Gledhill Boilermate CP Design Installation and Servicing Instructions

BOILERMATE CP

MAINS PRESSURE HOT WATER THERMAL STORE FOR USE WITH CENTRAL PLANT BOILERS

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

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INSTRUCTION MANUAL
DESIGN, INSTALLATION & SERVICING

ONE NAME. EVERY SOLUTION.                                  WWW.GLEDHILL.NET

ISSUE 6.2: JUNE 2018

Section  Description
DESIGN Introduction
Technical Data
System Details
INSTALLATION Site Requirements
Installation
Commissioning
Installation Review
SERVICING Annual Service
Changing Components
Short Parts List
Fault Finding
ADDENDIX Addendix A
Addendix B
Addendix C
Notes
Terms & Conditions
BENCHMARK Commissioning Checklist
Service Record

 

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Benchmark places responsibilities on both manufacturers and installers. The purpose is to ensure that customers are provided with the correct equipment for their needs, that it is installed, commissioned and serviced in accordance with the manufacturers instructions by competent persons and that it meets the requirements of the appropriate Building Regulations. The Benchmark Checklist can be used to demonstrate compliance with Building Regulations and should be provided to the customer for future reference.

Installers are required to carry out installation, commissioning and servicing work in accordance with the Benchmark Code of Practice which is available from the Heating and Hot Water Industry Council who manage and promote the Scheme. Visit www. centralheating.co.uk for more information.

For further information on the HWA Charter Statement, please refer to the HWA website hotwater.org.uk.

The Gledhill BoilerMate CP range is a WBS listed product and complies with the HWA Specification for hot water only thermal storage products. The principle was developed in conjunction with British Gas. This product is manufactured under an ISO 9001:2008 Quality System audited by BSI.

Gledhill’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.

DESIGN

Any water distribution system/installation must comply with the relevant recommendations of the current version of the Regulations and British Standards listed below:-

Gas Safety (Installation and use) Regulations 1998
Building Regulations
Water Supply (Water Fittings) Regulations 1999
Manual Handling Operations Regulations

British Standards
BS EN 806:1-5: BS EN 8558:2011
Requirements for Electrical Installations BS7671:2008 and A2:2013 17th Edition

Most new building work will require the relevant building control body to be notified prior to the building work commencing. This will not be required if the work is carried out under a self certification scheme or if the work is not notifiable. Full details of the self certification schemes and work that is not notifiable can be obtained from page 9 of Approved Document G, available from www.planningportal.gov.uk.

A suitably competent trades person must install the BoilerMate CP and carry out any subsequent maintenance/repairs. In fact the appliance front cover is secured by 2 screws and this should only be removed by a competent trades person. The manufacturer’s notes must not be taken as overriding statutory obligations.

The Domestic Building Services Compliance Guide 2013 defines, one of the fixed building services, as any part of or controls associated with fixed systems for domestic hot water. All fixed building services, including theircontrols, should be commissioned by testing and adjustment to ensure that they use no more fuel and power than is reasonable in the circumstances. Where commissioning is required, if it is completed by a person registered with a competent person scheme, the commissioning notice will be supplied by that person, otherwise the person carrying out the work must notify the relevant building control body, that commissioning has taken place in accordance with the Domestic Heating Compliance Guide.The building control body will then be able to issue a completion certificate. This applies to England, for other jurisdictions in the UK, it may be necessary to consult their own building regulations and guidance.

The BoilerMate CP is not intended for use by persons (including children) with reduced physical, sensory or mental capabilities, or lack of experience or knowledge, unless they have been given supervision or instruction concerning use of the appliance by a person responsible for their safety.

Children should be supervised to ensure that they do not play with the appliance.

The information in this manual is provided to assist generally in the selection of equipment. The responsibility for the selection and specification of the equipment must however remain that of the customer and any Designers or Consultants concerned with the design and installation.

Please Note: We do not therefore accept any responsibility for matters of design, selection or specification or for the effectiveness of an installation containing one of our products unless we have been specifically requested to do so.

All goods are sold subject to our Conditions of Sale, which are set out at the rear of this manual.

In the interest of continuously improving the BoilerMate CP range, Gledhill Building Products Ltd reserve the right to modify the product without notice, and in these circumstances this document, which is accurate at the time of printing, should be disregarded. It will however be updated as soon as possible after the change has occurred.

INTRODUCTION

DESIGN

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1. Boiler ow
2. Backup immersion heater
3. PHE pump
4. Cold Feed
5. CW inlet
6. HW outlet
7. Drain
8. Return from PHE to store
9. Flow from store to PHE
10. Feed and expansion tank
11. Boiler return
12. Flow sensor
13. Thermostat pocket

The BoilerMate CP shown schematically above is designed to provide an improved method of supplying mains pressure hot water when used with a central plant system or domestic boiler.

An important feature of the concept is that hot water can be supplied directly from the mains at conventional flow 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 control board, which controls the speed of the pump circulating the primary water from the store through the plate heat exchanger.

The Domestic Building Services Compliance Guide (2013) provides more detailed information on the guidance contained in Approval Documents L1A and L1B, guidance to the Building Regulations. The recommended minimum standards 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 fitted in-line scale inhibitor should be specified 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 specified at the time of order. However, this will need to be fitted by the installer at a suitable point in the cold water supply to the appliance.

This unit uses minimal power in stand by mode, but can be turned off if required.

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 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. This is because the unvented and vented cylinders are tested at 65°C and the thermal store at 75°C.

DESIGN

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Notes:-
1. Plastic top up cistern will be supplied separately.
2. The flow rates are based on a 35°C temperature rise and assume that recommended pressures and adequate flow are available at the appliance. The actual flow rate from the appliance is automatically regulated to a maximum of 15 litres/min.
3. Unit is supplied on a 100mm high installation base.
4. The domestic hot water outlet temperature is automatically regulated to approximately 55°C, and the temperature is not user adjustable.

 TECHNICAL DATA

DESIGN

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Standard Equipment

The standard configuration of the BoilerMate CP is shown opposite. The Printed Circuit Control Board, mounted inside the appliance, controls the production of the domestic hot water. This is pre-wired to a terminal strip where all electrical connections terminate. The installer must fit components to control the operation of the immersion heater. It is supplied with the following factory fitted equipment:-

1. Boiler flow
2. 3kW backup immersion heater
3. Printed Circuit Board
4. Plate heat exchanger
5. Domestic hot water primary (plate heat
exchanger) pump
6. Incoming cold water sensor
7. Strainer and flow regulator
8. Screwed connection for a drain tap
9. Top up cistern complete with cold feed/
open vent pipework assembly is supplied separately
10. Store sensor
11. Cylinder thermostat
12. Boiler return
13. Flow sensor

Note

The immersion heater is a low watt density type with incaloy 825 sheaths and are specially manufactured to suit thermal stores. It is recommended that any replacements should be obtained from Gledhill Spares.

The immersion heater is fitted with control thermostats and overheat thermostats. Immersion heaters without these components must not be fitted to the unit.

Optional Extra Equipment

• In line scale inhibitor for mains water services with hardness levels between 200 and 300ppm (mg/l) fitted but ready for wiring by the installer to the suitable 230V ac supply.

• Polyphosphate scale inhibitor for fitting on site by the installer.

• Ballvalve/overflow connector for top up cistern.

DESIGN

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Appliance Dimensions

Model Height A Width B  Depth C
BMSCP120 1075 530 595
BMSCP150 1145 560 630
BMSCP180 1275 560 630
BMSCP220 1575 560 630



Note: The Appliance dimensions above do not allow for the100mm high installation base.

The following table of minimum cupboard dimensions only allow the minimum space required for the appliance (including the F & E cistern). Any extra space required for shelving etc in the case of airing cupboards etc must be added.

Model Height D Width E  Depth F
BMSCP120 1825 570 610
BMSCP150 1895 600 645
BMSCP180 2025 600 645
BMSCP220 2325 600 645


Note: The above dimensions are based on the Appliance and the Top up cistern (fitted with a ballvalve) being in the same cupboard. If the manual fill method is chosen the heights can be reduced by 125mm.

If pipework needs to rise vertically adjacent to the appliance the width/depth will need increasing to accommodate this.

 DESIGN

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Plan Of Appliance Connections

The BoilerMate CP 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 +/- 10mm in any direction. Space will also be required for a 22mm cold water supply and a 22mm warning / overflow pipe (if the optional extra ball valve and overflow connector have been specified. If a warning/overflow pipe is NOT provided the F&E Cistern should be filled from a temporary hose connection incorporating a double check valve. This can be from a temporary hose connection supplied from a cold water tap or a permanent cold branch provided adjacent to the Top up Cistern. The temporary connection must be removed once the appliance is filled.

Note: All dimensions are shown in mm and are to the centre line of the pipework.

DESIGN

Hot and Cold Water System
General

A schematic layout of the hot and cold water services in a typical small dwelling is shown below. BoilerMate CP will operate at mains pressures as low as 1 bar and as high as 5 bar although the recommended range is 2-3 bar dynamic at the appliance. It is also important to check that all other equipment and components in the hot and cold water system are capable of accepting the mains pressure available to the property. If the mains pressure can rise above 5 bar or the maximum working pressure of any item of equipment or component to be fitted in the system, a pressure limiting (reducing) valve set to 3 bar will be required.

If you encounter a situation where the water pressure is adequate but flow rates are poor please contact our technical helpline for details of an effective solution.

Note : Each BoilerMate CP is fitted with a strainer and flow regulator on the cold mains supply connection. If the supply pressure is less than 2 bar or if all taps are provided with flow regulators the flow regulator on the cold inlet should be removed.

No check valve or similar device should be fitted on the cold water supply branch to the BoilerMate CP.

The hot water flow rate from the BoilerMate CP is directly related to the adequacy of the cold water supply to the dwelling. This must be capable of providing for those services, which could be required to be supplied simultaneously, and this maximum demand should be calculated using procedures defined in BS EN 806:1-5: BS EN 8558:2011.

If a water meter is fitted in the service pipe, it should have a nominal rating to match the maximum hot and cold water peak demands calculated in accordance with BS EN 806:1-5: BS EN 8558:2011. Please note, the BoilerMate CP is fitted with a 15 l/m flow restrictor.

Note: The diagram below shows the top up cistern with ballvalve and warning/overflow pipe which can be supplied as an optional extra if required. However, the standard preferred arrangement is for the cistern to be manually filled from a temporary hose connection fitted with a double check valve.

The cistern must not be fitted more than 10 metres above the BoilerMate CP appliance itself.

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DESIGN

Hot and Cold Water System
Pipe Sizing / Materials

To achieve even distribution of the available supply of hot and cold water, it is important in any mains pressure system, that the piping in a dwelling should be sized in accordance with BS EN 806:1-5: BS EN 8558:2011. This is particularly important in a large property with more than one bathroom.

However, the following rule of thumb guide lines should be adequate for most smaller property types as long as water pressures are within the recommended range.

1. A 15mm copper or equivalent external service may be sufficient for a small 1 bathroom dwelling (depending upon the flow rate available), but the minimum recommended size for new dwellings is 22mm (25mm MDPE).

2. The internal cold feed from the main incoming stop tap to the BoilerMate CP should be run in 22mm pipe. The cold main and hot draw-off should also be run in 22mm as far as the branch to the bath tap.

3. The final branches to the hand basins and sinks should be in 10mm and to the baths and showers in 15mm (1 metre minimum).

4. We would recommend that best results for a balanced system are achieved by fitting appropriate flow regulators to each hot and cold outlet. This is particularly relevant where the water pressures are above the recommended water pressure range. Details of suitable flow regulators are provided in Appendix A.

All the recommendations with regard to pipework systems in this manual are generally 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 hot and cold water systems by the manufacturer and is installed fully in accordance with their recommendations.

This is particularly important in relation to use of push fit connections when using the optional flexible hose kits - see installation section of this manual.

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.

Hot and Cold Water System

If the length of the hot water draw off pipework is excessive and the delivery time will be more than 60 seconds before hot water is available at the tap, you may wish to consider using trace heating to the hot water pipework such as the Raychem HWAT system. Also a conventional pumped secondary circulation system (shown below) can be used with any model of the BoilerMate CP.

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Bath hot water supplies should be limited to a maximum of 48°C by the use of an inline blending valve.

It is important that the cold water pipework is adequately separated/protected from any heating/hot water pipework to ensure that the water remains cold and of drinking water quality.

A pipe thermostat is incorporated in the circuitry which cuts the supply to the pump when the water in the return pipe reaches the set temperature. Ensure the hot water temperature is set correctly to avoid excessively hot water at the outlets and long pump run times.

Secondary circulation pipework must be insulated to prevent energy loss in both heated and unheated areas.

Taps/Shower Fittings
Aerated taps are recommended to prevent splashing.

Any type of shower mixing valve can be used as long as both the hot and cold supplies are mains fed. However all mains pressure systems are subject to dynamic changes particularly when other hot and cold taps/ showers are opened and closed, which will cause changes in the water temperature at mixed water outlets such as showers. For this reason and because these are now no more expensive than a manual shower we strongly recommend the use of thermostatic showers with this appliance.

The shower head provided must also be suitable for mains pressure supplies.

However, if it is proposed to use a ‘whole body’ or similar shower with a number of high flow/ pressure outlets please discuss with the Gledhill technical department.

The hot water supply to a shower-mixing valve should be fed wherever practical directly from the BoilerMate CP or be the first drawoff point on the hot circuit. The cold supply to a shower-mixing valve should wherever practical be fed directly from the rising mains via an independent branch. The shower must incorporate or be fitted with the necessary check valves to provide back-syphonage protection in accordance with the Water Regulations.

The supply of hot and cold mains water directly to a bidet is permitted provided that it is of the over-rim flushing type and that a type ‘A’ air gap is incorporated.

 DESIGN

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General – Sealed And Open Vented Heating Systems

The BoilerMate CP is suitable for both an open vented and a sealed heating systems shown schematically above. The system components can be installed inside the appliance case. Although, the heating system can be either open vented or sealed, the thermal store must always be open vented as shown above and also: -

• The combined cold feed and open vent pipe arrangement must not be used.
• No valve should be fitted in the safety open vent and which must be a minimum of 22mm copper pipe or equivalent.

The BoilerMate CP is designed to be installed with condensing or non condensing oil or gas boilers which is capable of delivering primary hot water at a minimum temperature of 80°C.

The boiler must be set to operate at nominal 82°C flow which usually corresponds to maximum boiler control thermostat setting.

It is recommended that an automatic bypass is fitted to compensate for pressure and hence the flow rate changes in the heating circuit e.g. when the thermostatic radiator valves close. The bypass valve must be set by the installer to suit the system i.e. to provide minimum flow required for the boiler when all TRVs are closed.

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Immersion Heaters

This is a 3kW 230V AC heater and incorporates a manual reset thermostat. They are incalloy elements to prolong their life expectancy in aggressive water conditions. We recommend best practice of connecting the wiring to the immersion heater is using crimp connections.

 

 

DESIGN

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District Heating Systems

The diagram opposite shows the BoilerMate CP installed to a system where the pumped supply is adequate to overcome the pressure loss of the BoilerMate CP heat exchanger coil, the pressure loss over the central heating system components and all other components fitted to it. In addition, all the components fitted are able to withstand the pressure in the district system.

In the diagram opposite, the cold water supply to the feed and expansion cistern is not shown, and neither is the overflow pipe which may by required if the ball valve is fitted to the F & E cistern. See page 9 for further details. Potentially a temporary filling loop complying with the water regulations can be installed.

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In this diagram an additional pump is shown fitted because the pressure loss in the central heating system is too large for the district pump.

The pump is now fitted in the district supply because the pressure loss over the BoilerMate CP coil is too large.

Here, the plate heat exchanger has been fitted because the expansion requirements of the central heating system are to be handled in the dwelling rather than the whole system, or the components in the central heating system are not capable of withstanding the pressure of the district heating system. 

In this instance, the plate heat exchanger provides a full pressure break between the district heating system and the dwelling system. The dwelling system will need to cater for expansion and circulation requirements. This may be used where excessive district heating pressure occurs.

INSTALLATION

The appliance is designed to be installed in an airing/cylinder cupboard and the relevant minimum dimensions are provided in the Technical Data section of this manual.

Because of the ease of installation we recommend that the cupboard construction is completed and painted before installation of the appliance. The cupboard door can be fitted after installation.

If the unit needs to be stored prior to installation it should be stored upright in a dry environment and on a level base/floor.

Installation and maintenance access is needed to the front of the appliance and above the Top up cistern. See the Technical Data section of this manual for further details.

The minimum dimensions contained in the Technical Data section of this manual allow for the passage/connection of pipes to the appliance from any direction as long as the appliance is installed on the installation base provided. If the installation base is not used extra space may be needed to allow connection to the pipework and the whole of the base area should be continuously supported on a material which will not easily deteriorate if exposed to moisture.

The floor of the cupboard needs to be level and even and capable of supporting the weight of the appliance when full. Details of the weight when full is provided in the Technical Data section of this manual.

The appliance is designed to operate as quietly as practicable. If the plate heat exchanger pump is noisy when the hot water tap is opened, then check the level of water in the F & E cistern and vent the pump if necessary. Water hammer may be caused by loose pipework and/or tap washers and/or washing machine valves.

Cupboard temperatures will normally be slightly higher than in a conventional system and the design of the cupboard and door will need to take this into account. No ventilation is normally required to the cupboard.

The separate Top up cistern will need to be located on top of the appliance or at high level in the cupboard housing the BoilerMate CP. The dimensions and clearances are provided in the Technical Data section of this manual. The location will need to provide a suitable route for the cold feed expansion pipe as well as the open safety vent pipe. The location will also need to provide a suitable route and discharge position for the warning/overflow pipe and the ballvalve supply from the mains cold water system (if provided) if these have been ordered as an optional extra.

Note: The standard appliance is supplied with a cistern without a ballvalve/ overflow for filling manually.

An electrical supply must be available which is correctly earthed, polarized and in accordance with the latest edition of the IEE requirements for electrical Installations BS 7671.

The electrical mains supply needs to be 230V/50Hz.

The sizes/types of electrical supplies must be as detailed in System Details section of this manual. A means for disconnection from the supply mains having a contact separation in all poles that provides full disconnection under over voltage category III conditions must be incorporated in the fixed wiring in accordance with the wiring rules. This shall be located within 1m of the appliance and only serve the appliance.

The hot and cold water ‘first fix’ pipework should be terminated 50mm above the finished floor level in accordance with the dimensions provided in the Technical Data section of this manual.

 SITE REQUIREMENTS

INSTALLATION

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Preparation/placing The Appliance In Position.

The appliance is supplied shrink wrapped on a timber installation base with the F&E cistern on top of the unit. Carrying handles are also provided in the back of the casing.

The appliance should be handled carefully to avoid damage and the recommended method is shown above.

Note: Although the above guidance is provided any manual handling/lifting operations will need to comply with the requirements of the Manual Handling Operations Regulations issued by the H.S.E.

The appliance can be moved using a sack truck on the rear face although care should be taken and the route should be even.

In apartment buildings containing a number of storeys we would recommend that the appliances are moved vertically in a mechanical lift.

If it is proposed to use a crane expert advice should be obtained regarding the need for slings, lifting beams etc.

Before installation the site requirements should be checked and confirmed as acceptable.

The plastic cover and protective wrapping should be removed from the appliance and the installation base (provided) placed in position.

The appliance can then be lifted into position in the cupboard on top of the base and the front panel removed by unscrewing the 2 screws and lifting the door up and out, ready for connection of the pipework and electrical supplies.

The feed and expansion cistern support shall be installed 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 section of this manual for details.

INSTALLATION

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Pipework Connections

The position of the pipework connections is shown opposite. The exact location dimensions are listed in the Technical Data section of this manual.

All the connections are also labelled on the appliance. It is essential that the pipework is connected to the correct connection.

Connections A and B are plain ended stainlesssteel pipe.

Connection C and D compression fittings.
Connection E is RC½ (½ in BSPT internal)

A - 22mm Safety open vent
B - 22mm Cold feed/expansion
C - 22mm Incoming mains cold water
D - 22mm Domestic hot water
E - ½” Drain tap connection
F - 28mm Boiler flow
G - 28mm Boiler return

Note: The safety open vent and cold feed/ expansion must be connected to the top up cistern using the pipework assembly provided. Do not alter or connect any pressure-relief device to the vent pipe of this water heater.

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

The fittings for the top up cistern should be installed following the instructions provided and the cistern fitted on its supports/top of the appliance.

The cold feed/expansion and safety open vent should be installed between the appliance and the top up cistern.

INSTALLATION

Feed And Open Vent Pipe

It is normally envisaged that the top up cistern will be located in the same cupboard as the BoilerMate CP appliance itself to maintain a dry roof space.

The cold feed/open vent pipework assembly (as supplied) should be used to install the top up cistern directly on top of the appliance.

If it is necessary to locate the cistern in the roof space (or on a higher floor) the cold feed/open vent pipework assembly (as supplied) should be used to connect to the top up cistern and pipework site run by the installler to connect this to the appliance.

Obviously, any pipework in the roof space and the feed and expansion cistern will need to be adequately insulated to protect against frost damage.

Combined Feed And Open 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 throughout its length.

The mains cold water supply to the ballvalve (if provided) shall be provided with a suitable servicing valve.

The overflow/warning pipe (if provided) shall have a continuous fall, be fitted to discharge clear of the building and be sited so that any overflow can be easily observed. It shall also be installed in a size and material suitable for use with heating feed and expansion cisterns in accordance with BS 5449 (e.g 22mm copper) and should not have any other connections to it.

Note: If a warning/overflow pipe is NOT provided the top up cistern should be filled from a temporary hose connection supplied from any cold water tap or from a permanent cold branch provided adjacent to the top up cistern. The temporary hose must be fitted with a double check valve and removed once the appliance is filled.

The store may fill more slowly than the feed tank. It is important to check the water level again in the cistern after commissioning.

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INSTALLATION

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INSTALLATION

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INSTALLATION

Open the incoming stop valve and fill the domestic mains cold and hot water systems including the BoilerMate CP appliance.

Check the water level in the top up cistern and if a ballvalve is fitted adjust if necessary.

Check the whole of the domestic hot and cold distribution systems for leaks. Fully flush and if necessary chlorinate the hot and cold water system in accordance with the recommendations in the Water Regulations and BS EN 806:1-5: BS EN 8558:2011.

Please note that the whole of the domestic hot and cold water systems including the appliance must be adequately flushed after chlorination. Failure to do this can cause damage to the plate heat exchanger/immersion heaters etc. If there are any doubts regarding this or the quality of the water being used to fill the BoilerMate CP appliance an inhibitor such as Fernox MBI or Sentinel X100 should be added to the appliance when filling in line with the manufacturers instruction for these products.

Check that the top up tank is filled up to the water level shown on the label. If it is a manual fill model, this is most important.

If a ballvalve is provided, turn down the servicing valve once the system is finally filled to the point where the warning/overflow pipe will cope with the discharge arising from a ballvalve failure.

If an overflow is not provided ensure the temporary filling hose is isolated and removed from its connection to the cold water supply.

It is essential that all systems function properly for optimum performance.

To achieve this the flow rate from each tap should be checked and a suitable number of taps run simultaneously to check the impact of this on the flow rate at individual taps. We recommend that flow regulators are provided for each tap/terminal fitting to ensure that the available flow is shared evenly - See Appendix A for further details

Commissioning the BoilerMate CP Control System

It can be checked that the boost immersion heater is drawing current by use of a clamp meter on the live supply when boost is active.

If the appliance has been connected with the polarity incorrect it will not operate at all.

See the fault finding section of the manual for further details.

Run a tap and using a digital thermometer check that the temperature of the hot water is about 52°C. This temperature is factory set and is independent of the store temperature assuming the store is above 55°C and typical hot water flow rates of 6-15l/min are being drawn.

At the time of commissioning, complete all relevant sections of the Benchmark Checklist located on the inside back pages of this document.

This must be completed during commissioning and left with the product to meet the Warranty conditions offered by Gledhill.

Basic pump operation testing

In order to confirm that the pump is operational, and that all air has been cleared from the pump circuit pipe work, including the PHE. Perform the following actions.

1. Ensure that the unit is full of water
2. Ensure that the primary pipework to the PHE and the PHE itself are bled of air 3. Open hot water tap
4. The pump should then run and hot water will be delivered through the tap

INSTALLATION

Circulating fluid in thermal store pipework

• The BoilerMate CP and the thermal store pipework must have completed filling prior to switching the electricity supply to the PWM controller PCB. If there is no water in these pipes then there may be significant wear on the PWM pump.

• This can be confirmed by

- Checking the thermal store pipework servicing valves are open
- Loosening the connection points on the thermal store pipework in a systematic manner and checking for water presence.
- Confirming that the feed and expansion tank has completed filling and the servicing valve is open.

Cold mains water supply to plate heat exchanger and hot water taps

• Confirm that the CW mains stop valve is open

• Open all HW taps and confirm that the water runs freely and that any air is bled from the DHW system

• Determine the maximum flow rate obtained and record

• 15l/min for all BoilerMate CP products currently limited with a flow restrictor

• If flow rate not as expected determine the cause and rectify
- clean inline strainer
- check the flow restrictor is present and not blocked. It is located in the top of the inline strainer

Power on

• Switch on the Local fuse spur and observe the PWM pump

• The green LED will flash showing the pump has a power supply and is in standby mode.

• Open a HW tap and observe the PWM pump

• The green LED will be constantly lit showing the pump has a power supply and is running to generate HW

NOTE: -The thermal store will only produce hot water when it is hot enough. A mid 40°C thermal store temperature will provide some hot water, higher thermal store temperatures will provide more.

Inline scale inhibitor (if fitted)

• Check power supply

• PWM Controller PCB supplies a maximum of 12vDC/300mA to the Scale inhibition board. (From J3)

• Check dip switches set correctly

• The correct settings for tube diameter 22mm is switch no. 3 on.

 • Switch no. 4 can be either on or off.

• If the switch no. 4 is turned on the output electromagnetic field is generated harmoniously otherwise the field is generated inharmoniously.

 INSTALLATION

Important Do’s and Don’ts

1. DO check the incoming mains water pressure. The preferred range of mains pressure is 2 -3 bar.

2. DO check the flow rate of the incoming cold water main is adequate to meet the maximum hot and cold water simultaneous demands.

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

4. DO check the water level is correctly set in the top up cistern when cold and if fitted that there is no overflow when the appliance is up to temperature.

5. DO check that the control thermostats switch the immersion heaters off at the correct set point i.e. approx 75°C.

6. DO insulate any exposed hot water pipework in the BoilerMate CP cupboard.

7. If the ballvalve in the F & E cistern is permanently connected to the mains cold water supply DO plumb the overflow/warning pipe in a 20mm internal diameter pipe and ensure it discharges in a conspicuous external position. Use a material which is suitable for use with heating F & E cisterns in accordance with BS 5449 (such as copper).

8. Once the appliance is filled and commissioned DO leave the electricity switched on to the appliance to ensure the automatic pump run facility can operate to prevent the pump sticking.

9. DO ensure that the functioning and control of the system is explained to the occupant.

10. DON’T place any clothing or other combustible materials against or on top of this appliance.

Annual Servicing

No annual servicing of the BoilerMate CP is necessary.

However, if required, the operation of the controls and a hot water performance test can be carried out to prove the appliance is working satisfactorily and within its specification.

If it is decided to carry out the above tests the water level in the top cistern should also be checked and if necessary topped up.

Changing Components

Free of charge replacements for any faulty components are available from Gledhill during the in-warranty period on return of the faulty part (normally 12 months).

After this, spares can be obtained direct from Gledhill Spares or through any of the larger plumbers merchants/specialist heating spares suppliers.

Help and advice is also available from the Technical Helpline on 01253 474584.

However, all components are readily accessible and can be changed quickly and easily by the installer using common plumbing/electrical practice.

Note: All maintenance work on the BoilerMate CP appliance must be carried out by a competent trades person.

 SERVICE / CHANGE COMPONENTS

SERVICING

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

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SERVICING AND MAINTENANCE

Test Equipment

The initial assumption in this procedure is that the plumbing and water supply is working effectively. If in doubt please confirm and refer to the end of this section for advice on specific components.

A multi meter, a weir gauge and a thermometer will be required to confirm that all the components are working effectively.

The PWM controller PCB manufacturer suggests “Fluke 87 TRUE RMS Multi meter” as a suitable product. This will be able to measure;
- the frequency output form the Board to the pump
- the Duty cycle % output from the Board to the pump

Connection numbering

For reference the connections to the PCB are numbered below for

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Logical sequence;

- check electrical connections fault finding section on page 23 first to ensure your own safety. This section will potentially identify any short circuited components and/or wiring faults that need to be rectified before continuing to work on the appliance.

- check that the correct information is being supplied to the board. This section will identify if any sensors are faulty or out of tolerance. These will need to be replaced before continuing

- check that the overheat link is present - check that the outputs to the board are being generated. If at this stage the board does not provide the correct outputs then potentially the board should be replaced

- check the pump electrical circuit

FAULT FINDING

SERVICING AND MAINTENANCE

Electrical power connections

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SERVICING AND MAINTENANCE

Gledhill-Boilermate -CP -Design -Installation -and -Servicing -Instructions-23

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SERVICING AND MAINTENANCE

Check for presence of overheat link

An overheat link connection should be present in connection Junction 7. If you are fitting a new board the overheat link that is on the board just removed must be retained as the newly supplied board will not have one fitted.

Check outputs from the PWM controller PCB to the pump

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SERVICING AND MAINTENANCE

Check pump electrical circuits

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SERVICING AND MAINTENANCE

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APPENDIX

water Savings
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 & 10 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 Handshowers (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 Options For taps & Mixers

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. Pushfit into Tap or Mixer seats. Produced in three sizes - 12.5mm (BS1010), 12mm & 10mm, Flangeless models also available for Taps with Low Lift washers.

3. MXF Standard 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" and 1" 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.

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Information by courtesy of
AquAFlOw RegulAtORS ltd
Haywood House, 40 New Road, Stourbridge, West Midlands DY8 1PA
TeLePHONe (01384) 442611 FAX: (01384) 442612

 

 

 APPENDIX

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APPENDIX

MANUAL HANDLING OF APPLIANCE PRODUCTS

Description

Manual handling means any transporting or supporting of a load (including lifting, putting down, pushing, pulling, carrying or moving) by hand or bodily force.

Scope

This assessment will cover the largest unit within each product range manufactured by Gledhill. For specific weights and dimensions please refer to technical data section.

Main Hazards

Vision may not be clear due to the size of the products. Adopting an incorrect method of lifting may cause injury, attempting to lift these products will require help from others. (Team lifts)

Control Measures
Manual lifting procedure
The lift, key factors in safe lifting are:

a. Balance
b. Position of back
c. Positioning of the arms and body
d. The hold
e. Taking the lead for team lifts

a. Balance - Since balance depends essentially upon the position of the feet, they should be apart about hip breadth with one foot advanced giving full balance sideways and forward without tension. In taking up this position, lifting is done by bending at the knees instead of the hips and the muscles that are brought into use are those of the thigh and not the back.

b. Position of back - Straight - not necessary vertical. The spine must be kept rigid, this coupled with a bent knee position, allows the centre line of gravity of the body to be over the weight so reducing strain.

c. Positioning of arms and body - The further arms are away from the side, the greater the strain on the shoulders, chest and back. Keep elbows close to the body arms should be straight.

d. The hold - Before lifting ensure you have a good hold. Two handles are provided on Appliance products at the top rear side, these allow one or two persons to have a purposely-designed hold at the top of the appliance to ensure easy lifting at the top of the product.

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 the items listed within this assessment. Make sure you and any others helping know the route you intend to take that it is clear of any obstructions. Never jerk the load as this will add a little extra force and can cause severe strain to the arms, back and shoulders. If there are steps involved decide on where you will stop and take a rest period. Move smoothly and in unison taking care to look and listen to others helping with the lift. Where possible use a sack truck to move the product over long flat distances, only lift the products when necessary. If in doubt stop and get more help.

Individual capability

Individual capability plays an important part in handling these products. Persons above average build and strength will find it easier and should be in good health. Persons below average build and strength may require more rest periods during the handling process.

Pregnant women should not carry out this operation.

Persons who are not in good health should seek medical advice prior to commencing any lifting or manual handling operation.

 Residual risk

Following the guidelines given above will reduce any risk to injury.

All persons carrying out this operation must be fully trained and copies of the specific risk assessment made available for inspection and use in their training process.

Further guidance on Manual Handling can be obtained from the Health and Safety Executive. Manual Handling Operations Regulations 1992.

 BENCHMARK

MAINS PRESSURE HOT WATER STORAGE SYSTEM COMMISSIONING CHECKLIST


This Commissioning Checklist is to be completed in full by the competent person who commissioned the storage system as a means of demonstrating compliance with the appropriate Building Regulations and then handed to the customer to keep for future reference.

Failure to install and commission this equipment to the manufacturer’s instructions may invalidate the warranty but does not affect statutory rights

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SERVICE RECORD

It is recommended that your hot water system is serviced regularly and that the appropriate Service Record is completed. Service Provider Before completing the appropriate Service Record below, please ensure you have carried out the service as described in the manufacturer’s instructions.

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