Table of Contents
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Summary of Contents for gledhill BoilerMate CP 120
- Page 1 BoilerMate CP Mains pressure hot water thermal store for use with central plant boilers Design, Installation & Servicing Instructions Models covered in this manual BoilerMate CP 120 BoilerMate CP 150 BoilerMate CP 180 BoilerMate CP 220...
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Page 2: Table Of Contents
9001:2008 Quality System audited by BSI. Building Regulations and should be provided to the customer for future reference. Gledhill’s fi rst priority is to give a high quality Installers are required to carry out installation, commissioning and servicing work in service to our customers. -
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 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. - Page 4 DESIGN 1. Boiler flow 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 Figure 1.1 The BoilerMate CP shown schematically above is designed to provide an improved The printed circuit board incorporates the...
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Page 5: Technical Data
DESIGN Table 1.1 Technical Specifi cation BoilerMate CP Model BMCP120 BMCP150 BMCP180 BMCP220 Height (mm) 1075 1145 1275 1575 Width (mm) Depth (mm) Min cupboard height (mm) 1825 1895 2025 2325 Min cupboard width (mm) Min cupboard depth (mm) Weight (empty) (kg) Weight (full) (kg) Domestic hot water volume (litres) Hot water fl ow rate (litres/minute) - Page 6 825 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 fi tted to the unit.
- Page 7 DESIGN Appliance Dimensions Height Width Depth *Min maintenance Model access to comply with the Water Regulations BMCP120 1075 (ballvalve model only) BMCP150 1145 BMCP180 1275 BMCP220 1575 Top up 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 DESIGN Plan Of Appliance Connections Connection Details/Dimensions For Top Of Unit 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.
- Page 9 DESIGN Note: The diagram below shows the top up Hot and Cold Water System cistern with ballvalve and warning/overfl ow pipe which can be supplied as an optional extra General if required. However, the standard preferred arrangement is for the cistern to be manually A schematic layout of the hot and cold water services in a typical small dwelling is fi lled from a temporary hose connection fi tted shown below.
- Page 10 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. The hot water supply to a shower-mixing valve should be fed wherever practical directly from the BoilerMate CP or be the fi rst draw-off point on the hot circuit.
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Page 11: System Details
DESIGN District return District flow Boilermate stainless for District Heating Air valve Cold water F&E Cistern Room thermostat Coil flow connection DHW Controller Programmer DHW Pump Back up immersion heater Cylinder thermostat Coil return connection DHW 24 Plate PHE Water meter Zone valve Cold water to dwelling DHW to dwelling... - Page 12 DESIGN In this diagram an additional pump is shown Coil flow and return fi tted because the pressure loss in the central Zone valve Diverter Valve (not mid position) CH Bypass heating system is too large for the district pump. District supply CH flow to dwelling...
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Page 13: Site Requirements
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. - Page 14 INSTALLATION 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.
- Page 15 INSTALLATION 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.
- Page 16 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.
- Page 17 INSTALLATION Electrical Connection - Standard Appliance C3: DHW outlet – S4 C2: CW inlet – S3 The external wiring/connections should be C1: Store sensor – S6 carried out by a competent person to BS7671. The arrangement of the internal wiring is shown opposite.
- Page 18 INSTALLATION The following control wiring diagrams ensure Store Room 2 port 3 port that the district heating system is isolated from thermostat thermostat zone valve divert valve the dwelling when charging is not required. ML MN E PL SL ML MN E PL SL Fuse Spur Programmer...
- Page 19 INSTALLATION Store Room 2 port 3 port thermostat thermostat zone valve divert valve ML MN E PL SL ML MN E PL SL Pump Fuse Spur Programmer Wiring diagram – HW & CH pump required INSTALLATION Page 19...
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Page 20: Commissioning
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 off ered by Gledhill. COMMISSIONING Page 20... -
Page 21: Changing Components
9. DO ensure that the functioning and control of the system is explained to the After this, spares can be obtained direct from occupant. Gledhill Spares or through any of the larger 10. DON’T place any clothing or other combustible materials against or on top of this plumbers merchants/specialist heating spares appliance. -
Page 22: Short Parts List
SERVICING Description Stock Code PHE pump UPR 15-50 GT089 Plate heat exchanger (24 Plate) GT017 Pump isolating valve - outlet (90° valve) GT135 Pump isolating valve - inlet GT133 Immersion heater 3kW SH003 Stat XB081 Main PCB controller XB103 Sensors GT198 Y strainer XB314... -
Page 23: Fault Finding
SERVICING The BoilerMate CP appliance control panel and printed circuit control board/display have been designed to be fully automatic whilst able to provide functional and diagnostic information to the householder/installer. The panel/board work in conjunction with a number of sensors (thermistors) located as shown in the diagram below. - Page 24 SERVICING Normal - standby state Indicate system status 2 digit display Press S2 2 push buttons S2 S1 Press Press Press Press Sensor temperature Main reading processor Press S2 Press Press Press Press Control set-point reading Press S2 Press Press Press Press Fault code indicator...
- Page 25 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 Unregulated Fitted with regulator TAPS & MIXERS 4 Fixing Options For Taps & Mixers 1. MK Range - Combined Regulators & Aerator for screwing onto Taps &...
- Page 26 APPENDIX APPENDIX B Page 26...
- Page 27 BoilerMate, SysteMate, PulsaCoil, Accolade and Stainless Lite manufactured by you intend to take that it is clear of Gledhill. any obstructions. Never jerk the load as this will add a little extra force and...
- Page 28 AMD.DECEMBER 2013 CONDITIONS OF SALE & GUARANTEE TERMS Gledhill (Building Products) Ltd (“We” or “Gledhills”) only do business upon the Conditions which appear below (i) free of all charge during the first year after delivery and no other. Unless we so agree in writing these Conditions shall apply in full to any supply of goods by us to the by us.
- Page 29 (2) above. We shall Gledhill have a policy of continuous product development not be responsible for and the Purchaser will indemnify us against liability in respect of damage caused to and may introduce product modifications from time to time.
- Page 30 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.
- Page 31 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 32 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.