gledhill BM125 Installation And Servicing Instructions
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gledhill BM125 Installation And Servicing Instructions

Boilermate 2000
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BOILERMATE 2000
DESIGN, INSTALLATION AND
SERVICING INSTRUCTIONS
Gas Council Approved Reference Numbers
BoilerMate 125 89-317-04A
BoilerMate 145 89-317-05A
BoilerMate 185 89-317-06A
BoilerMate 210 89-317-07A
BoilerMate 225 89-317-08A
AN OPEN VENTED CENTRAL HEATING
AND MAINS PRESSURE HOT WATER SUPPLY
SYSTEM INCORPORATING
A THERMAL STORE
ALL MODELS COMPLY WITH THE
WATER HEATER MANUFACTURERS
SPECIFICATION FOR INTEGRATED THERMAL
TEL: 0800 14 55 55 7
www.gledhill-boilermate.co.uk
STORES

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  • Page 1 AND MAINS PRESSURE HOT WATER SUPPLY BoilerMate 185 89-317-06A SYSTEM INCORPORATING BoilerMate 210 89-317-07A A THERMAL STORE BoilerMate 225 89-317-08A ALL MODELS COMPLY WITH THE WATER HEATER MANUFACTURERS SPECIFICATION FOR INTEGRATED THERMAL STORES TEL: 0800 14 55 55 7 www.gledhill-boilermate.co.uk...

  • Page 2: Table Of Contents

    Quality System audited by BSI. Patents Pending As part of the industry wide “Benchmark” Initiative all Gledhill BoilerMates now include a Benchmark Installation, Commissioning and Service Record Log Book. Please read carefully and complete all sections relevant to the appliance installation.

  • Page 3: Design

    Sale, which are set out at the rear of this manual. 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 document, which is accurate at the time of printing, should be disregarded.
  • Page 4 Gledhill. For further details see Section 1 Hot and Cold Remote Water System page 10. F&E tank...

  • Page 5: Technical Data

    1.0 DESIGN 1.2 TECHNICAL DATA ) l l l i o & ) l i ½ ½ ½ ½ ½ l i o 5 1 W 0 2 W 5 2 W 0 3 W 5 3 W c t i Notes:- The BoilerMate 225 appliance is suitable for use in large properties because it produces the same ‘peak hour output’...
  • Page 6 1.0 DESIGN 1.2 TECHNICAL DATA Standard Equipment The standard confi guration of the BoilerMate 2000 is shown opposite. The Appliance Control Board (A.C.B.), mounted inside the appliance, controls the operation of the complete system. The A.C.B. is pre-wired to a terminal strip where all electrical connections terminate.
  • Page 7 1.0 DESIGN 1.2 TECHNICAL DATA Min maintenance access to comply with the Water Regulations F & E Cistern 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 &...
  • Page 8 1.0 DESIGN 1.2 TECHNICAL DATA Suggested location for 15mm 595 (650) cold mains feed to the F & E tank. Safety/Open Vent Cold feed/Expansion REAR (490) (390) (325) (245) (230) (155) (70) REMOVABLE FRONT ACCESS PANEL Cut out area through base of unit - showing recommended pipework riser positions.
  • Page 9 1.0 DESIGN 1.2 TECHNICAL DATA AWAITING HOT WATER PERFORMANCE GRAPHS FOR EACH MODEL SIZE TO BE ADDED PERFORMANCE GRAPHS OF GRUNDFOS PUMPS litres/sec litres/sec GRUNDFOS 15/50 GRUNDFOS 15/60 Page 9...

  • Page 10: System Details

    1.0 DESIGN 1.3 SYSTEM DETAILS Hot and Cold Water System General When specifying this appliance we would A schematic layout of the hot and cold water services in a typical small dwelling is recommend that for hardness levels above shown below. BoilerMate 2000 will operate at mains pressures as low as 1 bar and as 200ppm (mg/l) a hard water appliance is used.
  • Page 11 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 fl ow/pressure outlets please discuss with the Gledhill technical department. Page 11...
  • Page 12 1.0 DESIGN 1.3 SYSTEM DETAILS Heating System General Warning/overflow Mains cold pipe water A schematic layout of the heating system in a typical small dwelling is shown opposite. Remote The flow and return from the boiler must F&E tank always run directly to the BoilerMate 2000 and the flow should rise continuously to Cold feed Open Vent...
  • Page 13 1.0 DESIGN 1.3 SYSTEM DETAILS Pipe Sizing/Materials Heating System It is also essential that if an alternative pipework The primary pipework connecting the boiler and the thermal store should be sized material/system is chosen the manufacturer to achieve a maximum of 8°C rise across the boiler or the maximum temperature confirms that the design criteria of the new rise specifi...
  • Page 14 1.0 DESIGN 1.3 SYSTEM DETAILS Heating System Boiler sited above the BoilerMate Any boiler used must be fi tted with an overheat thermostat i.e. it must be suitable for use in a sealed system. The F & E cistern must be fi tted at a height which will provide the minimum head required for the boiler and must be at least 250mm above the highest point of the system.
  • Page 15 1.0 DESIGN 1.3 SYSTEM DETAILS Heating System Connection of Bathroom Radiator/ Towel-Rail for Summer use F & E Cistern If a pumped circuit is required for the bathroom Radiator radiator/towel rail, the fl ow pipework can be teed anywhere into the primary fl ow between the boiler and the BoilerMate.
  • Page 16 This arrangement is not suitable for BoilerMate appliances fi tted with Switch. If it is proposed to use this arrangement please advise Gledhill at the time of order, Gledhill will then supply a suitable vent assembly for fi tting on the safety/open vent connection and a blank for the cold feed connection of each BoilerMate 2000, in lieu of the F &...

  • Page 17: Installation

    1.0 DESIGN 1.3 SYSTEM DETAILS ‘Switch’ The BoilerMate 2000 can be ordered with the option of ‘Switch’ which provides a 9kW electrical emergency back up in the case of failure of the main heat source i.e. gas boiler. This must NOT be used to provide hot water only in summer if the main system is working correctly.

  • Page 18: Site Requirements

    2.0 INSTALLATION 2.1 SITE REQUIREMENTS An electrical supply must be available which is The appliance is designed to be installed in an airing/cylinder cupboard and the correctly earthed, polarized and in accordance relevant minimum dimensions are provided in section 1.2 Technical Data. with the latest edition of the IEE requirements for electrical Installations BS 7671.

  • Page 19: Installation

    2.0 INSTALLATION 2.2 INSTALLATION Preparation/placing the appliance in position. Details of the recommended positions for termination of the first fix pipework are provided in section 1.2 Technical Data. The pipework can be located or its position checked using the template provided with each appliance.
  • Page 20 2.0 INSTALLATION 2.2 INSTALLATION Pipework connections The position of the pipework connections is shown opposite. The connection sizes and dimensions are listed in Section 1.2 Technical Data. All the connections are also labelled on the appliance. It is essential that the pipework is connected to the correct connection.
  • Page 21 2.0 INSTALLATION 2.2 INSTALLATION It is normally envisaged that the feed and expansion cistern will be located in the same cupboard as the BoilerMate appliance itself to maintain a dry roof space. The cold feed/open vent pipework assembly (as supplied) should be used if it is intended to install the F &...
  • Page 22 2.0 INSTALLATION 2.2 INSTALLATION 2000 WIRING DIAGRAM - STANDARD BOILERMATE APPLIANCE DHW Sensor PHE return sensor STORE Sensor Clock 1 2 3 4 5 Neon BLUE BROWN GREEN/YELLOW DHW pump BLACK Heating pump YELLOW WHITE Boiler pump LOAD FILTER LINE TERMINAL BLOCK SCALE...
  • Page 23 2.0 INSTALLATION 2.2 INSTALLATION Electrical Connection - Standard Appliance The BoilerMate 2000 is pre-wired to a 12 way terminal strip from the A.C.B. and plumbers are well able to complete the electrical installation provided they adhere strictly to the IEE Requirements for Electrical Installations BS 7671.
  • Page 24 2.0 INSTALLATION 2.2 INSTALLATION The BoilerMate 2000 incorporates a pump overrun for the boiler pump and terminal 6 on the terminal strip (as shown on page 22) should only be used if the boiler requires a permanent live for another purpose. The boiler manufacturers wiring instructions should be read in conjunction with this manual.
  • Page 25 2.0 INSTALLATION 2.2 INSTALLATION 2000 WIRING DIAGRAM - BOILERMATE WITH SWITCH Optional Extra BLUE if fitted BROWN GREEN/YELLOW BLACK Relay DHWp pump Clock YELLOW WHITE SCALE INHIBITOR 1 2 3 4 5 Gas / Electric control PCB DHW sensor Pump sensor Store sensor Manual reset safety stat...
  • Page 26 2.0 INSTALLATION 2.2 INSTALLATION Electrical Power Supplies - BoilerMate 2000 with Switch. WARNING : IF THE BOILERMATE IS FITTED WITH AN OPTIONAL ELECTRIC BACKUP SYSTEM I.E. ‘SWITCH’ . A heavy duty electrical supply, see table on page 18, is required for this model and we IMPORTANT : ELECTRICIAN/INSTALLER PLEASE NOTE.

  • Page 27: Commissioning

    Corrosion inhibitor agent Sentinel X100 Fernox MB1 When determining the quantity of inhibitor required, be sure to allow for the increased BM125 1¼ 1¼ volume of water in the primary circuit due to the thermal store - see section 1.2 Technical BM145 1½...
  • Page 28 2.0 INSTALLATION 2.3 COMMISSIONING Once the system is fi nally fi lled turn down LED DISPLAY the servicing valve for the ballvalve in BAR 1 - HT the F & E cistern to the point where the BAR 2 - ST warning/overfl...
  • Page 29 Warranty conditions offered • If the boiler is range rated, then adjust it to the maximum heat input. by Gledhill. • Check the boiler thermostat is set to maximum. • On completion:- Set the boiler pump speed so that the temperature difference across the boiler is about 8°C - when the space heating is off.
  • Page 30 2.0 INSTALLATION 2.3 COMMISSIONING Important Do’s and Don’ts 1. DO check the incoming mains water pressure and fl ow rate are adequate. (The preferred range of mains pressure is 2-3bar). 2. DO check that all connections are in accordance with the labelling on the thermal store.

  • Page 31: Servicing

    Gledhill during the in-warranty period (normally 12 months). After this, spares can be obtained direct from Gledhill using the ‘Speed Spares’ service, or through any of the larger plumbers merchants/ specialist heating spares suppliers. Help and advice is also available from the Technical Helpline on 08449 310000.

  • Page 32: Short Parts List

    3.0 SERVICING 3.3 SHORTS PART LIST i r c l i c e i f v l l l i a c i t l d i ½ " ½ " i l p ) B . n i l a t i n i l .
  • Page 33 3.0 SERVICING 12/13 Page 33...

  • Page 34: Fault Finding

    3.0 SERVICING 3.4 FAULT FINDING Despite everyones best efforts some problems could occur and lead to complaints 3. Causes of ‘Unsatisfactory Space Heating’ from the householder. Check the boiler thermostat - this should be Complaints can be grouped into the following three main categories:- set at maximum.
  • Page 35 3.0 SERVICING In addition to the main LED display the ACB has four green LED’S which can be used to check a supply is being provided when required to the Boiler (LED 1), Boiler pump (LED 2) and Heating pump (LED 3). LED 4 is not used on this appliance.

  • Page 36: Appendix A

    APPENDIX A WATER SAVINGS WATER RELATED COSTS CAN BE REDUCED BY GOOD PLUMBING PRACTICE. TAPS & MIXERS 2 TAP 5, 6 OR HALF OPEN OVER 8 L/M 20 L/M Unregulated Fitted with regulator SHOWERS 4 FIXING OPTIONS FOR TAPS & MIXERS 1.

  • Page 37: Appendix B

    APPENDIX B MANIFOLDS Manifold type: 1 - Stock Code MIP 050 Two sets of manifolds are available as an (one bathroom, one en suite shower room, one cloakroom, one kitchen) optional extra. Each set comprises a separate hot and cold water manifold. Both are Flow regulator Terminal fi...
  • Page 38 APPENDIX B The pressure loss through a flow regulator at the designated fl ow rate is about 1.8 bar. Therefore for the fl ow regulator to control the fl ow rate at pre-set level, the inlet pressure must be greater than 1.8 bar. If the inlet pressure is lower, the fl...
  • Page 39 APPENDIX B The size of the distribution pipes supplying the manifold should be calculated using the method set out in BS 6700. A typical diagrammatic arrangement of a system using Manifold Type 1 is shown below. This is only meant to show the principles involved and the actual connection of fi...

  • Page 40: Appendix C

    APPENDIX C G U I D A N C E N O T E S Inhibitor (Corrosion & scale protection of primary heating circuit) On filling the heating system and before the boiler is fired up, it is important to ensure the system water is treated with a suitable corrosion inhibitor, in accordance with the boiler manufacturer’s instructions.

  • Page 41: Appendix D

    APPENDIX D Page 41...

  • Page 42: Appendix E

    APPENDIX E Page 42...
  • Page 43 APPENDIX E Typical arrangement of a SolarPod with a BoilerMate thermal store Page 43...
  • Page 44 Page 44...
  • Page 45 Page 45...
  • Page 46 Sales, Service & Repair BoilerMate 2000 C/O Hot Water Cylinders Limited 302 Foxhunter Drive Milton Keynes MK14 6GD TEL: 0800 14 55 55 7 www.gledhill-boilermate.co.uk...

This manual is also suitable for:

Bm145Bm 185Bm 210Bm 225

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