8/11/2019 Boilermate BM2000-Iss10 http://slidepdf.com/reader/full/boilermate-bm2000-iss10 1/46 DESIGN,INSTALLATION AND SERVICINGINSTRUCTIONS ANOPENVENTEDCENTRALHEATING AND MAINS PRESSUREHOT WATER SUPPLY SYSTEM INCORPORATING ATHERMALSTORE ALL MODELS COMPLY WITHTHE WATERHEATERMANUFACTURERS SPECIFICATIONFORINTEGRATEDTHERMAL STORES BOILERMATE 2000 BOILERMATE 2000 TM benchmark The code of practice for the installation, commissioning & servicing of central heating systems GasCouncil ApprovedReferenceNumbers BoilerMat e 125 89-317-04A BoilerMat e 145 89-317-05A BoilerMat e 185 89-317-06A BoilerMat e 210 89-317-07A BoilerMate 225 89-317-08A
This document is posted to help you gain knowledge. Please leave a comment to let me know what you think about it! Share it to your friends and learn new things together.
The Gledhill BoilerMate range is a WBSlisted product and complies with the WMASpecification for integrated thermal storageproducts. The principle was developed inconjunction with British Gas. This productis manufactured under an ISO 9001:2000Quality System audited by BSI.
Patents Pending
The Gledhill Group’s first priority is to give ahigh quality service to our customers.
Quality is built into every Gledhill product
and we hope you get satisfactory servicefrom Gledhill.
If not please let us know.
ISSUE 10: 06-08
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 a ll sections relevant to t he appliance insta llat ion.
The deta ils of the Log Book will be required in th e event of any warranty w ork beingrequired. There is also a section to be completed a fter each regular service visit.
The completed Log Book and these instructions should be left in the pocket
provided on the back of the front panel.
TM
benchmark The code of practice for the installation,
commissioning & servicing of central heating systems
The BoilerMate 2000 shown schemat ically ab ove is designed to provide improved space
heat ing and m ains pressure hot w ater when coupled to any remotely sited condensingor non condensing boiler - as long as they comply with the recommendations
contained in the rest of t his manual.
A report b y the Cranfi eld Institute o f Techno logy found tha t this system g ives a
potential for energy sa vings of up to 15%.
Because of the efficiency of the appliance improved SAP ratings can be achieved.
Further deta ils a re ava ilab le from t he Gledhill Technical Depa rtment .
The principle of a BoilerMate 2000 is to separat e th e hea t g enerator e.g. a bo ilerfrom heat emitters (radiators) by a thermal store, which evens out the fluctuating
dema nds for heating a nd hot wa ter. Thus, by storing energy produced when t hedema nd is low a nd d ischarging it whe n the demand is high (i.e. during property
wa rm up or wh en hot w ater is drawn o ff), a sma ller boiler can poten tially be used.
An important fea ture of this concept is that hot w ater can be supplied d irectly from
the ma ins at conventional flow rates without t he need for temperature and pressure
relief safet y valves or expansion vessels. This is achieved by pa ssing the ma inswa ter through a plate hea t exchanger. The outlet temperature of the domestic
hot water is maintained by a printed circuit board, which controls the speed of
the pump circulating the primary w ater from the store through t he plate hea t
exchanger.
To co mply w ith th e Benchma rk Guidance Note for Water Treatmen t in hea ting andhot w ater systems th e installer should check the ha rdness levels of the wa ter supply
and if necessary fit an in-line scale inhibitor/reducer to provide protect ion to t he
who le of the domestic wa ter system.
1.0 DESIGN
Description
1.1 INTRODUCTION
If scale should ever become a problem the plateheat exchanger is easily isolated and quickly
replaced with a service exchange unit which
can be ob ta ined at a nominal cost from Gledhill.
For further deta ils see Section 1 Hot and Cold
Wat er System page 10.
The pcb also incorporates the facility to operate
the heat ing pump for a few seconds every few
days when the heating is not being used, to
reduce the likelihood of the pumps sticking
as well as providing a boiler pump overrun
facility.
Any automa tic boiler designed to operate on an
820C flow and a 710C return up to a maximum
of 35kWcan be linked to a ny suitable mod el of
BoilerMate 2000 and the d eciding factor is the
space heating and the hot w ater requirementsof a dw elling . See Section 1.2 Technica l Data for
further det ails.
The BoilerMat e 2000 is availab le w ith t he
option of ‘Switch’ which will provide a 9kWelectrical emergency b ackup in case of fa ilure
of the m ain heat source. See section 1.3 System
Remote
F&E tank
Full bore automatic bypass valve NOTREQUIRED
unless the heating system incorporates
mechanical thermosta tic control valves e.g.
T.R.V's to all rad iato rs or 2 po rt zo ne valves.
1. The BoilerMat e 225 appliance is suita ble for use in large properties beca use it produces the sam e ‘peak hour output ’ as a typical350-400 litre unvent ed cylinder. [Ask for report - Unvented v ’s Inte grated Therma l Sto rag e]. [Please note t hat this model requires
a larger cupbo ard a nd a 686mm wide d oor]. For properties req uiring the BM 225 the incoming ma in should b e a minimum of
35mm MDPE with a pressure of not less than 2 bar dynamic and an adequate flow in line with the pipe sizing calculations.In ma ny cases, properties of t his size w ill benefi t from ha ving 2 smaller sized a ppliances loca ted ad jacent t o th e a reas of
peak hot w ater use. This w ill allow 2 heating zon es to be provided a nd remove the need to provide a second ary circulation
on the hot w ater system.
2. Plastic feed and expansion cistern w ill be supplied separately including ba llvalve, floa t and overflow fi tting .
3. The flow rates are based on a 35°C temperature rise and a ssume normal pressure and ad eq uate flow to the appliance. The actua l
flow rate from the appliance is automat ically regulated to a maximum of 28 litres/min.4. Mod els will be availab le in Hard and Soft w at er versions (suffixed ‘H’ or ‘S’).
5. Unit is supplied on a 100mm high installation base.
6. The domestic hot w ater outlet temp erature is automa tically regulated to a pproximat ely 55°C at the bath flow rate of 18 litres/min
recommend ed b y BS 6700. The tempera ture is not user adjusta ble.
Sugg ested locat ion for 15mmcold mains feed t o t he F &E
tank.
The BoilerMate 2000 units a re supplied on an installation b ase t o a llow thepipe runs to connect to the appliance from any d irection. It is easier if allpipes protrude vertically in the cut o ut a rea show n. Compression or pushfit connect ions can b e used and we d o offer a set of flexible connectors asan o ption. All pipe positions are approximate and subject to a t olerance of
+ /- 20mm in a ny direction. A 15mm co ld w ater supply and a 22mmwarning /overflow pipe will also b e required for the separate feed a nd
expansion tank.
Dimensions in brackets apply to the 225 model only
A schematic layout of the hot and cold water services in a typical small dwelling is
show n below . BoilerMate 2000 will operate at mains pressures as low a s 1 bar and a s
high as 5 ba r although th e recommended rang e is 2-3 ba r. If the manifolds (availab le as
an optional extra) are being used the inlet pressure to the ma nifold must be a minimum
of 2 ba r. It is also importa nt to check tha t all othe r eq uipment and comp onent s in
the hot and cold wa ter system a re capable of accepting t he mains pressure availab leto the property. If the mains pressure can rise ab ove 5 bar or the ma ximum wo rking
pressure of a ny item of eq uipment or component to be fi tted in the system a pressure
limiting (reducing) valve set to 3 ba r will be required.
If you encounter a situation where the w ater pressure is adeq uate b ut flow rates are
poor please co nta ct our technical helpline for det ails of an e ffective solution.
Note: Each BoilerMate 2000 is fitt ed w ith a strainer and fl ow regulato r on the cold
mains supply connection. If the supply pressure is less than 2 bar or if the ma nifolds
(available as an optional extra) are being used or if all taps are provided with flow
regulators the fl ow regulator on the cold inlet should be removed.
No check valve or similar device should be fitted on the cold water supply branch
to the BoilerMate 2000.
To com ply with the Benchmark Guidance Note for Water Treat ment in Heating an d
Hot Water Systems t he insta ller should check the ha rdness level of the w ater supply
and if necessary fit an in-line scale inhibitor/reducer to provide protect ion to t hewh ole of the do mestic wa ter system. See Append ix C for a copy of the relevant pa rt
of the Benchm ark Guidance Note.
1.0 DESIGN
When specifying th is app lian ce we w ould
recommend that for hardness levels above
200ppm (mg/l) a hard w at er appliance is used.
For ha rdness levels above 250ppm (mg/l) we
would recommend that some form of in-line
scale inhibitor/reducer is recommended by oneof t he Water Treatmen t compa nies listed in the
Benchmark Guidan ce Note (see Appen dix C).”
The hot wa ter flow rate from the BoilerMate
2000 is directly related to the adequacy of the
cold water supply to the dw elling. This must
be capa ble of providing for those services,which could be required to be supplied
simultaneously, and this maximum demand
should be calculated using procedures defin ed
in BS 6700.
If a wat er meter is fi tt ed in the service pipe,
To a chieve even distribut ion of t he a vailab le supply of hot and cold w at er, it is
important in any mains pressure system, that the piping in a dwelling should be
sized in accordance with BS 6700. This is part icularly importa nt in a large property
with more than one ba throom.
However, the following rule of thumb guide lines should be adequate for most
smaller property types a s long as w ater pressures are within the recommended
range of 2-3 bar.
1. A 15mm copp er or equivalent exte rnal service may b e sufficient for a
small 1bathroom dwelling (depending upon the flow rate available), butthe minimum recommended size for new dwellings is 22mm (25mm MDPE).
2. The internal cold feed from the main incoming stop ta p to the BoilerMat eshould be run in 22mm pipe. The cold ma in and h ot d raw-off should also
be run in 22mm as far as the branch to t he ba th ta p.
3. The fi nal branches to t he hand ba sins and sinks should be in 10mm and t o
the ba ths an d show ers in 15mm. (1 metre minimum)4. We would recommend that best results for a balanced system are achieved
by fitting appropriate flow regulators to each hot and cold outlet. This isparticularly relevant where the water pressures are above the recommendedwater pressure range of 2-3 bar. Details of suitable flow regulators areprovided in Appendix A.
Note: If manifolds (available as an optional extra) are being used suitable flowregulators are automatically provided in the manifold and do not need to beprovided at each outlet - See Appendix B for further details.
All the recommendations with regard to pipework systems in this manual are
generally ba sed on t he use of BS/EN Stand ard copp er pipew ork and fit tings.
However, we a re happy tha t plastic pipework systems can b e used in place of copper
internally as long as the chosen system is recommended for use on domestic hot
and cold water systems by the manufacturer and is installed fully in accordance
with their recommendations.
This is particularly important in relat ion to use of push fi t con nections w hen using
the opt ional flexible ho se kits - see 2.2 Insta llat ion, Pipework connections.
It is also essential tha t if a n a lternat ive pipew ork material/system is chosen the
manufacturer confirms tha t the design criteria of the new system is at least eq uivalentto t he use of BS/EN Stand ard cop per pipework and fi tt ings.
Taps/Shower Fittings
Aerated taps are recommended to prevent splashing.
Any type of shower mixing valve can be used as long as both the hot and coldsupplies are mains fed. However, all mains pressure systems are subject todynamic changes particularly when other hot and cold taps/showers are openedand closed, which will cause changes in the water temperature at mixed wateroutlets such as showers. For this reason and because these are now no moreexpensive than a manual shower we strongly recommend the use of thermostaticshowers with this appliance.The shower head provided must also be suitable for mains pressure supplies.
However, if it is proposed to use a ‘whole b ody’ or similar show er with a numbe r ofhigh fl ow /pressure out lets please discuss with the Gledhill technical dep artment.
1.0 DESIGN
The ho t w ater supply to a show er-mixing va lve
should be fed w herever pract ical directly from
the BoilerMate 2000 or be the fi rst draw-off
point o n the h ot circuit. The cold supp ly
to a showe r-mixing valve should w herever
practical be fed d irectly from the rising ma insvia an independ ent branch. The show er must
incorporate or be fitted with the necessary
check valves to provide back-syphonage
protect ion in acco rdance w ith the Wat er
Regulations.
The supply of ho t a nd cold ma ins wa ter directly
to a bidet is permitted provided tha t it is of theover-rim flush ing t ype a nd tha t a type ‘A’ air
gap is incorporated.
Hot and Cold Water System.
If the leng th of the hot wa ter draw off pipework
is excessive an d t he d elivery time w ill be mo re
than 60 seconds b efore hot wa ter is available
at t he tap, you may w ish to consider using t race
heating to the hot wa ter pipework such as theRaychem HWATsystem. Plea se consult Gledhill
Technical Depa rtment for further d eta ils.
It is important that the cold water pipework
is ad eq uate ly separated /protected from a ny
heating/hot wa ter pipework to ensure th atthe wa ter remains cold and of drinking wa ter
facilitat e venting . The hea ting circuit is ta ken
from the BoilerMate 2000 and is piped in theconventional manner.
The BoilerMat e 2000 is on ly suitable for an
open vented system.
The F &E cistern can b e fi tted remotely up t o
10m above the base of the BoilerMate 2000
i.e. the maximum static pressure in the store
must no t exceed 1 bar.
If any rad iators are located ab ove the levelof the BoilerMate 2000 the system should
be designed so that gravity circulation does
not occur when the hea ting pump is not
running. To be certa in of preventing t his it is
recommended tha t a check valve, or valves, are
fitt ed on t he vertical flow pipes.
The water level in the F & E cistern should beat least 250mm above the highest point onthe system including the radiators and mustbe high enough to provide the minimumhead required by the boiler being used.
1.3 SYSTEM DETAILS
The bo iler ma nufact urer’s instructions with
regard to minimum head must always be
follow ed . This is pa rticularly impo rta nt insituations where the headroom is restricted
(e.g. in a fla t).
Range rated boilers can be used but should
always be set at the highest ou tp ut . The
system e ffi ciency w ill not b e impaired w hilethe recovery rate w ill be improved.
It is not necessary to provide a boiler bypass
on the primary circuit with thermal storage
appliances (i.e. bet ween the boiler and t he
thermal store.)
Remote
F&E tank
Full bore automatic bypass valve NOTREQUIRED
unless the heating system incorporates
mechanical thermosta tic control valves e.g.
T.R.V's to all rad iato rs or 2 po rt zo ne valves.
The primary pipew ork connect ing the bo iler and t he thermal store should be sizedto achieve a maximum of 8°C rise across the boiler or the maximum temperature
rise specified by t he b oiler man ufacturer, wh ichever is smaller, but in any instance it
should not be less than 22mm copper tube.
Note: There should b e no va lves in the pipework connect ing the b oiler to the
BoilerMate 2000.
The h eat ing circuit o perates on the normal primary boiler temp eratures i.e. 82°C
flow and 71°C return. Therefore any traditional hot w ater rad iators or convecto rs
can be used with this system and no special over-sizing of the heat emitters isnecessary.
All the recommendations with regard to pipework systems in this manual are
generally ba sed o n the use of BS/EN Stand ard cop per pipework and fi tting s.
However, we are happy that plastic pipework systems can be used in place ofcopper internally as long a s the chosen system is recommended for use on domestic
heat ing syste ms b y t he ma nufacturer and is installed fully in accordance with
their recommendations. We a lways recommend the use of barrier pipe for these
systems.
Heating System
F E Cistern
Primary flow
Primary return
BM 2000
Boiler
It is also essent ial that if an alternat ive pipewo rk
ma terial/system is chosen the m an ufact urer
confirms that the design criteria of the newsystem is at least eq uivalent to the use of BS/EN
Standa rd copper pipework and fitt ings.
Boiler Size
It is only necessary to calculate the heatingrequirements in accordance w ith BS 5449. The
allowa nces shown b elow should b e ad ded
for do mest ic hot w at er. The control system
automa tically gives priority t o ho t w ater w hen
necessary.
Boiler Sited Below BoilerMate 2000
Any boiler can be used when the flow pipe
from the boiler to the BoilerMate 2000 rises
cont inuously. No valve shall be fi tte d in th eprimary flow or open vent.
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 hea t
source is to fi t th e BoilerMates as normal but to provide a single check valve on the
branch immediately afte r each primary pump.
The hea ting and hot wa ter from each appliance must serve separate zones/bathroomswithin the property.
The electrical supplies from ea ch app liance to t he boiler will need tw inning so th at
the bo iler will operat e on a ca ll from either/bo th a ppliances.
Both primary pumps and the primary pipework sizes should be checked to e nsurethat t hey are adeq uate for the system that ha s been installed.
If the primary pipework dips or the boiler is located above the BoilerMatea single F & E cistern with a cold feed and open vent piped to the cisternshould be used.
This arrangement is not suitable for BoilerMate appliances fitted with Switch.
If it is proposed to use t his arrang ement please a dvise Gledhill at the time of o rder,
Gledhill will then supply a suitable vent a ssembly for fitting on th e safet y/open vent
connection and a blank for the cold feed connection of each BoilerMate 2000, in
lieu of the F &E cistern no rmally provided .
If the boiler is a long way from the BoilerMate the resistance should be checked
to ensure the pumps cannot produce a negative pressure in the BoilerMateappliance.
The sing le F &E cistern w ill need to b e provided, (by t he installer) an d b e suitablefor the size of the t ota l system insta lled.
For further de ta ils please ring the Gledhill Techn ical helpline.
Electrical Supply requirements for BoilerMate2000with Switch
2.0 INSTALLATION
2.1 SITE REQUIREMENTS
The appliance is designed to b e installed in an a iring/cylinder cupboa rd and the
relevant minimum dimension s are provided in section 1.2 Technical Data.
Because of the ease of installation w e recommend tha t the cupboard construction
is completed a nd pa inted be fore installation of the appliance. The cupboard door
can be fi tted after installation.
If the unit needs to be stored prior to installation it should be stored upright in a
dry environmen t a nd o n a level ba se/floor.
Installation and maintenance access is nee de d t o t he fro nt of t he a pplian ce a nd
a b ove the F &E cistern. See Technical Dat a section fo r further det ails.
The m inimum d imensions con ta ined in sec tion 1.2 Technical Da ta allow for the
passag e/connection of pipes to t he a ppliance from any direction as long as theappliance is installed on the installation base provided. If the installation base is
not used extra space may be needed to a llow connection to t he pipework and t hewhole of t he ba se area should be continuously supported on a material which will
not easily det eriorate if exposed to moisture.
The floo r of the cupboa rd needs to be level and even and capab le of supportingthe weight o f the appliance whe n full. Det ails of the weight w hen full is provided
in sect ion 1.2 Technical Data .
The appliance is designed t o op erate a s quietly as practicab le. However, some no ise
(from pumps et c) is inevitab le in a ny hea ting system. This will be mo st no ticeab le
in cupboa rds formed on bulkheads, or at the mid span of a suspended fl oor. In the secases the situation can be improved by placing the appliance on a suitable sound
dea den ing m aterial (i.e. carpet underlay o r similar).
Cupboard temperatures will normally be higher than in a conventional systemand the d esign of the cupbo ard and door w ill need to take this into a ccount. No
ventilation is normally required to the cupboard.
A suitable location will be needed for the separate feed and expansion cistern.
This w ill oft en be at high level in t he cupb oa rd housing the BoilerMate 2000. The
dimen sions and clearances are provided in section 1.2 Techn ical Data . The location
will need to provide a suitable route for the cold feed and expansion pipe as well
as the open sa fety vent pipe. The location w ill also need to provide a suitab leroute an d d ischarge position for the w arning/overflow pipe and the ballvalve supply
from the mains cold water system.
An electrical supply must be available w hich is
correctly earthed, polarized and in accordance
with the latest edition of the IEE requirementsfor electrical Installations BS 7671.
The e lectr ical ma ins supply needs to be
230V/50Hz.
Connection must b e mad e using a doub le-polelinked isolator with a contact separation of
3mm in bo th po les which is loca ted w ithin 1m
of the appliance. The supply must only serve
the appliance.
The supply to the sta nda rd appliance sha ll befused a t 3 amp.
If t he ‘Switch’ electrical em ergency ba ckup
is being provided , the minimum breaking
capacity of t he ma in isolation sw itch and
cab le sizes/lengt hs a t 230V shall follow t herecommenda tions in the ta ble below.
Nominalfull loadcurrent
Min rating of isolatingswitch
Cable size
Max. recommendedcable run-based on9.2V drop and 0.4
second disconnectiontime using a type
1 or B breaker
41.0 Amps 45 Amps 10 mm2 49 metres
Recommended circuitprotection device - based on
0.4 second disconnectiontime
45 A type 1 - MCB to BS 387145A type B circuit breaker to BS EN60898
Electrical Power Supplies - BoilerMate 2000 with Switch.
A heavy duty electrical supply, see table on
page 18, is required for this model and we
recommend tha t a fully qua lifi ed electricianmust und ertake this work.
The elect rical insta llat ion must co mply with
the IEE Req uiremen ts for Electrical Installat ions
BS 7671.
Note: do not attempt the electrical workunless you are competent to carry it out tothe above standards.
A 10.0mm2 power cable is fit ted w ith a 3 metretail for the installer to connect to a doub lepole linked isolator with a contact separation
of 3mm in bo th poles which must not b e more
than 2 metres away from the appliance.
A schematic arrangement of the internal w iring
is shown o n pag e 24.
All termina ls are labelled.
Before commencing check that the power
supply source (i.e. isolator) is in accordance
with section 1.2 Site Req uirements and ensureit is isolated .
Run the 3 metre tail through the service slot
provided in the ba se of a ppliance.
The recommend at ions conta ined und erElectrical Connection - Standard Appliance
should b e followed when connecting a remote
clock, room thermosta t, boiler etc.
WARNING : DO NOT SWITCH ON ELECTRICBACKUP, IF FITTED, UNTIL THE APPLIANCEHAS BEEN FULLY COMMISSIONED i.e.
PRIMARY STORE IS FILLED AND VENTED.
WARNING: IF THE BOILERMATE IS FITTED WITH AN OPTIONAL ELECTRICBACKUP SYSTEM I.E. ‘SWITCH’.
IMPORTANT: ELECTRICIAN/INSTALLER PLEASE NOTE.
THE 2 x 25A FUSES FOR THE ‘SWITCH’ ELECTRIC BACKUP SYSTEM ARESUPPLIED IN THE ACTIVE FUSE CARRIER. THE GAS BOILER CAN BECOMMISSIONED WITHOUT INSERTING THESE FUSES.
IT IS IMPORTANT THAT THE GAS BOILER IS COMMISSIONED BEFORE TESTINGOR USING EMERGENCY SWITCH FACILITY.
AFTER THE GAS BOILER HAS BEEN COMMISSIONED CUT AND REMOVE THEPLASTIC TIE AND PUSH DOWN FULLY THE CARRIAGE TO COMMISSION THE
Fully flush a nd if necessary chlorinate t he ho t
and cold w ater system in accordance w ith the
recommendat ions in the Model Water Byelaw san d BS 6700.
Commissioning the BoilerMate ControlSystem
For maximum system efficiency the storethermost at must be in control of the b oiler i.e.
the b oiler cycles on t he store thermostat and
not o n its integral thermostat.
The BoilerMate control system will automa tically
commission i t sel f to match the ac tualperformance of the insta lled bo iler.
The control system/A.C.B has been initialised at
the fa ctory and will operate auto matically.
However, the operation of the control systemshould be checked as follows on the A.C.B
(show n opp osite).
1. Set the bo iler thermost at to MAXIMUM
2. Switch off heating on the clock/
programmer and room thermostat3. Switch off hot wa ter on the prog rammer
if 2 channel clock is fitt ed
4. Check the jumper settings arecorrect. These must all be in thecorrect positions for the appliance towork correctly i.e. fitted on terminals1, 3 and 4.
5. Switch on the mains supply.
The A.C.B. will au tomatica lly commissionitself to suit the system/bo iler and t he do t
after the ON the display w ill fla sh
The co nt rol system is now initialised. The
operation of the controls can now b e checked.
1. Horizonta l LED bar 2 ‘store’ will be lit.
Boiler and boiler pump will be running and
green LED’s 1 and 2 on the A.C.B will be
switched on.
2.0 INSTALLATION
Once the system is finally filled turn downthe servicing valve for the ballvalve in
the F & E cistern to the point where thewarning/overflow will cope with the dischargearising from a ballvalve failure.
• If the boiler is range rated, then ad just it to the maximumheat input.
• Check the boiler thermostat is set to maximum.
• Set t he b oiler pump speed so t hat the temperature difference across the
boiler is about 8°C - when the space heating is off. NOTE: For op timum
performance when using a condensing boiler such as the Keston C25 set
the boiler pump in the BoilerMate to give about 15ºC temperature rise across
the bo iler.
• Set the heating system pump speed so tha t the temperat ure difference across
the flow and return is not greater than 11°C.• Check the DHWplate heat exchang er pump is set to maximum.
• Check tha t there is no overflow w hen the who le of the system is fully up
to temperature.
• Check tha t the Y type strainer on the incoming mains cold water inlet to the
app liance is clean.
Note: If the appliance is operating a t mains cold w ater pressures below 1½ bar the
flow regulato r fitted on the outlet to t he Y type strainer can b e removed if required
to improve performance.
Because the A.C.B is able to adjust to suit thewa ter temperatures delivered by the bo iler the
thermostat should always be set a t maximumduring comm issioning.
However, the boiler thermostat setting can be
reduced in summer, in the normal way, if theappliance is being used for hot w ater only.
The temp erature sett ings esta blished during
commissioning can be checked using push
button switches sw1 and sw2 on the PCB as
described in section 3.3 Fault Finding.
The cloc k/prog ramm er provide d o n th e
appliance controls the heating system only
and should be set to suit the householdersrequirements using the instructions show n
on the separate leaflet and the label on thefront of the appliance. If the appliance is fitted
with Switch (see figure on pa ge 25) the b oiler
should be switched off and Switch operated
to ensure it is working co rrectly.
• When the selector knob is not in normal
position, the PCB, room thermostat and
the time clock are electrically isolated .
• When th e select or knob is in HW on ly
position the plate heat exchanger pump
will run cont inuously a t full speed.
• When the selecto r knob is in the HWand
HTG position, the p late h ea t excha ng er
pump and the heating pump will run
continuously.
This product is covered by the ‘Benchmark’scheme and a separate commissioning/service log book is included with thisproduct. This must be completed duringcommissioning and left with the productto meet the Warranty conditions offeredby Gledhill.
On completion:-
1. Do ensure that the electrical connection(e.g. mains supply, room thermostat) to
the uni t i s correct and t ight before
sta rting the commissioning p rocedure.
2. Do ensure that the funct ioning and
control of the system is explained to theoccupant.
These Instructions should b e placed along with
the component manufacturers instructions in thepocket provided on t he rear of t he front p ane l.
The front pa nel should then be refitt ed.
2.3 COMMISSIONING
2.0 INSTALLATION
Note: The con trols within the A.C.B will not allow t he hea ting system to funct ion
until the sto re temperature has reach ed 60°C. Therefore althoug h the LED bar 1
‘HT’ will light when hea ting is switched on, the heat ing pump (Green LED -3) will notswitch on if the store tempe rature is less tha n 60°C. Time will need to be allowed for
this to ha ppen d uring initial commissioning. This will vary depend ing on the bo iler
size and the model of the BoilerMate 2000 being used.
2. Once a temperature of 60°C has been reached on th e thermal store, switch on
space hea ting clock/programm er and room thermosta t.
• Horizont al LED b ar 1 ‘HT’ will light .
• Green LED 3 on the A.C.B will switch on. Heating pump will run.
3. Switch off space heat ing on clock/programm er or room thermosta t
• Horizont al LED bar 1 ‘HT’ w ill sw itch of f.
• Green LED 3 on the A.C.B will switch off. Heating pump will switch off.
4. Open the hot tap
• Horizontal LED bar 3 ‘HW’ on the LED display will light.
• Domest ic hot wa ter pump will run.
5. Close the hot wat er tap
• Horizont al LED ba r 3 will switch off
• Domestic hot water pump will continue to run for a short period of time before
switching off.
6. The A.C.B incorporat es a 3 minute p ump ove rrun facility. Check green LED2 remains lit for this period of time when the boiler switches off i.e. the
thermal store reach es temperature.
The control functions have now been checked.
Let t he boiler hea t the sto re and when the sto re is satisfied , i.e. green LED’s 1 and 2
on the A.C.B are off, the radiator circuit and hot water can be checked and balanced
in the normal way.
The b oiler the rmosta t sho uld be left at maximum for optimum performance/
6. DO ensure that the water level in the F &E cistern is at least 250mm abovethe highest point on t he radiator circuit o r the highest point of t he system.
7. DO insulate any exposed pipework in the BoilerMate cupboard.
8. DO plumb the overflow/wa rning pipe in a 20mm interna l diamet er pipe
material which is suitable for use with a heating F &E cistern, in accordancewith BS 5449 (such as copper) and ensure it has a continuous fall and
discharges in a co nspicuous external position.
9. DO check the pump settings
a. The boiler pump should be set to g ive a t emp era ture diffe rence a cross
the bo iler of 8°C or less. b. The hea ting p ump should b e set t o g ive a t emperat ure difference across
the flow and return of not more than 11°C.
c. The hot wa ter plate heat exchang er pump should b e set a t maximum.
10. DO ensure that the bypass valve for the heating system (if fitted) is set
correctly.
11. DON’T use a combined feed an d vent on BoilerMate installat ions.
12. DON’T use a BoilerMate on a sealed primary i.e. closed system.
13. DON’T u s e p i p e s m a l l e r t h a n 2 8 m m be tween th e bo i l e r an d th eBoilerMate w hen t he b oiler rat ing exceeds 20kW(abo ut 68,000 Btu/h).
14. DON’T use dipped flow and return between the boiler and the BoilerMate
unless the b oiler is fitted with a n overheat t hermostat . If necessary check
with the suppliers of the bo iler.
15. DON’T operate t he ‘switch’ ba ckup facility unt il the system is fully fi tted, vented
and commissioned.
16. DON’T place any clothing or other combustible materials aga inst o r on top of
this appliance.
2.0 INSTALLATION
2.3 COMMISSIONING
Important Do’s and Don’ts
1. DO check the incoming mains wat er pressure and flow rate are ad equa te.(The p referred ran ge o f ma ins pressure is 2-3ba r).
2. DO check that a ll connections are in accordance w ith the labelling on t he
thermal store.
3. DOad just th e ba llvalve so tha t the w ater level in the F &E cistern when
the system is cold is correct and do es not overflow w hen the w hole of thesystem is at maximum temperature.
4. DO make sure tha t the re is ade q uat e clearance ab ove the F &E
cistern to service the b allvalve.
5. DO ensure tha t the range rated appliances are set at the highest output
and the b oiler thermostat is set to maximumfor all bo ilers.
Despite everyones best efforts some problems could occur and lead to complaints
from the househ older.
Complaints can b e g rouped into the following three main cat ego ries:-
1. The syste m is noisy
2. Hot w ater service is unsatisfacto ry
3. Space heat ing is unsat isfactory
The fo llowing che cks should b e ca rried out by the installer before calling themanufacturer.
1. Causes of a ‘Noisy’ System
Noisy pump op eration
Check the level of w at er in the F &E cistern - ad just a nd ven t t he pump /system
if necessary.Check the pump speed set ting o f the b oiler pump - reduce if necessary but ensure
tha t the t emperature rise across the boiler does not exceed 8°C.
Check the pump speed sett ing of the hea ting pump - reduce if necessary but ensure
a temperature d ifference across the fl ow and return d oes not exceed 11°C.
Check a nd a djust if necessary the heating system bypass valve.
Check tha t t he radiators are correctly balanced.
Noisy boiler operation
Check the flow rate through the boiler at full ga s rate by mea suring the t emperature
rise across the bo iler. If the tempe rature rise is greate r than 8° C, then increase
the pump speed.
Check the level of w ater in the F &E cistern an d t he w orking hea d on the bo iler.
Check and vent the system if necessary.
Noise w hen hot wa ter tap is opened
If the plate hea t exchanger pump is noisy when t he hot wa ter tap is opened, then
check the level of wa ter in the F &E cistern and vent the pump if necessary.Water hamm er - loose pipew ork and/or ta p w ashers.
2. Causes of ‘Unsatisfactory Hot Water Service’
Check that the BoilerMate is full of water i.e. level of water in the F &E cistern is
correct w hen system is cold.
Check bo iler thermosta t - this should be set a t ma ximum.
Check tha t the boiler flow temperature is adeq uate w hen it stops fi ring. Boilers
should provide a flow temperature of 82 ± 3°C but temperatures as low as 76°C will
allow the BoilerMate 2000 to provide a sa tisfacto ry performance.
Check tha t the store is charging to a t least 75°C.
Check that the hot water plate heat exchanger pump stops and starts when thehot w ater tap is opened a nd closed.
Check tha t the plate heat exchang er pump is set at maximum speed.
Check that t he space heating and hot w ater load is not g reater than the b oiler output
and tha t the BoilerMate 2000 model is suita ble for the type o f dwelling.
If all the above checks are satisfactory then it is possible that the performance of
the hea t exchang er is impa ired by sca le. In this case the ho t water flow rate w ill benoticeably less than the cold w ater flow rate. Replace with a factory exchange unit
and re-check hot w ater performance.
3. Causes of ‘Unsatisfactory Space Heating’
Check the boiler thermostat - this should beset at maximum.
Check tha t t he bo iler flow temperature b efore
it is switched off by its ow n internal thermosta t
or the store sensor is ad eq uate - it should not
be less tha n 80°C.
Check the operation and the sett ings of
the heat ing programmer and the room
thermostat.
Check that the heating system pump is
circulating the w ater to the radiat or circuit.
If some rooms a re not being hea ted properly,then b alance the system/check the op eration
of the thermosta tic rad iator valves (if fit ted ).
Overflow from Feed and Expansion Cistern
Check tha t the controlled level of wa ter in thecistern is no high er tha n necessa ry. Adjust
if required.
The ACB can be used to est ab lish/chec k
the operating and set temperatures of the
appliance as well as identify faults on anyof the 3 sensors. This is done b y operat ing
switches SW1 and SW2 as show n op posite and
read ing th e LED display. (See pag e 27)
Store T1, PHE T2, an d DHW T3 ind ica te thecurrent value being read by the store, PHEan d DHWsen sors respect ively. The loca tion
of the sensors is shown in the d iagram shown
oppo site/below.
T1 ON and T1 OFF show the sto re temperature
set points which are automatically reset oneach boiler cycle to match the temperature
produced by the bo iler.
T1 ON show s the t emperature at wh ich the
store will call for heat , i.e signal the boiler to fi re.
T2 OFF shows the t emperature at wh ich thestore will be satisfied, i.e signal the boiler to
switch off.
POWERFLUSHING/CLEANING OF THE HEATINGSYSTEM
If it is proposed to ‘powerflush’ the heating
system we would recommend that the
BoilerMate appliance is isolated from the
hea ting system being cleaned. Failure to do
this could seriously damage the appliance.
When ca rrying o ut the w ork always comp ly
fully with the manufacturers instructions forthe pow erflushing equipment being used.
Note: If the A.C.B. board is replaced it willre-initialize itself automatically.
The operation of the system controls/operation can then be checked.
The same appliance control board is usedon a number of appliances and the jumpersMUST be in the correct position for theappliance to work satisfactorily.
See section 2.3 Commissioning for details.
If the problem cannot be resolved and the
appliance is fitted with the switch emergencyelectric backup this should be sw itched on a nd
operated in accorda nce w ith t he instructions
on the label fitted to the appliance until the
installer/manufa cturer can at tend .
When requesting a visit from themanufacturer the installer must have thecompleted ‘Benchmark’ commissioning/service record sheet to hand to enable helpto be provided.
In add ition to the ma in LED display the ACB has
four green LED’S which can be used t o checka supply is being provided when required tothe Boiler (LED 1), Boiler pump (LED 2) and
Heating pump (LED 3). LED 4 is not used on
this appliance.
The following procedure should b e followed
to ca rry out t hese checks.
• Switch off mains
• Check and i f necessary insert correct
jumpers 1, 3 &4) to suit appliance type
• Insert jumper 5
• Switch on mains
• The PCB w ill carry out funct iona l checks an d
WATER RELATED COSTS CAN BE REDUCED BY GOODPLUMBING PRACTICE.
Vast q uantities of wat er are needlessly run off to w aste d ue toTaps, Mixers and Showers discharging flow rates far in excess ofthe rates req uired for them t o perform their duties.The cont rasting flow rates show n on t his leaflet clearly illustratethe savings that can be made whilst still providing a goodperformance.British mad e Aq uaflow Regulators provide constant flow ratesby automatically compensating for supply pressure changesbet ween 1 bar &10 ba rs.To fa cilitate installat ion into the w ide range of plumbingequipment which is encountered in the U.K, Four FixingOptions are availab le:-
1. MXF “DW” Rang e - For fi tt ing behind Fixed Shower Head s or onto Flexible Hoses for Hand show ers (preferab ly onto the inlet end when lightw eight hoses are used).
2. Compression Fitt ing Rang e. “In Line” regulators as in Opt ion4 for Taps &Mixers.
APPENDIX A
WATER SAVINGS
OPTIONS FOR SHOWERS
4 FIXING OPTIONS FOR TAPS &MIXERS
1. MK Range - Combined Regulators &Aeratorfor screwing onto Taps &Mixers with interna lor external thread s on their noses. Anti Vandalmod els also available.
2. MR05-T Rang e - Interna l Reg ulat ors. Push-fi t
into Tap or Mixer sea ts. Produced in three sizes - 12.5mm (BS1010), 12mm &10mm, Flang eless mod els also ava ilab le for Taps with Low Lift washers.
3. MXF Sta nda rd Rang e - Screw on ta i l models for Taps &Mixers. Fix onto the ta ils
before fi tt ing t he t ap connectors. Availab le in3/8", 1/2", 3/4" and 1" BSP.
4. Compression Fitting Range - “In Line” regulato rshoused in 15mm &22mm CXC Couplers &Isolat ing Valves. “ ”UK WFBS listed by the WaterResearch Centre. Isolat ion valves ava ilab le for
slot ted screwdriver operation or with colouredplastic handles. Now available also in plasticbo died push-fi t couplers &valves.
Informat ion by courtesy of
AQUAFLOW REGULATORS LTDHaywood House, 40 New Roa d, Stourbridg e, West Midlands DY8 1PA
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.
Since the concentration of inhibitor present in a system can become diluted, for a number of
different reasons, the system should be checked annually and re-treated as required, or after
every full or partial drain-down. A water treatment manufacturer’s test kit
may be used to check the correct concentration of inhibitor in the system.
Where recommended by a boiler manufacturer, a ‘physical corrosion
protection device’ may be fitted in the primary pipework in accordance
with the boiler manufacturer’s instructions.
The Benchmark log book should be completed indicating the date and
details of any of the above products added and a permanent label
should be fixed to the system in a prominent location.
Where a combi boiler and/or a hot water storage vessel is installed in areas where the mains
water can exceed 200ppm Total Hardness (as defined by BS 7593: 1993 Table 2) a scale
reduction device should be installed, in accordance with the boiler manufacturer’s instructions.
The levels of water hardness may be measured using a water hardness test kit.
BUILDING REGULATIONS
Completion of the BENCHMARK log book requires that the ‘competent person’ undertaking the
installation and commissioning provide information relating to Cleaning, Inhibitor and Scale Protection.
This will demonstrate that the work complies with the requirements of the appropriate Building
Regulations.
This Guidance Note is produced on behalf of its members by the Central Heating Information Council.For a full list of members visit www.centralheating.co.uk and for further advice on water treatment contact thefollowing members: