gledhill BOILERMATE OV PP, Instruction Manual

Page 1: ... ONE NAME EVERY SOLUTION 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 ...

Page 2: ... carry out installation commissioning and servicing work in accordance with the Benchmark Code of Practice which is available from the Heating and Hot Water Industry Council who manage and promote the Scheme Visit www centralheating co uk for more information For further information on the HWA Charter Statement please refer to the HWA website hotwater org uk Section Page DESIGN Introduction 3 Mode...

Page 3: ...inghastakenplaceinaccordance 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 jurisdictions in the UK it may be necessary to consult their own building regulations and guidance The BoilerMate is not intended for use by persons including children with reduced physical sensory or mental capabili...

Page 4: ...uld not be directly compared with heat losses from unvented or vented cylinders because they are treated differently in SAP This is because the unvented and vented cylinders are tested at 65 C and the thermal store at 75 C The feed and expansion tank must be located above the thermal store with the SP and SP PP variants In the case of the integrated thermal store BMST OV PP the feed and expansion ...

Page 5: ...deviation 0 280 637 670 0 174 271 335 508 537 670 0 280 591 617 670 670 Minimum Cupboard Width 58 45 3 2 1 4 6 7 Drain Wiring Centre Immersion Control Stat 2a 5 8 C y l i n d e r C o l d F e e d t o F E Number Description Size mm 1 Return To Boiler 28 2 CH Zone 1 22 2a Optional CH Zone 2 22 3 Flow From Boiler 28 4 CH Return 22 5 Drain Tapping Fem 6 Hot Water Out 22 7 Mains Cold Supply 22 8 Cylinde...

Page 6: ...on 2 Domestic hot water PCB box 3 Compression elbow 22mm 4 Straight isolator 22mm to FF3 4 5 System wiring panel 6 Domestic hot water pump PWM2 7 Boiler flow 22mm compression 8 Compression elbow 22mm 9 Domestic hot water PHE insulated 24 plate 10 3kW immersion heater backup 11 Flow sensor and hot water sensor 12 Compression elbow 22mm 13 Central heating pump including isolation valves 14 Cold wate...

Page 7: ...12 6 Test volume above 40 C litres 138 154 196 Average DHW temperature C 54 53 52 Average temperature rise C 44 42 44 Thermal store test temperature C 75 75 75 DHW performance Space heating Test flow rate litres min 12 6 12 6 12 6 Test volume above 40 C litres 78 103 137 Average DHW temperature C 50 49 51 Average temperature rise C 40 37 42 Thermal store test temperature C 61 63 63 Notes 1 The hei...

Page 8: ...own opposite It is supplied with the following factory fitted equipment 1 90 degree elbow vent 22mm compression 2 Domestic hot water PCB box 3 Compression elbow 22mm 4 Straight isolator 22mm to FF3 4 5 Bent isolator CV fitted 22mm to FF3 4 6 Domestic hot water pump PWM2 7 Store PHE insulated 24 plate 8 Boiler flow 22mm compression 9 Domestic hot water PHE insulated 24 plate 10 Flow sensor and hot ...

Page 9: ...eheat time 3 mins 18 26 29 Maximum DHW pressure bar 5 5 5 DHW performance Test flow rate litres min 12 6 12 6 12 6 Test volume above 40 C litres 138 154 196 Average DHW temperature C 54 53 55 Average temperature rise C 41 41 43 Thermal store test temperature C 75 75 75 Notes 1 The height stated is to the top of the unit plus 550mm which should allow for a 25mm thick shelf board and room for servic...

Page 10: ...e following factory fitted equipment 1 90 degree elbow vent 22mm compression 2 Domestic hot water PCB box 3 Compression elbow 22mm 4 Straight isolator 22mm to FF3 4 5 System wiring panel 6 Bent isolator CV fitted 22mm to FF3 4 7 Domestic hot water pump PWM2 8 Boiler zone valve for store charging 9 Store PHE insulated 24 plate 10 Domestic hot water PHE insulated 24 plate 11 Auto bypass valve 12 Cen...

Page 11: ...9 Average reheat time 3 mins 18 26 29 Maximum DHW pressure bar 5 5 5 DHW performance Test flow rate litres min 12 6 12 6 12 6 Test volume above 40 C litres 138 154 196 Average DHW temperature C 54 53 55 Average temperature rise C 41 41 43 Thermal store test temperature C 75 75 75 Notes 1 The height stated is to the top of the unit plus 550mm which should allow for a 25mm thick shelf board and room...

Page 12: ...e spine must be kept rigid this coupled with a bent knee position allows the centre line of gravity of the body to be over the weight so reducing strain c Positioning of arms and body The further arms are away from the side the greater the strain on the shoulders chest and back Keep elbows close to the body arms should be straight d The hold Before lifting ensure you have a good hold e Taking the ...

Page 13: ...e cold water supply branch to the BoilerMate Water Hardness The Domestic Building Services Compliance Guide 2013 provides more detailed information on the guidance contained in Approval Documents L1A and L1B guidance to the Building Regulations The recommended minimum standards specify that where the mains water hardness exceeds 200ppm provision should be made to treat the feed water to water heat...

Page 14: ...mped secondary circulation system shown below can be used with any model of the BoilerMate SP INSTALLATION DOMESTIC HOT WATER BoilerMate Inline filter flow regulator Single check valve Single check valve Pump isolation valves Cold water inlet Plate heat exchanger Hot water outlets Pipework length and diameter to suit property demands Pipework length and diameter to suit recirculation flow rate app...

Page 15: ...emperature sensor L Brown PR61 E G Y N Blue PWM PWM SPARE Fuse Dip Switch 1 2 3 4 To DHW pipe All the these sensor inputs carry a Voltage of 5V The max cable length is 1 meter The sensors connected to the control Should be free from the appliance earth INSTALLATION DOMESTIC HOT WATER Connector 2x3 poles with temperature output from flow sensor perspective Domestic Hot Water Controls Wiring ...

Page 16: ...7 17 0 DHW Temperature in degress C Time in mInutes at flow rate in table DHW performance no space heating load OV PP BMSTOV150PP DITS BMSTOV180PP DITS BMSTOV210PP DITS 0 0 10 0 20 0 30 0 40 0 50 0 60 0 0 0 0 3 0 5 0 8 1 0 1 3 1 5 1 8 2 0 2 3 2 5 2 8 3 0 3 3 3 5 3 8 4 0 4 3 4 5 4 8 5 0 5 3 5 5 5 8 6 0 6 3 6 5 6 8 7 0 7 3 7 5 7 8 8 0 8 3 8 5 8 8 9 0 9 3 9 5 9 8 10 0 10 3 DHW temperature in degrees ...

Page 17: ... 75 112 154 BMSTSP210 IDHWTS 0 21 0 21 55 55 75 75 130 196 Productreference DHW flow rate Hotwater delivery temperature Thermal store temperature HW delivered above 40 degrees C l sec C C Litres INSTALLATION DOMESTIC HOT WATER Hot water draw off volume VHW N Hot water draw off volume VHW L 0 0 10 0 20 0 30 0 40 0 50 0 60 0 70 0 0 0 0 3 0 5 0 8 1 1 1 3 1 6 1 9 2 1 2 4 2 7 2 9 3 2 3 5 3 7 4 0 4 3 4 ...

Page 18: ...ments must not be used No valve should be fitted in the safety open vent The safety vent must be a minimum of 22mm copper pipe or equivalent The Boilermate OV PP s space heating system and boiler must be open vented The Boilermate SP s and SP PP s space heating system and boiler can be either open vented or sealed the expansion system for the thermal store and the boiler space heating system are s...

Page 19: ... 15 Pump housing length 130 130 130 Maximum delivered head 7 6 6 Maximum power consumption Watts 50 43 43 Control box orientation 6 o clock 12 o clock 12 o clock Function Store pump for DHW PHE Space heating and or Boiler PHE Store pump for Boiler PHE Control iPWM 2 SC Push button Speed PWM2 speed controlled by PCB Variable Pressure x 3 defined curves Constant Pressure x 3 defined curves Constant ...

Page 20: ...ressure Variable Δp v Ι Ι Ι Ι Ι Ι Recommended for two pipe heating systems with radiators to reduce the flow noises at thermostatic valves Constant differential pressure Δp c Ι Ι Ι Ι Ι Ι Recommended for underfloor heating or for large sized pipes applications without a variable pipe network curve e g storage charge pumps or single pipe heating systems with radiators Constant speed Ι Ι Ι Ι Ι Ι Reco...

Page 21: ...Page 21 INSTALLATION CENTRAL HEATING Wilo Para Self Control Smart Functions Air Venting Mode Manual Restart Lock and Unlock Push To Change The Pump Setting ...

Page 22: ...nds that most domestic situations will be set between0 2 0 3Bar Iftheflowistoohighincreasethepressuresettingandconversely if too low decrease the pressure setting Thebypassvalvemustbesetbytheinstallertosuitthesystemi e toprovideminimum flow required for the boiler when allTRVs are closed and or when all the zone valves are closed Benefits include reduced system noise reduced pump impeller wear and ...

Page 23: ...e from the boiler to the BoilerMate is not achievable BoilerMate OV PP Plumbing Schematic Primary Circuit Central heating Central heating Typical Arrangement Connection Details Boiler No valves to be fitted onto the boiler flow Domestic hot water Mains cold water Open vent for boiler store and central heating ...

Page 24: ...G Central heating Typical Arrangement Connection Details Boiler Domestic hot water Mains cold water Open vent for store Open vent for boiler and heating connected to F E cistern BoilerMate SP Plumbing Schematic Open vented heating system ...

Page 25: ...ON CENTRAL HEATING Central heating zone 1 Typical Arrangement Connection Details Boiler Sealed system kit Domestic hot water Mains cold water Open vent for store PRV BoilerMate SP Plumbing Schematic Sealed heating system ...

Page 26: ...system kit Central heating zone 1 Typical Arrangement Connection Details Boiler Alternative position for the safety valve and discharge Domestic hot water Mains cold water Open vent for store BoilerMate SP PP Plumbing Schematic INSTALLATION CENTRAL HEATING ...

Page 27: ...irement for excess district pressure District supply District return Coil flow and return Plate heat exchanger Local expansion system connection 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 Dis...

Page 28: ...re to supply N terminals N L N N PE PE 3 core cable PE SL2 IS ONLY FITTED FOR LOGIC HEAT BOILERS WITH PE WEATHER COMPENSATION KITS FITTED 3 core cable TIMER DHW Controller CP006 Scale Inhibitor XB153 13 S H C Control Stat BOILER SL2 BOILER PUMP CH PUMP SUPPLY SUPPLY SL1 TIMER DHW OFF DHW ON HTG ON CP006 Terminal Block XB521 Ideal wired cylinder using Danfoss wiring centre WC4 B HTG 1 HTG 2 ROOM TH...

Page 29: ... PE SL2 IS ONLY FITTED FOR LOGIC HEAT BOILERS WITH PE WEATHER COMPENSATION KITS FITTED 13 3 core cable 1 2 3 4 TI SUPPLY SUPPLY SL1 SL2 BOILER Relay TIMER DHW OFF DHW ON HTG ON DHW DUAL AQUASTAT CP006 Terminal Block XB521 DHW Controller CP006 Ideal wired cylinder using Danfoss wiring centre WC4 B HTG 1 HTG 2 ROOM THERMOSTATS Connections made by the installer CH PUMP HTG 2 HTG 1 Pump 8 N L BOILER P...

Page 30: ...and fit live link between terminal 9 and L or set timer CH to permanent ON 3 core cable SL2 TIMER BOILER ROOM THERMOSTATS HTG 1 DHW OFF DHW ON HTG ON PE SUPPLY SUPPLY SL1 PUMP THERMAL STORE THERMAL STORE BOILER PUMP TIMER SL2 IS ONLY FITTED FOR LO HEAT BOILERS WITH WEATH COMPENSATION KITS FITT Control Stat Cable 2 Cable 1 Ideal wired cylinder using Danfoss wiring centre WC4 B HTG 1 HTG 2 Connectio...

Page 31: ...ermostats and fit live link between terminal 9 and L or set timer CH to permanent ON 3 core cable BOILER PUMP TIME H DHW Controller CP006 Ideal wired cylinder using Danfoss wiring centre WC4 B HTG 1 HTG 2 L N 12 Pump DELAY TIMER XB041 1 2 3 4 Connections made by the installer SUPPLY SUPPLY SL1 PUMP THERMAL STORE THERMAL STORE SL2 TIMER BOILER ROOM THERMOSTATS CP006 Terminal Block XB521 X HTG 1 HTG...

Page 32: ...ring diagram on the next page for the required modifications to the above diagram BoilerMate OV 2 zone The two zone space heating system runs in a similar manner to the single zone However in this system both heating zone thermostats are supplied with 240Volt AC simultaneously If independent timing of the second zone is required then another programmer or programmable room thermostat will be requi...

Page 33: ...ions The immersion heater must be fully earthed earth post and connected via a double pole isolator switch The immersion heater is supplied with a thermostat which has been tested for operation in the thermal store and complies with the European directives for Electromagnetic compatibility and radio interference It is Rated at 20 Amp 250V AC The thermostat supplied with this product is set to 75 C...

Page 34: ...ws Filling loop Double Check Valve Filling loop Hose Filling loop Mini Ball Valves ERV Gauge Second Heating Zone kit Zone valve 22 mm 2 port 22mm ef equal tee 22mm copper pipe 110mm 22mm ef 90 elbow 22mm copper pipe 50mm table Y Pump Over Run Kit Pump delay timer PCB PCB support M20 Cable Gland with Locknut Dhw Scale Prevention Kit Scale prevention PCB PCB support Scale Board harness Scale Harness...

Page 35: ...old water systems including the appliance must be adequately flushed after disinfection Failure to do this may cause damage to the plate heat exchanger and other components in the DHW system In domestic installations disinfection is not normally required It is essential that all systems function properly for optimum performance To achieve this the flow rate from each tap should be checked and a suit...

Page 36: ...the correct set point i e approx 75 C 6 DO insulate any exposed hot water pipework in the BoilerMate cupboard 7 If the ballvalve in the F E cistern is permanently connected to the mains cold water supply DO plumb the overflow warning pipe in a 20mm internal diameter pipe and ensure it discharges in a conspicuous external position Use a material which is suitable for use with heating F E cisterns i...

Page 37: ...4 Label Water Level LA011 15 Label Sight Glass LA923 16 22mm Tank Connector Comp XB379 17 Sight Glass Level Indicator XB443 18 22 mm 90 Compression Elbow SF012 19 PCS F E Pipe 22mm MIP608 20 Rubber Grommet XG133 21 Washer Fibre 42 2 x 29 0 x 3 0 mm FT402 22 Horstmann H27 XL RP170 23 Sealed system ROBOKIT SG032 24 Zone valve 22 mm 2 port XG083 25 Pump delay timer PCB XB041 26 PCB support XB045 27 M...

Page 38: ...g Components 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 Help and advice is also available from the Technical Helpline on 01253 474584 How...

Page 39: ...onfirm that the water runs freely and that any air is bled from the DHW system Determine the maximum flow rate obtained and record 15l min for all BoilerMate products currently limited with a flow restrictor If flow rate not as expected determine the cause and rectify Clean inline strainer Check the flow restrictor is present and not blocked It is located in the top of the inline strainer Power On Swi...

Page 40: ...ctions to the PCB are numbered below for Logical sequence check electrical connections fault finding section on page 23 first to ensure your own safety This section will potentially identify any short circuited components and or wiring faults that need to be rectified before continuing to work on the appliance check that the correct information is being supplied to the board This section will iden...

Page 41: ... gives clear instructions to on how to perform these tests Menu options 1st Boiler Fault finder 2nd Electrical safety checks Reference schematic opposite Check procedure CW temperature sensor Power off Disconnect J18 Measure and record the resistance across terminals 6 and 13 Measure the cold water inlet temperature Compare the resistance measured with chart Tasseron NTC 12k thermistor The reading...

Page 42: ... 145 26 2 75 13 5 150 27 2 80 14 4 155 28 1 85 15 3 160 29 0 90 16 2 165 29 9 flow rate determination Check for presence of overheat link An overheat link connection should be present in connection Junction 7 If you are fittinganewboardtheoverheatlinkthatisontheboardjustremovedmustberetained as the newly supplied board will not have one fitted Check outputs from the PWM controller PCB to the pump ...

Page 43: ...clean system if debris Blinks red Pump out of function Pump stopped blocked Blockage the pumps is fully blocked due to debris in system Check for blockage Turn ON OFF to reset the pump by unplugging the power supply If the pumps still blinking red after a power reset then replace the pump Faulty electronic module and or faulty motor LED off No power supply No voltage on electronics Pump is not con...

Page 44: ...ad if necessary Building does not warm up Thermal output of the heating surfaces are too low Increase set point Change the control mode from Ap c to Ap v LED Faults Cause Remedy Lights up red Blocking Rotor blocked Active manual restart or contact customer service Contacting winding Winding defective Flashes red Under over voltage Power supply too low high on mains side Check mains voltage and ope...

Page 45: ...agram polarity correct OK OK Sensors in correct loca on OK OK OK N OK OK LED Blinks red green Resolve OK Under voltage U 160 V or Over voltage U 253 V Resolve OK Pump overhea ng Check water and ambient temperatures Resolve Pump Over speed Ensure that there is no other external flow other pump running on system OK Resolve Over current the stator winding is in short circuit due to water Check for lea...

Page 46: ...ood 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 ...

Page 47: ...Page 47 APPENDIX APPENDIX B ...

Page 48: ...tallationandserviceinstructions 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 replacing the unit or parts for any of the following products listed 9 2 9 If the newly fitted water heater is not in...

Page 49: ...wing events namely i if the Purchaser fails to make payment in full for the goods within the time stipulated in clause 4 hereof ii if the Purchaser not being a company commits any act of bankruptcy makes a proposal to his or her creditors for a compromise or does anything which would entitle a petition for a Bankruptcy Order to be presented iii if the Purchaser being a company does anything or fai...

Page 50: ...ate will then be issued to the customer Heating and Hotwater Industry Council HHIC www centralheating co uk 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 Customer name T...

Page 51: ...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 52: ...sable 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 to copy or adapt this document without consent of the owner WWW GLEDHILL NET TO REGISTER CALL 08000 420 430 VISIT WWW GLEDHILL NET UNIT REGISTRATION FOR TECHNICAL SUPPORT 01253 474584 FOR ANNUAL SERVICE AND MAINTENANCE 0800 380...