gledhill BoilerMate CP 120, Design, Installation & Servicing Instructions

Page 1: ...tion Servicing Instructions Models covered in this manual BoilerMate CP 120 BoilerMate CP 150 BoilerMate CP 180 BoilerMate CP 220 BoilerMate CP Mains pressure hot water thermal store for use with central plant boilers ...

Page 2: ...edhill product and we hope you get satisfactory service from Gledhill If not please let us know Benchmarkplacesresponsibilitiesonbothmanufacturersandinstallers Thepurposeisto ensure that customers are provided with the correct equipment for their needs that it is installed commissionedandservicedinaccordancewiththemanufacturersinstructions by competent persons and that it meets the requirements of...

Page 3: ...s completed by a person registered with a competent person scheme the commissioning notice willbesuppliedbythatperson otherwisethepersoncarryingouttheworkmustnotify therelevantbuildingcontrolbody thatcommissioninghastakenplaceinaccordance with the Domestic Heating Compliance Guide The building control body will then be able to issue a completion certificate This applies to England for other jurisd...

Page 4: ...ibitorshould be specified at the time of order for hardness levels between 200 and 300 ppm mg l Wherethewaterisveryhardie300ppm mg l andabovethe optionalpolyphosphate type inhibitor should be specified at the time of order However this will need to be fitted by the installer at a suitable point in the cold water supply to the appliance The printed circuit board incorporates the facility to automat...

Page 5: ...22 0 22 0 28 Standing heat loss kWh 24hr 1 19 1 35 1 44 1 71 Model Selection Guide BoilerMate CP Dwelling Type Bedroom 1 2 2 3 2 3 2 4 Bathroom 1 or 1 1 2 En suite shower rooms 1 1 2 1 Model required BMCP120 BMCP150 BMCP180 BMCP220 Notes 1 Plastic top up cistern will be supplied separately 2 Theflowratesarebasedona35 Ctemperatureriseandassumethatrecommended pressures and adequate flow are availabl...

Page 6: ...0 Top up cistern complete with cold feed open vent pipework assembly is supplied separately 11 Store sensor 12 Cylinder thermostat 13 Boiler return Note The immersion heater is a low watt density type with incaloy 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 cont...

Page 7: ...ent to the appliance the width depth will need increasing to accommodate this Appliance Dimensions Model Height A Width B Depth C BMCP120 1075 530 595 BMCP150 1145 560 630 BMCP180 1275 560 630 BMCP220 1575 560 630 Minimum Cupboard Dimensions Model Height D Width E Depth F BMCP120 1825 570 610 BMCP150 1895 600 645 BMCP180 2025 600 645 BMCP220 2325 600 645 B E C BoilerMate CP Top up cistern Top up c...

Page 8: ... connector have been specified If a warning overflow pipe is NOT provided the F E Cistern should be filled from a temporary hose connection incorporating a double check valve This can be from a temporary hose connection supplied from a cold water tap or a permanent cold branch provided adjacent to theTop up Cistern The temporary connection must be removed once the appliance is filled Note All dime...

Page 9: ...smustbecapableofprovidingforthoseservices which could be required to be supplied simultaneously and this maximum demand should be calculated using procedures defined in BS EN 806 1 5 BS EN 8558 2011 If a water meter is fitted in the service pipe it should have a nominal rating to match the maximum hot and cold water peak demands calculated in accordance with BS EN 806 1 5 BS EN 8558 2011 Please no...

Page 10: ...nufacturer confirms that the design criteria of the new system is at least equivalent to the use of BS EN Standard copper pipework and fittings 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 cold supplies are mains fed However all mains pressure systems are subject to dynamicchangesparticularlywhenother...

Page 11: ...e above diagram shows the BoilerMate CP installed to a system where the pumped supplyisadequatetoovercomethepressurelossoftheBoilerMateCPheatexchanger coil the pressure loss over the central heating system components and all other components fitted to it In addition all the components fitted are able to withstand the pressure in the district system In the above diagram the cold water supply to the...

Page 12: ... Temp filling loop required Heat meter Diverter Valve not mid position CH flow to dwelling CH return from dwelling Pump and plate heat exchanger position to overcome pressure loss additional expansion requirement and excess district pressure requirements District supply District return Coil flow and return Plate heat exchanger Local expansion system connection required CH Bypass Zone valve Open ve...

Page 13: ...rk and or tap washers and or washing machine valves Cupboardtemperatureswillnormallybeslightlyhigherthaninaconventionalsystem and the design of the cupboard and door will need to take this into account No ventilation is normally required to the cupboard The separate Top up cistern will need to be located on top of the appliance or at high level in the cupboard housing the BoilerMate CP The dimensi...

Page 14: ... the H S E The appliance can be moved using a sack truck on the rear face although care should be taken and the route should be even In apartment buildings containing a number of storeys we would recommend that the appliancesaremovedverticallyinamechanical lift If it is proposed to use a crane expert advice should be obtained regarding the need for slings lifting beams etc Beforeinstallationthesit...

Page 15: ...coming mains cold water D 22mm Domestic hot water E Drain tap connection F 28mm Boiler flow G 28mm Boiler return Note The safety open vent and cold feed expansion must be connected to the top up cistern using the pipework assembly provided Do not alter or connect any pressure relief device to the vent pipe of this water heater All factory made joints should be checked after installation in case th...

Page 16: ... 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 throughout its length The mains cold water supply to the ballvalve if provided shall be provided with a suitable servicing valve The overflow warning pipe if provided shall have a continuous fall be fitted to dischargeclearofthebuildingandbesitedsothatanyoverf...

Page 17: ...xternal wiring from the adjacent isolator through the service slot provided in the base of the appliance Clamp the cables in the grips provided and ensure all cables are routed to avoid hot surfaces Note The appliance pipework should be bonded to earth to comply with the IEE Requirements for Electrical Installations BS 7671 Before switching on the electrical supply check all the factory made termi...

Page 18: ...N E PL SL Wiring diagram no pump required Programmer Fuse Spur L N E L N On On Off Off HW CH Store thermostat E C 1 2 2 port zone valve ML MN E PL SL Room thermostat E C 1 2 3 port divert valve ML MN E PL SL Wiring diagram CH pump required CH Pump L N E The following control wiring diagrams ensure that the district heating system is isolated from the dwelling when charging is not required ...

Page 19: ...STALLATION Programmer Fuse Spur L N E L N On On Off Off HW CH Store thermostat E C 1 2 2 port zone valve ML MN E PL SL Room thermostat E C 1 2 3 port divert valve ML MN E PL SL Wiring diagram HW CH pump required CH Pump L N E ...

Page 20: ...ng from a ballvalve failure If an overflow is not provided ensure the temporary filling hose is isolated and removed from its connection to the cold water supply It is essential that all systems function properly for optimum performance Toachievethistheflowratefromeachtapshouldbecheckedandasuitablenumberof taps run simultaneously to check the impact of this on the flow rate at individual taps We r...

Page 21: ...n facility can operate to prevent the pump sticking 9 DO ensure that the functioning and control of the system is explained to the occupant 10 DON T place any clothing or other combustible materials against or on top of this appliance The front panel should then be refitted Annual Servicing No annual servicing of the BoilerMate CP is necessary However if required the operation of the controls and ...

Page 22: ...ate heat exchanger 24 Plate GT017 3 Pump isolating valve outlet 90 valve GT135 4 Pump isolating valve inlet GT133 5 Immersion heater 3kW SH003 6 Stat XB081 7 Main PCB controller XB103 8 Sensors GT198 9 Y strainer XB314 1 9 8 2 3 4 5 6 7 SERVICING SHORT PARTS LIST ...

Page 23: ...rn and vent the pump if necessary Water hammer loose pipework and or tap washers and or washing machine valves Causes of Unsatisfactory Hot Water Service See table opposite Overflow from Feed and Expansion Cistern Check that the controlled level of water in the cistern is at the correct level Adjust if required and check the ballvalve is shutting off the water supply S6 On P Heater Off P Heater S4...

Page 24: ...ay is controlled by 2 buttons S1 and S2 The flow chart of display modes is shown above Generally each press of button S2 cycles the display from top to bottom and each press of button S1 cycles the display functions from left to right The button S2 is also used to reset the appliance i e clear the lockout errors and reset the appliance Note Appliance resetting can also be carried out using the pus...

Page 25: ...d House 40 New Road Stourbridge West Midlands DY8 1PA TELEPHONE 01384 442611 FAX 01384 442612 Water Savings Water Related Costs Can Be Reduced By Good Plumbing Practice TAPS MIXERS SHOWERS Unregulated 25 30 l m Regulated 10 12 l m Over 20 l m 5 6 or 8 l m 2 tap half open Fitted with regulator Unregulated 4 Fixing Options For Taps Mixers 1 MK Range Combined Regulators Aerator forscrewingontoTaps Mi...

Page 26: ...Page 26 APPENDIX APPENDIX B ...

Page 27: ...ifting at the top of the product Each appliance is supplied with a pallet which has been attached to the unit via the packaging The pallet will also allow for one or two persons to get a good hold e Taking the lead for team lifts As more than one person is required for these products ensure that one person is taking the lead This may be you so ensure that each person that is helping is made aware ...

Page 28: ...on chloride sulphate Max 300 mg l in total 9 2 5 Whereappropriatetheunithasbeenregularlymaintainedasdetailedintheinstallationandserviceinstructions 9 2 6 Defects caused by corrosion or scale deposits are not covered by any Guarantee 9 2 7 Where we agree to rectify any defect we reserve the right to undertake the work on our own premises 9 2 8 We will not accept any labour charges associated with r...

Page 29: ... i the Purchaser shall hold the goods in a fiduciary capacity for us and shall store the same separately from any other goods in the Purchaser s possession and in a manner which enables them to be identified as our goods ii the Purchaser shall immediately return the goods to us should our authorised representative so request All the necessary incidents associated with a fiduciary relationship shal...

Page 30: ...Other Is the cylinder solar or other renewable compatible Yes No What is the hot water temperature at the nearest outlet C All appropriate pipes have been insulated up to 1 metre or the point where they become concealed Yes UNVENTED SYSTEMS ONLY KHUH LV WKH SUHVVXUH UHGXFLQJ YDOYH VLWXDWHG LI WWHG What is the pressure reducing valve setting bar DV D FRPELQHG WHPSHUDWXUH DQG SUHVVXUH UHOLHI YDOYH D...

Page 31: ...ame Telephone No Comments Signature SERVICE 05 Date Engineer name Company name Telephone No Comments Signature SERVICE 07 Date Engineer name Company name Telephone No Comments Signature SERVICE 09 Date Engineer name Company name Telephone No Comments Signature SERVICE 02 Date Engineer name Company name Telephone No Comments Signature SERVICE 04 Date Engineer name Company name Telephone No Comments...

Page 32: ...o provide further customer support with a range of services including Low cost annual repair and maintenance contracts direct from Gledhill Annual servicing and safety checks Expert response to out of warranty breakdowns at fixed charges Please call 08445 679898 or visit www gledhill net for further details Only the best is acceptable FM 02057 Gledhill Building Products Limited Sycamore Estate Squ...