Commissioning; Installation Review - gledhill BOILERMATE CP BMSCP120 Instruction Manual

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.

COMMISSIONING

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
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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

INSTALLATION REVIEW

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