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gledhill BOILERMATE SP Instruction Manual

Mains pressure hot water thermal store for use with domestic and central plant boilers
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BOILERMATE
INCLUDING SP, SP PRE-PLUMBED AND OV
PRE-PLUMBED
MAINS PRESSURE HOT WATER THERMAL STORE
FOR USE WITH DOMESTIC AND CENTRAL PLANT BOILERS
DESIGN, INSTALLATION & SERVICING
ONE NAME. EVERY SOLUTION.
INSTRUCTION MANUAL
WWW.GLEDHILL.NET

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  • Page 1 BOILERMATE INCLUDING SP, SP PRE-PLUMBED AND OV PRE-PLUMBED MAINS PRESSURE HOT WATER THERMAL STORE FOR USE WITH DOMESTIC AND CENTRAL PLANT BOILERS INSTRUCTION MANUAL DESIGN, INSTALLATION & SERVICING ONE NAME. EVERY SOLUTION. WWW.GLEDHILL.NET...

  • Page 2: Table Of Contents

    Short Parts List Annual Service Changing Components The Gledhill BoilerMate range complies with the HWA Specification for hot water only Fault Finding 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.

  • Page 3: Design

    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 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.
  • Page 4 DESIGN BoilerMate products are vented cylinders, so there is no requirement for a pressure and temperature relief valve to be fitted to them. This is a key benefit of a thermal store over an unvented cylinder. This enables greater flexibility of location in the building, as there is no requirement to install discharge pipework with a constant fall to an outside wall, or upgrade the soil and vent pipework to be able to withstand high temperature discharges.

  • Page 5: Model Selection

    DESIGN BoilerMate OV PP BoilerMate SP Minimum Cupboard Width = Minimum Cupboard Width = Description Size (mm) Number Description Size (mm) Number Return To Boiler Return To Boiler CH Zone 1 Optional CH Zone 2 Flow From Boiler Flow From Boiler...
  • Page 6 22 23 Open vented header tank kit (BCK001) Switch Back up conversion 6kW to 3kW kit (BCK003) Timer kit (BCK004) Second Heating Zone kit (BCK006) Pump over run kit (BCK007) DHW scale prevention kit (BCK008) BOILERMATE OV PP Page 6...

  • Page 7: Ov Pp Technical Specification

    3. Full thermal store volume reheated from 35°C to 75°C. 4. Please refer to page 5 for the minimum cupbard space requirement. This can be reduced by approximately 35mm if the insulation is removed from the plate heat exchanger. BOILERMATE OV PP Page 7...

  • Page 8: Sp Components

    SELECTION The BoilerMate SP is a hot water only thermal store. It is intended to be used in Domestic hot water is generated instantaneously conjunction with a sealed primary system. This is generally expected to be a system by the BoilerMate domestic hot water assembly. boiler;...

  • Page 9: Sp Technical Specification

    SELECTION Technical Specification BoilerMate SP Product Stock Code BMSTSP150 BMSTSP180 BMSTSP210 Energy efficiency class watts Heat loss kWh/24hr 1.48 1.78 2.08 Height 1118 1306 1494 Diameter Min cupboard height 1668 1856 2044 Min cupboard width Min cupboard depth Weight (empty) Weight (full) Thermal store volume litres...

  • Page 10: Sp Pp Components

    SELECTION The BoilerMate SP Pre-Plumbed is a hot water only thermal store. It is intended to be Domestic hot water is generated instantaneously used in conjunction with a sealed primary system. This is generally expected to be a by the BoilerMate domestic hot water assembly. system boiler;...

  • Page 11: Sp Pp Technical Specification

    SELECTION Technical Specification BoilerMate SP Pre-Plumbed Product Stock Code BMSTSP150PP BMSTSP180PP BMSTSP210PP Energy efficiency class watts Heat loss kWh/24hr 1.48 1.78 2.08 Height 1118 1306 1494 Diameter Min cupboard height 1668 1856 2044 Min cupboard width Min cupboard depth Weight (empty) Weight (full) Thermal store volume litres...

  • Page 12: Lifting And Handling

    TRANSPORT Preparation / Placing The Appliance in Position The hold - Before lifting ensure you have a good hold. The appliance should be handled carefully to avoid damage and the recommended Taking the lead for team lifts- As more method is shown above. than one person is required for these Note: Although the above guidance is provided any manual handling/lifting products ensure that one person is taking...

  • Page 13: Installation

    INSTALLATION Hot And Cold Water Water Hardness An important feature of the BoilerMate is that hot water can be supplied directly from The Domestic Building Services Compliance the mains at conventional flow rates without the need for temperature and pressure Guide (2013) provides more detailed relief safety valves or expansion vessels.
  • Page 14 flow/ will be more than 60 seconds before hot water is available at the tap, you may wish to pressure outlets please discuss with the Gledhill consider using trace heating to the hot water pipework such as the Raychem HWAT technical department.

  • Page 15: Installation Domestic Hot Water

    INSTALLATION Domestic Hot Water Controls Wiring Switch 1 2 3 4 DOMESTIC HOT WATER Page 15...
  • Page 16 INSTALLATION Domestic Hot Water Performance Test Flow rates DHW performance no space heating load, OV PP 70.0 60.0 50.0 40.0 30.0 20.0 10.0 Time in mInutes at flow rate in table BMSTOV150PP (DITS) BMSTOV180PP (DITS) BMSTOV210PP (DITS) DHW performance with simulated space heating load, OV PP 60.0 50.0 40.0...
  • Page 17 INSTALLATION DHW performance no space heating load, SP & SP PP 70.0 60.0 50.0 40.0 30.0 20.0 10.0 Time in minutes at the flow rate in table BMSTSP150 & …PP(IDHWTS) BMSTSP180 (IDHWTS) BMSTSP210 (IDHWTS) Hot water draw off volume VHW-N Pressure Flow Characteristics Of The DHW Heat Exchanger Hot water delivery...

  • Page 18: Central Heating

    INSTALLATION Sealed And Open Vented Systems The Boilermate OV-PP product range is an integrated thermal store which supplies space heating from the thermal store. The Boilermate SP and SP-PP product ranges are hot water only thermal stores where the space heating is supplied directly from the boiler.
  • Page 19 INSTALLATION Pumps Supplied With BoilerMate Products GBP part code XB530 XB531 XB532 WILO Pump type Ku15-130/7 iPWM2 25-130/6SC Ku15/6-43/SC - = Inline cast iron pump Pump housing type Ku = inline Composite OEM Ku = inline Composite OEM housing Threaded connection DN Pump housing length Maximum delivered head Maximum power...
  • Page 20 INSTALLATION Differential Pressure Variable Δp-v (Ι, Ι Ι, Ι Ι Ι) Pump curves:- The XB530 pump curve is not included below because it is not relevant to the installation of the product. The XB530 (25/6) and XB531 (15/6) pump curves are identical and are shown below.
  • Page 21 INSTALLATION Push To Change The Pump Setting Wilo-Para Self Control / Smart Functions Air-Venting Mode Manual Restart Lock and Unlock CENTRAL HEATING Page 21...
  • Page 22 INSTALLATION Automatic Bypass Valve Some low water content boilers require greater flow rates than the heating load of the property requires. Please check your boiler manufacturer’s instructions for requirements. The system bypass will enable this minimum flow rate to be achieved. The 22mm straight bypass fitted to the SP-PP version has a maximum rating of 30kW.
  • Page 23 INSTALLATION BoilerMate OV PP Plumbing Schematic Typical Arrangement / Connection Details Open vent for boiler, store and central heating Mains cold water Domestic hot water No valves to be fitted onto the boiler flow Central heating Primary Circuit Boiler Central heating...
  • Page 24 INSTALLATION BoilerMate SP Plumbing Schematic (Open vented heating system) Typical Arrangement / Connection Details Open vent for store Open vent for boiler and heating (connected to F&E cistern) Mains cold water Domestic hot water Boiler Central heating CENTRAL HEATING Page 24...
  • Page 25 INSTALLATION BoilerMate SP Plumbing Schematic (Sealed heating system) Typical Arrangement / Connection Details Open vent for store Mains cold water Domestic hot water Sealed system kit Boiler Central heating zone 1 CENTRAL HEATING Page 25...
  • Page 26 INSTALLATION BoilerMate SP PP Plumbing Schematic Typical Arrangement / Connection Details Open vent for store Mains cold water Domestic hot water Central heating zone 2 Sealed system kit Primary Circuit Alternative position for the safety valve and discharge Boiler Central heating zone 1 CENTRAL HEATING Page 26...
  • Page 27 INSTALLATION District Heating Systems District return District flow Boilermate stainless for District Hea�ng The diagram opposite shows the BoilerMate SP Cold water F&E Cistern installed to a system where the pumped supply Room thermostat is adequate to overcome the pressure loss of the BoilerMate SP heat exchanger coil, the DHW Controller pressure loss over the central heating system...
  • Page 28 INSTALLATION BoilerMate OV PP - 1 Zone Controls Schematic and Wiring Diagram HTG ON CH PUMP HTG 1 Room HTG 1 Zone Stat Valves DHW ON TIMER DHW OFF DELAY TIMER BOILER PUMP BOILER XB041 *SL2 IS ONLY FITTED FOR LOGIC...
  • Page 29 INSTALLATION BoilerMate OV PP - 2 Zone Controls Schematic and Wiring Diagram HTG ON CH PUMP HTG 1 HTG 1 Zone Room Stat Valves DHW ON TIMER DHW OFF HTG 2 HTG 2 Zone Room Stat Valves *SL2 IS ONLY FITTED FOR LOGIC...
  • Page 30 INSTALLATION BoilerMate SP - 1 Zone Controls Schematic and Wiring Diagram HTG ON HTG 1 Room HTG 1 Zone BOILER PUMP BOILER Stat Valves DHW ON TIMER DHW OFF *SL2 *SL2 IS ONLY FITTED FOR LOGIC THERMAL HEAT BOILERS WITH WEATHER THERMAL STORE PUMP CONTROL STAT...
  • Page 31 INSTALLATION BoilerMate SP PP - 2 Zone Controls Schematic and Wiring Diagram HTG ON DELAY TIMER HTG 1 HTG 1 Zone BOILER PUMP BOILER XB041 Room Stat Valves DHW ON TIMER DHW OFF *SL2 HTG 2 HTG 2 Zone Room Stat Valves *SL2 IS ONLY FITTED FOR LOGIC THERMAL...
  • Page 32 INSTALLATION Boiler Thermostat Setting BoilerMate SP PP – 2 zone The BoilerMate OV-PP, SP and SP-PP may be installed with condensing or non- The SP two-zone space heating system runs in condensing oil or gas boilers. These boilers should be capable of delivering primary the same manner as the OV two zone;...

  • Page 33: Store Charging

    INSTALLATION Immersion Heater The Immersion heater supplied with the Boilermate is a 3 kW 240AC version which is supplied as a DHW back up heat source should your boiler fail at any time. The product replacement code is SH003. Check that the mains supply conforms to this, and all external wiring conforms to the most recent revision of the IEE wiring regulations.
  • Page 34 INSTALLATION Kits Open Vented Header Tank Kit (BCK001) Expansion tank white c/w lid XB343 Float Plastic Red 4.5” FT429 1/2 HP PT 2 Ball Valves 6” arm FT206 Label Water Level LA011 Carton Plain 25LTR Kits SC028 Sealed Primary Header Tank Kit (BCK002) Expansion tank white c/w lid XB343...
  • Page 35 COMMISSIONING Commissioning and installation checks Open the incoming stop valve and fill the domestic mains cold and hot water systems, the BoilerMate appliance and central heating system. Check the whole of the domestic hot and cold distribution systems for leaks, and repair if necessary. Central heating systems should be thoroughly cleaned and flushed out before installing a new boiler.
  • Page 36 COMMISSIONING 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.
  • Page 37 SERVICING AND MAINTENANCE Description Stock Code DHW PHE pump iPWM2 XB530 Plate heat exchanger (24 plate) GT017 Pump isolating valve – outlet (90 valve) GT135 Pump isolating valve - inlet GT133 Immersion heater 3kW SH003 Immersion thermostat XB081 Main PCB controller XB111 Sensors GT198...

  • Page 38: Annual Service

    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.
  • Page 39 SERVICING AND MAINTENANCE Circulating Fluid In Thermal Store Pipework • The BoilerMate 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. •...

  • Page 40: Fault Finding

    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.
  • Page 41 SERVICING AND MAINTENANCE Electrical power connections Reference schematic Check procedure opposite Power supply to PWM Electrically isolate power supply at fused spur switch and remove fuse. Controller PCB Earth continuity test (dead test) – to ensure that the appliance is earthed Mains voltage test (dead test) - to ensure that the appliance is isolated Resistance to earth (dead test) –...
  • Page 42 SERVICING AND MAINTENANCE Tasseron NTC 12k thermistor Huba combined flow sensor and NTC 10k thermistor flow rate determination Temperature Temperature Resistance Resistance l/min l/min °C ±°C °C ±°C 17.1 309396 334275 171840 47369 18.0 98932 26023 19.0 58879 11000 36129 10500 19.9 22804...
  • Page 43 SERVICING AND MAINTENANCE Check pump electrical circuits Meaning Diagnosis Cause Remedy Lights green Normal running Pump runs according Normal operation PWM input Blinks red/ green Abnormal running mode The pump has stopped Under voltage U<160 V Check voltage supply -pump stopped but still due to external failure 195 V <U<...
  • Page 44 SERVICING AND MAINTENANCE Faults, Causes and Remedies The troubleshooting must only be carried out by a qualified specialist, and work on the electrical connection must only be carried out by a qualified electrician. Faults Cause Remedy Electrical fuse defective Check fuses Pump is not running although the power supply is switched on No voltage supply to pump...
  • Page 45 SERVICING AND MAINTENANCE FAULT FINDING Page 45...
  • Page 46 APPENDIX water Savings water Related Costs Can Be Reduced By good Plumbing Practice 2 tap 5, 6 or half open Over 8 l/m 20 l/m Fitted with regulator Unregulated TAPS & MIXERS 4 Fixing Options For taps & Mixers 1. MK Range - Combined Regulators & Aerator for screwing onto Taps &...
  • Page 47 APPENDIX APPENDIX B Page 47...

  • Page 48: Terms & Conditions

    IT SHOULD BE NOTED THAT THE FACTORY FITTED TEMPERATURE AND PRESSURE RELIEF VALVE (i) economic loss which shall include loss MUST NOT BE REMOVED OR ALTERED IN ANY WAY OR THE GUARANTEE WILL NOT BE VALID. GLEDHILL WILL of profits, business revenue, goodwill or NOT BE RESPONSIBLE FOR ANY CONSEQUENTIAL LOSS OR DAMAGE HOWEVER IT IS CAUSED.
  • Page 49 PRODUCT DEVELOPMENT events, namely :- Gledhill have a policy of continuous product development (i) if the Purchaser fails to make payment in full for the goods within the time stipulated in clause 4 hereof. and may introduce product modifications from time to time.

  • Page 50: Benchmark Checklist

    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. MAINS PRESSURE HOT WATER STORAGE SYSTEM COMMISSIONING CHECKLIST Customer name: Telephone number: Address:...

  • Page 51: Benchmark Service Record

    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. SERVICE 01 SERVICE 02 Date:...
  • Page 52 T: 01253 474550 enquiries@gledhill.net WWW.GLEDHILL.NET Due to a programme of continuous improvement Gledhill Building Products reserve the right to modify products without prior notice. It is advisable to check the product technical detail by using the latest design and installation manuals available from our technical support team or on our website.It is an offence...

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