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Benchmark Gledhill BoilerMate 2000 125 Design, Installation And Servicing Instructions

Open vented central heating and mains pressure hot water supply system incorporating a thermal store
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2000
2000
BOILERMATE
BOILERMATE
DESIGN, INSTALLATION AND
SERVICING INSTRUCTIONS
PLEASE LEAVE THESE INSTRUCTIONS IN THE POCKET PROVIDED ON
THE BACK OF THE FRONT PANEL
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
���������
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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
STORES

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  • Page 1 2000 2000 BOILERMATE BOILERMATE DESIGN, INSTALLATION AND SERVICING INSTRUCTIONS PLEASE LEAVE THESE INSTRUCTIONS IN THE POCKET PROVIDED ON THE BACK OF THE FRONT PANEL 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 ���������...

  • Page 2: Table Of Contents

    The Gledhill Group’s first priority is to give a high quality service to our customers. As part of the industry wide “Benchmark” Initiative all Gledhill BoilerMates now Quality is built into every Gledhill product include a Benchmark Installation, Commissioning and Service Record Log Book.

  • Page 3: Design

    1.0 DESIGN 1.1 INTRODUCTION T h e s e i n s t r u c t i o n s s h o u l d b e r e a d i n conjunction with the Installation and Servicing Instructions issued by the manufacturers of the heat source e.g.
  • Page 4 Details for further information. ������ ��� ������� ������ ������������ ���������� ������������ ������� ������ ���� Gledhill are part of the ‘Benchmark’ scheme ������� �� ��� ��������� �� � ���� ���� ������� and a separate commissioning/service log book is included with the product.

  • Page 5: Technical Data

    1.0 DESIGN 1.2 TECHNICAL DATA ) l l l i o & ) l i 1⁄2 1⁄2 1⁄2 1⁄2 1⁄2 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 configuration 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 420mm 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 ��������� �������� ��� ���� ��� ����� ���� ����� ���� �� ��� � � � ����� ����������� ���� ���� �������������� ���� ��� ��� ��� ��� ����� ��� ����� ��� ��� ����� ��� ����� ��� ��� ����� ���...
  • 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

    BoilerMate 2000. Because of the innovative method of hot water production no scale reducer is required on the branch to the appliance. However, to comply with the Benchmark Guidance Note for Water Treatment in Heating and Hot Water Systems the installer should check the hardness level of the water supply and if necessary fit a scale reducer to provide protection to the whole of the domestic water system.
  • Page 11 1.0 DESIGN 1.3 SYSTEM DETAILS Hot and Cold Water System Pipe Sizing / Materials The hot water supply to a shower-mixing valve To achieve even distribution of the available supply of hot and cold water, it is should be fed wherever practical directly from important in any mains pressure system, that the piping in a dwelling should be the BoilerMate 2000 or be the first draw-off sized in accordance with BS 6700.
  • Page 12 1.0 DESIGN 1.3 SYSTEM DETAILS Heating System General ���������������� ����� ���� ���� ����� A schematic layout of the heating system in a typical small dwelling is shown opposite. ������ The flow and return from the boiler must ��� ���� always run directly to the BoilerMate 2000 and the flow should rise continuously to ����...
  • 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 specified by the boiler manufacturer, whichever is smaller, but in any instance it system is at least equivalent to the use of BS/EN...
  • Page 14 1.0 DESIGN 1.3 SYSTEM DETAILS Heating System Boiler sited above the BoilerMate ���� ��������� ��� ���� ���� ������� ����� ����� Any boiler used must be fitted with an overheat � � � � � � � � � � thermostat i.e. it must be suitable for use in ����...
  • Page 15 1.0 DESIGN 1.3 SYSTEM DETAILS Heating System Connection of Bathroom Radiator/ Towel-Rail for Summer use � � � ������� If a pumped circuit is required for the bathroom radiator/towel rail, the flow pipework can be �������� teed anywhere into the primary flow between the boiler and the BoilerMate.
  • Page 16 1.0 DESIGN 1.3 SYSTEM DETAILS Heating System Method of connecting two BoilerMates to one heat source. If the primary flow and return pipework continuously rises from the boiler to the BoilerMate the recommended method for connecting two BoilerMates to one heat source is to fit the BoilerMates as normal but to provide a single check valve on the branch immediately after each primary pump.

  • 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

    2.0INSTALLATION 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 2.0INSTALLATION 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 2.0INSTALLATION 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 ���������� ���� ���� ����� WIRING DIAGRAM - STANDARD BOILERMATE 2000 APPLIANCE ��� ������ �� �� ��� ��� ������ ������ ����� ������ �� ��� �� ����� � �� �� ��� � � � � � �� ���� ��...
  • 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 WIRING DIAGRAM - BOILERMATE WITH SWITCH 2000 �� �� � � �� � �� � ����� ��� ���� ��� ��� ��� �� �� ��� ��� ��� � � ���� ����� � � � � � �� �...
  • 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

    2.0 INSTALLATION 2.3 COMMISSIONING Open the incoming stop valve and fill the domestic mains cold and hot water When using either cleansing or corrosion systems. inhibitor chemical, the manufacturers instructions must be followed. Fill the whole of the primary heating system with potable water through the feed and expansion cistern.
  • Page 28 2.0 INSTALLATION 2.3 COMMISSIONING Once the system is finally filled turn down ��� ������� the servicing valve for the ballvalve in ��� � � �� the F & E cistern to the point where the ��� � � �� warning/overflowwillcopewiththedischarge ���...
  • Page 29 A.C.B are off, the radiator circuit and hot water can be checked and balanced in the normal way. This product is covered by the ‘Benchmark’ The boiler thermostat should be left at maximum for optimum performance/ scheme and a separate commissioning/ efficiency.
  • Page 30 2.0 INSTALLATION 2.3 COMMISSIONING Important Do’s and Don’ts 1. DO check the incoming mains water pressure and flow 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

    3.0 SERVICING 3.1 ANNUAL SERVICING No annual servicing of the BoilerMate 2000 is necessary. However, if required, the operation of the controls and a hot water performance test can be carried out when servicing the boiler to prove the appliance is working satisfactorily and within its specification.

  • 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 1⁄2 " 1⁄2 " i l p ) B . n i l a t i n i l .
  • Page 33 3.0 SERVICING � � � � � � � � � �� ����� �� �� �� �� �� �� �� �� �� �� �� �� �� �� Page 33...

  • Page 34: Fault Finding

    3.0 SERVICING 3.4 FAULT FINDING 3. Causes of ‘Unsatisfactory Space Heating’ Despite everyones best efforts some problems could occur and lead to complaints 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 When requesting a visit from the manufacturer the installer must have the B oiler completed ‘Benchmark’ commissioning/ service record sheet to hand to enable help to be provided. Page 35...

  • Page 36: Appendix A

    APPENDIX A WATER SAVINGS WATER RELATED COSTS CAN BE REDUCED BY GOOD PLUMBING PRACTICE. ���� � ������ � � � � � ��� �� � �� ���� ���� ���� � ��� �� ��� ����������� ������ ���� ��������� � � ������� 4 FIXING OPTIONS FOR TAPS &...

  • Page 37: Appendix B

    APPENDIX B MANIFOLDS Two sets of manifolds are available as an optional extra. Each set comprises a separate hot and cold water manifold. Both are provided with a 22mm inlet connection t t i t i l located centrally. All outlet connections are 15mm compression.
  • Page 38 APPENDIX B The pressure loss through a flow regulator at the designated flow rate is about 1.8 bar. Therefore for the flow regulator to control the flow rate at pre-set level,the inlet pressure must be greater than 1.8 bar. If the inlet pressure is lower, the flow rate will be correspondingly less than the pre-set values.
  • 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 fittings to the manifold will need to suit the arrangements shown on page 35.
  • Page 40 Gledhill (Water Storage) AMD. AUGUST 2000 1. We only do business upon the Conditions which appear below and no other. Unless we so agree in (2) Domestic Mains Fed Products If the copper storage vessel itself or any integral pipework writing these Conditions shall apply in full to any supply of goods by us to the exclusion of any Conditions as part of the storage vessel assembly proves to be defective or terms sought to be imposed by any purchaser.
  • Page 41 The Purchaser warrants to repair and make good any (f ) nothing in these Conditions shall confer on the purchaser any rights or remedies to which the purchaser damage caused by the affixation of the goods to or their would not otherwise be legally entitled. removal from any land or building and to indemnify us (6) Notwithstanding any other provision contained herein the Purchaser's hereby agree to fully indemnify against all loss damage or liability we may incur or sustain...

This manual is also suitable for:

Gledhill boilermate 2000 seriesGledhill boilermate 2000 185Gledhill boilermate 2000 210Gledhill boilermate 2000 145Gledhill boilermate 2000 225

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