Option 4 for Taps & Mixers.

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4 FIXING

1. MK RANGE - Combined Regulators & Aerator for screwing onto Taps & Mixers with internal or external threads on their noses. Anti Vandal models also available.

2. MR05-T RANGE - Internal Regulators. Push flt into Tap or Mixer seats. Produced in three sizes - 12.5mm (881010), 12mm & 10mm, Flangeless models also available for Taps with Low Lift washers.

3. MXF STANDARD RANGE - Screw on tail models for Taps & Mixers. Fix onto the tails before fitting the tap connectors. Available in 3/8", 1/2" ,3/4" and1 11 BSP.

4. COMPRESSION FITTING RANGE - "In Line" regulators housed in 15mm & 22mm CXC COUPLERS & ISOLATING VALVES." "UK WFBS LISTED BY THE WATER RESEARCH CENTRE. Isolation valves available for slotted screwdriver operation or with coloured plastic handles. Now available also In plastic bodied push-fit couplers & valves.

Information by courtesy of
AQUAFLOW REGULATORS LTD
Haywood House, 40 New Road, Stourbridge, West Midlands DVB 1PA
Telephone (01384) 442611 Fax: (01384) 442612

PERFORMANCE SPECIFICATION 

BOILERMATE // PERFORMANCE WHEN TESTED IN ACCORDANCE WITH THE BRITISH GAS SPECIFICATION FOR DIRECT INTEGRATED THERMAL STORES

These tests are carried out at flow rates of 18 litres/minute and 30 litres/minute but certain units have outputs that fall between these criteria, these are shown below as SC2+ and represent the same temperature rise at an enhanced flow rate.

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PERFORMANCE SPECIFICATION

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For Gledhill BoilerMate 2 Parts and Spares click on the following links: Gledhill BoilerMate 2 Parts And Spares