gledhill BM 185 Page 28 Installation And Servicing Instructions Download | Manualshive

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Page 28

2.3 COMMISSIONING

Fully fl ush and if necessary chlorinate the hot
and cold water system in accordance with the
recommendations in the Model Water Byelaws
and BS 6700.

Commissioning the BoilerMate Control
System

For maximum system efficiency the store
thermostat must be in control of the boiler i.e.
the boiler cycles on the store thermostat and
not on its integral thermostat.

The BoilerMate control system will automatically
commission itself to match the a c t u a l
performance of the installed boiler.

The control system/A.C.B has been initialised at
the factory and will operate automatically.

However, the operation of the control system
should be checked as follows on the A.C.B
(shown opposite).

1. Set the boiler thermostat to MAXIMUM
2. Switch off heating on the clock/

programmer

and room thermostat

3. Switch off hot water on the programmer

if 2 channel clock is fi tted

4. Check the jumper settings are

correc t. These must all be in the

correct positions for the appliance to

work correctly i.e. fi tted on terminals

1, 3 and 4.

5. Switch on the mains supply.

The A.C.B. will automatically commission

itself to suit the system/boiler and the dot

after the

ON the display will fl ash

The control system is now initialised. The
operation of the controls can now be checked.

1. Horizontal 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 fi nally fi lled turn down
the servicing valve for the ballvalve in
the F & E cistern to the point where the
warning/overfl ow will cope with the discharge
arising from a ballvalve failure.

Cleansing Hot/Cold Water System Treatment

e.g.

1

2

3

4

APPLIANCE CONTROL BOARD (A.C.B)

4 = Not used on this appliance
3 = Heating pump on
2 = Boiler pump on
1 = Boiler on

Green

LED'S

Fuse

Jumper

Settings

SW1

SW2

8

LED DISPLAY

BAR 1 - HT

BAR 2 - ST

BAR 3 - HW

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Summary of Contents for BM 185

Page 1: ...SSURE HOT WATER SUPPLY SYSTEM INCORPORATING A THERMAL STORE ALL MODELS COMPLY WITH THE WATER HEATER MANUFACTURERS SPECIFICATION FOR INTEGRATED THERMAL STORES BOILERMATE 2000 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: ... Patents Pending TheGledhillGroup sfirstpriorityistogivea high quality service to our customers Quality is built into every Gledhill product and we hope you get satisfactory service from 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 re...

Page 3: ...e BoilerMate 2000 is not covered by section G3 of the current Building Regulations and is therefore not notifiable to Building Control The information in this manual is provided to assist generally in the selection of equipment The responsibility for the selection and specification of the equipment must however remain that of the customer and any Designers or Consultants concerned with the design ...

Page 4: ...m the store through the plate heat exchanger To comply with the Benchmark Guidance Note for Water Treatment in heating and hot water systems the installer should check the hardness levels of the water supply and if necessary fit an in line scale inhibitor reducer to provide protection to the whole of the domestic water system 1 0 DESIGN Description 1 1 INTRODUCTION Ifscaleshouldeverbecomeaproblemt...

Page 5: ... 0 DESIGN l e d o M 5 2 1 M B 5 4 1 M B 5 8 1 M B 0 1 2 M B 5 2 2 M B y t p m e t h g i e W g k 8 5 g k 1 6 g k 5 6 g k 6 7 g k 8 8 l l u f t h g i e W g k 3 7 1 g k 6 8 1 g k 5 1 2 g k 6 4 2 g k 8 7 2 p m u P W H D 0 5 5 1 s o f d n u r G 0 5 5 1 s o f d n u r G 0 5 5 1 s o f d n u r G 0 5 5 1 s o f d n u r G 0 5 5 1 s o f d n u r G p m u P g n i t a e H 0 5 5 1 s o f d n u r G 0 5 5 1 s o f d n ...

Page 6: ...sion cistern complete with ballvalve overflow fitting and cold feed open vent pipework assembly is supplied separately Optional Equipment A soft water model is available for areas where the hardness level is below 200 p p m mg ltr Flexible connectors for quick connection to first fix pipe installation For further details see 2 2 Installation Pipework connections Switch emergency electrical back up...

Page 7: ... O I S N E M I D E C N A I L P P A l e d o M t h g i e H h t d i W h t p e D A B C 5 2 1 M B m m 0 4 1 1 m m 5 9 5 m m 5 9 5 5 4 1 M B m m 0 4 1 1 m m 5 9 5 m m 5 9 5 5 8 1 M B m m 0 5 3 1 m m 5 9 5 m m 5 9 5 0 1 2 M B m m 0 0 5 1 m m 5 9 5 m m 5 9 5 5 2 2 M B m m 0 5 5 1 m m 0 5 6 m m 5 9 5 S N O I S N E M I D D R A O B P U C M U M I N I M l e d o M t h g i e H h t d i W h t p e D F D E 5 2 1 M B...

Page 8: ... location for 15mm cold mains feed to the F E tank The BoilerMate 2000 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 Compression or push fit connections can be used and we do offer a set of flexible connectors as an option All pipe positions are approximate and...

Page 9: ... BOILERMATE 2000 1 2 TECHNICAL DATA AWAITING HOT WATER PERFORMANCE GRAPHS FOR EACH MODEL SIZE PERFORMANCE GRAPHS OF GRUNDFOS PUMPS 1 0 DESIGN GRUNDFOS 15 50 litres sec 6 litres sec GRUNDFOS 15 60 TO BE ADDED ...

Page 10: ...ould check the hardness level of the water supply and if necessary fit an in line scale inhibitor reducer to provide protection to the whole of the domestic water system See Appendix C for a copy of the relevant part of the Benchmark Guidance Note 1 0 DESIGN 0RESSURE LIMITING VALVE 4 2 15 2 AT PRESSURES BELOW BAR UNLESS ANY COMPONENTS HAVE A LOWER MAXIMUM WORKING PRESSURE 3ECOND DWELLING 7 3 SUPPL...

Page 11: ...tion to use of push fit connections when using the optional flexible hose kits see 2 2 Installation Pipework connections It is also essential that if an alternative pipework material system is chosen the manufacturerconfirmsthatthedesigncriteriaofthenewsystemisatleastequivalent to the use of BS EN Standard copper pipework and fittings Taps Shower Fittings Aerated taps are recommended to prevent sp...

Page 12: ...ves are fitted on the vertical flow pipes ThewaterlevelintheF Ecisternshouldbe at least 250mm above the highest point on thesystemincludingtheradiatorsandmust be high enough to provide the minimum head required by the boiler being used 1 3 SYSTEM DETAILS The boiler manufacturer s instructions with regard to minimum head must always be followed This is particularly important in situations where the...

Page 13: ...in place of copper internally as long as the chosen system is recommended for use on domestic heating systems by the manufacturer and is installed fully in accordance with their recommendations We always recommend the use of barrier pipe for these systems Heating System F E Cistern Primary flow Primary return BM 2000 Boiler It is also essential that if an alternative pipework material system is ch...

Page 14: ...e boiler and depending upon the pipe layout a manual air vent may also be required on the return adjacent to the boiler Boiler sited with dipped flow and return pipes to the BoilerMate Any boiler must be fitted with an overheat thermostat i e it must be approved for use in a sealed system An automatic air vent will be required on the flow and return connections adjacent to the boiler The height of...

Page 15: ...ators If this is not done the performance of the BoilerMate will be adversely affected If heating of a single bathroom radiator or towel rail is required in summer then it can be piped as a gravity circuit The flow pipe to the radiator can be teed into the safety open ventpipeandthereturnpipefromtheradiator canbeconnectedtothestoredrainconnection and the drain moved to the return pipe The radiator...

Page 16: ...he system that has been installed If the primary pipework dips or the boiler is located above the BoilerMate a single F E cistern with a cold feed and open vent piped to the cistern should be used This arrangement is not suitable for BoilerMate appliances fitted with Switch If it is proposed to use this arrangement please advise Gledhill at the time of order Gledhill will then supply a suitable ve...

Page 17: ...d heating modes In the former only hot water pump and electric heating element are energized In the latter the heating system pump is also energized This means that the heating will be on permanently unless manually switched back to the hot water only position It also means that wherever Switch is being used the normal domestic hot water temperature controls are over ridden Initially dependent on ...

Page 18: ...ed by placing the appliance on a suitable sound deadening material i e carpet underlay or similar Cupboard temperatures will normally be higher than in a conventional system and the design of the cupboard and door will need to take this into account No ventilationisnormallyrequiredtothecupboard A suitable location will be needed for the separate feed and expansion cistern This will often be at hig...

Page 19: ...installation the site requirements should be checked and confirmed as acceptable The plastic cover and protective wrapping should be removed from the appliance the installation base provided placed in position The appliance can then be lifted into position in the cupboard on top of the base and the front panel removed by unscrewing the 2 screws and lifting the door up and out ready for connection ...

Page 20: ... fittings Connection E is blanked 15mm copper pipe Connection J is RC in BSPT internal A Safety open vent B Cold feed expansion C Primary flow from boiler D Primary return to boiler E Towel rail circuit return F Central heating return G Central heating flow H Domestic hot water I Incoming mains cold water J Drain valve is not provided with the appliance 2 0INSTALLATION 2 2 INSTALLATION Pipework co...

Page 21: ...staller to connect this to the appliance Obviously any pipework in the roof space and the feed and expansion cistern will need to be adequately insulated to protect against frost damage Combined feed and open vent pipe arrangements must not be used No valves should be fitted in the safety open vent which must be a minimum of 22mm copper pipe or equivalent The overflow warning pipe shall have a con...

Page 22: ...eturn sensor STORE Sensor TERMINAL BLOCK Heating pump Neon R BR BR BR BR LOAD LINE BR BL BL BL BL G Y G Y G Y G Y G Y G Y BL BL BR BR RD Boiler pump G Y G Y G Y G Y BR BR BR BR BL BL BL BL L R R L L N N N E E E SL SL Clock 1 2 3 4 5 N N L L FILTER SCALE INHIBITOR N L BL BR Optional Extra if fitted KEY BL BLUE BR BROWN G Y GREEN YELLOW R RED BLK BLACK Y YELLOW WH WHITE ...

Page 23: ...e from an earthing strap on the primary return to boiler pipe to the earth stud on the wiring panel 2 0 INSTALLATION Make the connections as shown opposite on the terminal strip provided The appliance is provided with a link betweenterminals9and11ontheterminal strip This must be removed if a room thermostat is fitted see opposite L E N L E N SL L E N SL ROOMSTAT BOILER MAINS 1 2 3 4 5 6 7 8 9 10 1...

Page 24: ...e a base temperature is required during cold weather then a frost thermostat should be wired across plug in terminals 21 and 23 on the A C B board An alternative to fitting a frost thermost would be to set the programmer to constant during the time required and adjust the room thermostat to a suitable setting When frost protection is required for the boiler circuit only a frost thermostat and pipe...

Page 25: ... ump HTG pump Relay CC Gas Electric control PCB Relay CC 32 AMP MAX 32 AMP MAX BS88 BS88 PROTEUS PROTEUS FS 3 Immersion OUT IN G Y G Y G Y BL R N N L L R BL BL G Y R R R R BL BL BR BL Y R OR R WH Y R BL BR BR BR BL BL BR BR Frost Stat Conn Control Thermostat Mains in via cable tail OR WH BR BR OR WH ISSUE NO 8 DATE SEPT 2004 APPROVED BoilerMate2000 with SWITCH Copper Bus Bar Terminal Link Bar Main...

Page 26: ...he service slot provided in the base of appliance The recommendations contained under Electrical Connection Standard Appliance should be followed when connecting a remote clock room thermostat boiler etc WARNING DO NOT SWITCH ON ELECTRIC BACKUP IF FITTED UNTIL THE APPLIANCE HAS BEEN FULLY COMMISSIONED i e PRIMARY STORE IS FILLED AND VENTED WARNING IF THE BOILERMATE IS FITTED WITH AN OPTIONAL ELECT...

Page 27: ...t water systems Fill the whole of the primary heating system with potable water through the feed and expansion cistern Check the water level in the feed and expansion cistern and adjust the ballvalve if necessary Check the whole of the primary heating and domestic hot and cold distribution systems for leaks It is essential that all systems function properly for optimum performance To achieve this ...

Page 28: ...on the programmer if 2 channel clock is fitted 4 Check the jumper settings are correct These must all be in the correct positions for the appliance to work correctly i e fitted on terminals 1 3 and 4 5 Switch on the mains supply The A C B will automatically commission itself to suit the system boiler and the dot after the ON the display will flash The control system is now initialised The operatio...

Page 29: ...heating pump will run continuously This product is covered by the Benchmark scheme and a separate commissioning service log book is included with this product This must be completed during commissioning and left with the product to meet the Warranty conditions offered by Gledhill On completion 1 Do ensure that the electrical connection e g mains supply room thermostat to the unit is correct and ti...

Page 30: ...sed system 13 DON T use pipe smaller than 28mm between the boiler and the BoilerMate when the boiler rating exceeds 20kW about 68 000 Btu h 14 DON T use dipped flow and return between the boiler and the BoilerMate unless the boiler is fitted with an overheat thermostat If necessary check with the suppliers of the boiler 15 DON T operate the switch backup facility until the system is fully fitted v...

Page 31: ...nts specialist heating spares suppliers Help and advice is also available from the Technical Helpline on 08449 310000 However allcomponentsarereadilyaccessible and can be changed quickly and easily by the installer using common plumbing practice If it is necessary to replace any of the pumps fitted to the appliance the pump head motor pack only should be removed as recommended by Grundfos Assuming...

Page 32: ... P p e w S 7 1 0 T G 4 6 6 5 0 E 0 1 B C A d r a o b l o r t n o c e c n a i l p p A k o l E 5 5 2 B X 8 5 1 9 3 E 1 1 r o s n e s e r o t S k o l E 9 4 1 T G 2 2 0 6 2 E 2 1 r o s n e s n r u t e r E H P k o l E 3 5 1 T G 4 2 0 6 2 E 3 1 r o s n e s e r u t a r e p m e t W H D k o l E 3 5 1 T G 4 2 0 6 2 E 4 1 k c o l c l a c i n a h c e m o r t c e l E n i l s s a r G 5 1 2 B X 3 7 8 5 8 3 5 1 k...

Page 33: ...Page 33 BOILERMATE 2000 3 0 SERVICING 1 2 3 4 5 6 7 8 9 10 11 14 15 16 18 19 21 22 23 20 12 13 17 25 24 26 ...

Page 34: ...hat the space heating and hot water load is not greater than the boiler output and that the BoilerMate 2000 model is suitable for the type of dwelling If all the above checks are satisfactory then it is possible that the performance of the heat exchanger is impaired by scale In this case the hot water flow rate will be noticeably less than the cold water flow rate Replace with a factory exchange u...

Page 35: ...d Benchmark commissioning service record sheet to hand to enable help to be provided InadditiontothemainLEDdisplaytheACBhas four green LED S which can be used to check a supply is being provided when required to the Boiler LED 1 Boiler pump LED 2 and Heating pump LED 3 LED 4 is not used on this appliance The following procedure should be followed to carry out these checks Switch off mains Check an...

Page 36: ...R SHOWERS 4 FIXING OPTIONS FOR TAPS MIXERS 1 MK Range Combined Regulators Aerator for screwing onto Taps Mixers with internal or external threads on their noses AntiVandal models also available 2 MR05 T Range Internal Regulators Push fit into Tap or Mixer seats Produced in three sizes 12 5mm BS1010 12mm 10mm Flangeless models also available for Taps with Low Lift washers 3 MXF Standard Range Screw...

Page 37: ...95mm 2 No 6mm fixing holes 18 l mm 12 l mm 9 l mm 9 l mm 9 l mm 9 l mm 12 l mm inlet 55mm 18 l mm 12 l mm 9 l mm 9 l mm 9 l mm 9 l mm 9 l mm 9 l mm 9 l mm 9 l mm 12 l mm inlet 165mm 595mm A hot B cold blank blank 18 l min 12 l min 12 l min 9 l min 9 l min 9 l min 9 l min 9 l min 12 l min 18 l min inlet 595mm C D 18 l min 12 l min 12 l min 9 l mm 9 l mm 9 l mm 9 l mm 9 l mm 9 l mm 9 l min 9 l min 9...

Page 38: ...and the resistance characteristics of the pipes The examples presented below are for 15mm copper pipe in table 1 and for plastic pipework in table 2 The preferred solution where space will allow An optional location where cupboard space is tight Table 1 Maximum equivalent pipe length in 15mm copper Inlet pressure bar Maximum equivalent length of pipe m 9 l m 12 l m 18 l m 2 0 25 10 5 2 5 75 30 15 ...

Page 39: ...should be branched off the cold water main prior to the treatment device instead of the cold water manifold Any other isolating control valves and backflow protection devices should be provided as necessary to comply with the Water Regulations Bath Toilet cistern Hand basin Toilet cistern Hand basin Hand basin Toilet cistern Mains supply Shower DW Kitchen sink Kitchen En Suite Bathroom Check valve...

Page 40: ...ld 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 BUI...

Page 41: ...Page 41 BOILERMATE 2000 APPENDIX D ...

Page 42: ...ARRANGE TO RELOCATE THE FEED CISTERN AT A HIGHER LEVEL 2 4 3 2 4HE INDIRECT 3OLAR0OD HAS X MM PIPE STUB CONNECTIONS A v 30 DRAIN AND A MM SENSOR POCKET THAT CAN BE USED FOR CONTROLLING THE HEAT INPUT AVAILABLE FROM THE SOLAR PANEL CONTROLS AVING FAMILIARISED YOURSELF WITH THE CONNECTIONS THE INDIRECT VERSION HAS A K7 HIGH EFlCIENCY RATED COIL HEAT EXCHANGER SUITABLE FOR CONNECTING TO SEALED SOLAR ...

Page 43: ...AND SERVICING INSTRUCTIONS WHICH MUST BE READ AND FULLY COMPLIED WITH DVICE MUST BE OBTAINED FROM LEDHILL TECHNICAL DEPARTMENT ON ANY DISCREPANCIES OR PROBLEMS ENCOUNTERED IN MEETING THESE REQUIREMENTS 7HEN THE 3OLAR0OD IS CONNECTED TO THE THERMAL STORE ANY HEAT PUT INTO THE 3OLAR0OD VIA THE SOLAR PANELS WILL TRANSFER TO THE THERMAL STORE 4HE THERMAL STORE THEN PROVIDES HOT WATER FOR THE HEATING S...

Page 44: ...Page 44 ...

Page 45: ...Page 45 BOILERMATE 2000 ...

Page 46: ...TEL 0800 14 55 55 7 www gledhill boilermate co uk Sales Service Repair BoilerMate 2000 C O Hot Water Cylinders Limited 302 Foxhunter Drive Milton Keynes MK14 6GD ...

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