gledhill BoilerMate CP 120, BoilerMate CP 180, BoilerMate CP 220, BoilerMate CP 150 Design, Installation & Servicing Instructions
Design, Installation & 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
Section Page
DESIGN
Introduction 3
Technical Data 5
System Details 9
INSTALLATION
Site Requirements 13
Installation 14
Commissioning 20
SERVICING
Annual Service 21
Changing Components 21
Short Parts List 22
Fault Finding 23
ADDENDIX
Addendix A 25
Addendix B 26
Addendix C 27
Terms & Conditions 28
BENCHMARK
Commissioning Checklist 30
Service Record 31
ISSUE 2: SEPTEMBER 2014
The Gledhill BoilerMate CP range is a
WBS listed product and complies with
the HWA Speci cation for hot water only
thermal storage products. The principle was
developed in conjunction with British Gas.
This product is manufactured under an ISO
9001:2008 Quality System audited by BSI.
Gledhill’s rst priority is to give a 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.
Benchmark places responsibilities on both manufacturers and installers. The purpose is to
ensure that customers are provided with the correct equipment for their needs, that it is
installed, commissioned and serviced in accordance with the manufacturers instructions
by competent persons and that it meets the requirements of the appropriate Building
Regulations. The Benchmark Checklist can be used to demonstrate compliance with
Building Regulations and should be provided to the customer for future reference.
Installers are required to 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 Membership, please refer to the HWA website
hotwater.org.uk.
Page 3
DESIGN
INTRODUCTION
Any water distribution system/installation must comply with the relevant
recommendations of the current version of the Regulations and British Standards
listed below:-
Gas Safety (Installation and use) Regulations 1998
Building Regulations
Requirements for Electrical Installations BS7671:2008 and A2:2013 17th Edition
Water Supply (Water Fittings) Regulations 1999
Manual Handling Operations Regulations
British Standards
BS EN 806:1-5: BS EN 8558:2011
Most new building work will require the relevant building control body to be noti ed
prior to the building work commencing. This will not be required if the work is carried
out under a self certi cation scheme or if the work is not noti able. Full details of the
self certi cation schemes and work that is not noti able can be obtained from page
9 of Approved Document G, available from www.planningportal.gov.uk.
A suitably competent trades person must install the BoilerMate CP and carry out
any subsequent maintenance/repairs. In fact the appliance front cover is secured
by 2 screws and this should only be removed by a competent trades person. The
manufacturer’s notes must not be taken as overriding statutory obligations.
The Domestic Building Services Compliance Guide 2013 de nes, one of the xed
building services, as any part of or controls associated with xed systems for domestic
hot water. All xed building services, including theircontrols, should be commissioned
by testing and adjustment to ensure that they use no more fuel and power than is
reasonable in the circumstances. Where commissioning is required, if it is completed
by a person registered with a competent person scheme, the commissioning notice
will be supplied by that person, otherwise the person carrying out the work must notify
the relevant building control body, that commissioning has taken place in accordance
with the Domestic Heating Compliance Guide.The building control body will then be
able to issue a completion certi cate. This applies to England, for other jurisdictions in
the UK, it may be necessary to consult their own building regulations and guidance.
The BoilerMate CP is not intended for use by persons (including children) with reduced
physical, sensory or mental capabilities, or lack of experience or knowledge, unless
they have been given supervision or instruction concerning use of the appliance by
a person responsible for their safety.
Children should be supervised to ensure that they do not play with the appliance.
The information in this manual is provided to assist generally in the selection of
equipment. The responsibility for the selection and speci cation of the equipment
must however remain that of the customer and any Designers or Consultants
concerned with the design and installation.
Please Note: We do not therefore accept any responsibility for matters of design,
selection or speci cation or for the e ectiveness of an installation containing one of
our products unless we have been speci cally requested to do so.
All goods are sold subject to our Conditions of Sale, which are set out at the rear of
this manual.
In the interest of continuously improving the BoilerMate CP range, Gledhill Building
Products Ltd reserve the right to modify the product without notice, and in these
circumstances this document, which is accurate at the time of printing, should be
disregarded. It will however be updated as soon as possible after the change has
occurred.
Page 4
The BoilerMate CP shown schematically above is designed to provide an improved
method of supplying mains pressure hot water when used with a central plant system.
An important feature of the concept is that hot water can be supplied directly from
the mains at conventional ow rates without the need for temperature and pressure
relief safety valves or expansion vessels. This is achieved by passing the mains water
through a plate heat exchanger. The outlet temperature of the domestic hot water
is maintained by a printed circuit control board, which controls the speed of the
pump circulating the primary water from the store through the plate heat exchanger.
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 heaters and the hot water circuit of combination boilers to
reduce the rate of accumulation of lime scale”.
To comply with this requirement the hardness of the mains water should be checked
by the installer and if necessary the optional factory tted in-line scale inhibitor should
be speci ed at the time of order for hardness levels between 200 and 300 ppm (mg/l).
Where the water is very hard ie 300ppm (mg/l) and above the optional polyphosphate
type, inhibitor should be speci ed at the time of order. However, this will need to
be tted by the installer at a suitable point in the cold water supply to the appliance.
The printed circuit board incorporates the
facility to automatically run the D.H.W. Primary
pump for about 3 seconds every 30 hours to
help prevent it sticking. For this reason we
would recommend that once the appliance is
installed it should be commissioned and the
electricity left on to the appliance.
Because this product does not require a safety
discharge from a temperature and pressure
relief valve, any installations will be easy to
incorporate into the building and will not su er
from the problems associated with using PVCu
soil stacks to take the discharge from unvented
cylinders.
The heat losses from thermal stores should not
be directly compared with heat losses from
unvented or vented cylinders because they are
treated di erently in SAP. This is because the
unvented and vented cylinders are tested at
65°C and the thermal store at 75°C.
Figure 1.1
1. Boiler flow
2. Backup immersion heater
3. PHE pump
4. Cold Feed
5. CW inlet
6. HW outlet
7. Drain
8. Return from PHE to store
9. Flow from store to PHE
10. Feed and expansion tank
11. Boiler return
7
2
1
11
3
9
5
8
6
4
10
DESIGN
INTRODUCTION
Page 5
Technical Speci cation BoilerMate CP
Model BMCP120 BMCP150 BMCP180 BMCP220
Height (mm) 1075 1145 1275 1575
Width (mm) 530 560 560 560
Depth (mm) 595 630 630 630
Min cupboard height (mm) 1825 1895 2025 2325
Min cupboard width (mm) 570 600 600 600
Min cupboard depth (mm) 610 645 645 645
Weight (empty) (kg) 48 52 57 65
Weight (full) (kg) 162 198 222 275
Domestic hot water volume (litres) 105 140 160 195
Hot water ow rate (litres/minute) 12.5 12.5 12.5 12.5
Coil rating (kW) 12 16 17 21
Coil surface area (m
2
) 1.18 1.56 1.92 2.54
Pressure loss of coil (bar) 0.20 0.22 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 1121
Model required BMCP120 BMCP150 BMCP180 BMCP220
Notes:-
1. Plastic top up cistern will be supplied separately.
2. The ow rates are based on a 35°C temperature rise and assume that recommended
pressures and adequate ow are available at the appliance. The actual ow rate
from the appliance is automatically regulated to a maximum of 15 litres/min.
3. Unit is supplied on a 100mm high installation base.
4. The domestic hot water outlet temperature is automatically regulated to
approximately 52°C, and the temperature is not user adjustable.
Table 1.2
Table 1.1
DESIGN
TECHNICAL DATA
Page 6
Standard Equipment
The standard con guration of the BoilerMate CP
is shown opposite. The Printed Circuit Control
Board, mounted inside the appliance, controls
the production of the domestic hot water.
This is pre-wired to a terminal strip where all
electrical connections terminate. The installer
must t components to control the operation
of the immersion heater. It is supplied with the
following factory tted equipment:-
1. Boiler ow
2. 3kW backup immersion heater
3. Printed Circuit Board
4. Plate heat exchanger
5. Domestic hot water primary (plate heat
exchanger) pump
6. DHW temperature sensor
7. Incoming cold water sensor
8. Strainer and ow regulator
9. Screwed connection for a drain tap
10. 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 control
thermostats and overheat thermostats.
Immersion heaters without these components
must not be tted to the unit.
Optional Extra Equipment
• In line scale inhibitor for mains water
services with hardness levels between 200
and 300ppm (mg/l) tted but ready for
wiring by the installer to the suitable 230V
ac supply.
• Polyphosphate scale inhibitor for tting on
site by the installer.
• Ballvalve/over ow connector for top up
cistern.
Figure 1.2
7
8
4
6
5
11
12
3
10
2
1
13
9
DESIGN
TECHNICAL DATA
Page 7
Note: The Appliance dimensions above do not
allow for the100mm high installation base.
The following table of minimum cupboard
dimensions only allow the minimum space
required for the appliance (including the F & E
cistern). Any extra space required for shelving
etc in the case of airing cupboards etc must
be added.
Note: The above dimensions are based on the
Appliance and the Top up cistern ( tted with a
ballvalve) being in the same cupboard. If the
manual ll method is chosen the heights can
be reduced by 125mm.
If pipework needs to rise vertically adjacent
to the appliance the width/depth will need
increasing to accommodate this.
Appliance Dimensions
Model
HeightAWidthBDepth
C
BMCP120 1075 530 595
BMCP150 1145 560 630
BMCP180 1275 560 630
BMCP220 1575 560 630
Minimum Cupboard Dimensions
Model
HeightDWidthEDepth
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
cistern
300 *350A10 0
D
F
Maintenance
access
Figure 1.3
280
420
*Min maintenance
access to comply with
the Water Regulations
(ballvalve model only)
The minimum
clear opening in
front of the
appliance to be
at least the
same depth as
the appliance.
The cupboard door
opening will need
to take into
account the various
sizes of appliances.
DESIGN
TECHNICAL DATA
Page 8
Plan Of Appliance Connections
The BoilerMate CP units are supplied on an
installation base to allow the pipe runs to
connect to the appliance from any direction.
It is easier if all pipes protrude vertically in the
cut out area shown. Compression or push t
connections can be used. All pipe positions
are approximate and subject to a tolerance of
+/- 10mm in any direction. Space will also be
required for a 22mm cold water supply and a
22mm warning / over ow pipe (if the optional
extra ball valve and over ow 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 the Top up Cistern.
The temporary connection must be removed
once the appliance is lled.
Note: All dimensions are shown in mm and
are to the centre line of the pipework.
DESIGN
TECHNICAL DATA
Connection Details/Dimensions For Top Of Unit
Figure 1.4
95
148
156
103
Open Vent (22mm)
Cold Feed (22mm)
Connection Details/Dimensions For Bottom Of Unit
Mains Cold Water Inlet (15mm/22mm)
Hot Water Outlet (18mm/22mm)
70
35
546
558
Page 9
Hot and Cold Water System
General
A schematic layout of the hot and cold water services in a typical small dwelling is
shown below. BoilerMate CP will operate at mains pressures as low as 1 bar and as
high as 5 bar although the recommended range is 2-3 bar dynamic at the appliance.
It is also important to check that all other equipment and components in the hot
and cold water system are capable of accepting the mains pressure available to the
property. If the mains pressure can rise above 5 bar or the maximum working pressure
of any item of equipment or component to be tted in the system, a pressure limiting
(reducing) valve set to 3 bar will be required.
If you encounter a situation where the water pressure is adequate but ow rates are
poor please contact our technical helpline for details of an e ective solution.
Note : Each BoilerMate CP is tted with a strainer and ow regulator on the cold mains
supply connection. If the supply pressure is less than 2 bar or if all taps are provided
with ow regulators the ow regulator on the cold inlet should be removed.
No check valve or similar device should be tted on the cold water supply branch to
the BoilerMate CP.
The hot water ow rate from the BoilerMate CP is directly related to the adequacy of the
cold water supply to the dwelling. This must be capable of providing for those services,
which could be required to be supplied simultaneously, and this maximum demand
should be calculated using procedures de ned in BS EN 806:1-5: BS EN 8558:2011.
If a water meter is tted 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 note, the BoilerMate CP is tted with a 15 l/m
ow restrictor.
Warning/
overflow
pipe
MCWS
Safety/open vent
Shower
Expansion/
cold feed
Second
dwelling
Pressure limiting valve
NOT REQUIRED at
pressures below 5 bar
unless any components
have a lower
maximum working
pressure
Double check valve
NOT REQUIRED unless
pipe supplies more
than one dwelling
‘a’ - flow regulator recommended for
better balance of hot and cold
water supplies
MCWS
supply
pipe
Sink
H C
a a
SV
a a a a
Bath
H C
Hand basin
H C
WC - fitted
with BS1212
ballvalve
C
Figure 1.5
Typical hot and cold water distribution
BOILERMATE CP
Check valve
NOT REQUIRED unless
chemical water
treatment unit is fitted
a
Top up cistern
DESIGN
TECHNICAL DATA
Note: The diagram below shows the top up
cistern with ballvalve and warning/over ow
pipe which can be supplied as an optional extra
if required. However, the standard preferred
arrangement is for the cistern to be manually
lled from a temporary hose connection tted
with a double check valve.
The cistern must not be tted more than 10
metres above the BoilerMate CP appliance itself.
Page 10
Hot and Cold Water System
Pipe Sizing / Materials
To achieve even distribution of the available supply of hot and cold water, it is
important in any mains pressure system, that the piping in a dwelling should be sized
in accordance with BS EN 806:1-5: BS EN 8558:2011. This is particularly important in
a large property with more than one bathroom.
However, the following rule of thumb guide lines should be adequate for most smaller
property types as long as water pressures are within the recommended range.
1. A 15mm copper or equivalent external service may be su cient for a small 1
bathroom dwelling (depending upon the ow rate available), but the minimum
recommended size for new dwellings is 22mm (25mm MDPE).
2. The internal cold feed from the main incoming stop tap to the BoilerMate CP should
be run in 22mm pipe. The cold main and hot draw-o should also be run in 22mm
as far as the branch to the bath tap.
3. The nal branches to the hand basins and sinks should be in 10mm and to the
baths and showers in 15mm (1 metre minimum).
4. We would recommend that best results for a balanced system are achieved
by tting appropriate ow regulators to each hot and cold outlet. This is
particularly relevant where the water pressures are above the recommended
water pressure range. Details of suitable ow regulators are provided in
Appendix A.
All the recommendations with regard to pipework systems in this manual are generally
based on the use of BS/EN Standard copper pipework and ttings.
However, we are happy that plastic pipework systems can be 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 relation to use of push t connections when using the
optional exible hose kits - see installation section of this manual.
It is also essential that if an alternative pipework material/system is chosen the
manufacturer con rms that the design criteria of the new system is at least equivalent
to the use of BS/EN Standard copper pipework and ttings.
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
dynamic changes particularly when other hot and cold taps/showers are opened
and closed, which will cause changes in the water temperature at mixed water
outlets such as showers. For this reason and because these are now no more
expensive than a manual shower we strongly recommend the use of thermostatic
showers with this appliance.
The shower head provided must also be suitable for mains pressure supplies.
However, if it is proposed to use a ‘whole body’ or similar shower with a number of
high ow/pressure outlets please discuss with the Gledhill technical department.
The hot water supply to a shower-mixing valve should be fed wherever practical
directly from the BoilerMate CP or be the rst draw-o point on the hot circuit. The
cold supply to a shower-mixing valve should wherever practical be fed directly from
the rising mains via an independent branch. The shower must incorporate or be
tted with the necessary check valves to provide
back-syphonage protection in accordance with
the Water Regulations.
The supply of hot and cold mains water directly
to a bidet is permitted provided that it is of the
over-rim ushing type and that a type ‘A’ air gap
is incorporated.
Hot and Cold Water System
If the length of the hot water draw o pipework
is excessive and the delivery time will be more
than 60 seconds before hot water is available at
the tap, you may wish to consider using trace
heating to the hot water pipework such as the
Raychem HWAT system. Please consult Gledhill
Technical Department for further details.
Note: A conventional pumped secondary
circulation system is NOT suitable for use with
this appliance.
It is important that the cold water pipework
is adequately separated/protected from any
heating/hot water pipework to ensure that
the water remains cold and of drinking water
quality.
DESIGN
TECHNICAL DATA
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