gledhill BM125 User guide

DESIGN, INSTALLATION AND
SERVICING INSTRUCTIONS
TEL: [phone]
www.gledhill-boilermate.co.uk
AN OPEN VENTED CENTRAL HEATING
AND MAINS PRESSURE 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
CONTENTS
Section Page
1.0 DESIGN
1.1 Introduction 3
1.2 Technical Data 5
1.3 System Details 10
2.0 INSTALLATION
2.1 Site Requirements 18
2.2 Installation 19
2.3 Commissioning 27
3.0 SERVICING
3.1 Annual Servicing 31
3.2 Changing Components 31
3.3 Short Parts List 32
3.4 Fault Finding 34
Appendix A 36
Appendix B 37
Appendix C 40
Appendix D 41
Appendix E 42
Terms & Conditions
The Gledhill BoilerMate range is a WBS
listed product and complies with theWMA
Specificationforintegratedthermal storage
products. The principle was developed in
conjunction with British Gas. This product
is manufactured under an ISO 9001:2000
Quality System audited by BSI.
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.
Pleaseread carefully andcomplete all sectionsrelevanttothe applianceinstallation.
The details of the Log Book will be required in the event of any warranty work being
required. There is also a section to be completed after 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

Page 3
BOILERMATE 2000
1.0 DESIGN
1.1 INTRODUCTION
These instructions should be read in
conjunctionwith theInstallationand Servicing
Instructions issued by the manufacturers of
the heat source e.g.the boiler used.
Any water distribution and central heating
installation must comply with the relevant
recommendations of the current version of
the Regulations and British Standards listed
below:-
Gas Safety Regulations
Building Regulations
I.E.E.Requirements for ElectricalInstallations
Water Regulations
British Standards
BS6798, BS5449, BS5546, BS5440:1, BS5440:2,
CP331:3,BS6700,BS5258,BS7593 and BS7671.
A competent person as stated in the Gas
SafetyRegulationsmust install theBoilerMate
heating system. The manufacturer’s notes
must not be taken as overriding statutory
obligations.
The BoilerMate 2000 is only suitable for use
with an open vented central heating system.
TheBoilerMate2000 is notcoveredbysection
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
remainthatofthecustomerandanyDesigners
orConsultantsconcernedwiththedesignand
installation.
Please Note: We do not therefore accept any
responsibility for matters of design,selection
or specification or for the effectiveness of an
installation containing one of our products
unless we have been specifically 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 range, Gledhill Water Storage
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
TheBoilerMate2000shownschematicallyaboveisdesignedtoprovideimprovedspace
heatingandmainspressurehotwaterwhencoupledtoanyremotelysitedcondensing
or non condensing boiler - as long as they comply with the recommendations
contained in the rest of this manual.
A report by the Cranfield Institute of Technology found that this system gives a
potential for energy savings of up to 15%.
Because of the efficiency of the appliance improved SAP ratings can be achieved.
Further details are available from the GledhillTechnical Department.
The principle of a BoilerMate 2000 is to separate the heat generator e.g. a boiler
from heat emitters (radiators) by a thermal store,which evens out the fluctuating
demands for heating and hot water. Thus, by storing energy produced when the
demand is low and discharging it when the demand is high (i.e. during property
warm up or when hot water is drawn off),a smaller boiler can potentially be used.
An important feature of this concept is that hot water can be supplied directly from
themains atconventionalflowrateswithout theneedfortemperature andpressure
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 board, which controls the speed of
the pump circulating the primary water from the store through the plate heat
exchanger.
To comply with the Benchmark Guidance Note forWaterTreatment in heating and
hotwatersystemstheinstallershouldcheck the hardness levelsof 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
Ifscaleshouldeverbecomeaproblemtheplate
heat exchanger is easily isolated and quickly
replaced with a service exchange unit which
canbeobtainedatanominalcostfromGledhill.
For further details see Section 1 Hot and Cold
Water System page 10.
Thepcbalsoincorporatesthefacilitytooperate
theheatingpumpforafewsecondseveryfew
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.
Anyautomaticboilerdesignedtooperateonan
820Cflowanda710Creturnuptoa maximum
of35kWcanbelinkedtoanysuitablemodelof
BoilerMate2000and the decidingfactor is the
spaceheatingandthehotwaterrequirements
ofadwelling. SeeSection1.2TechnicalDatafor
further details.
The BoilerMate 2000 is available with the
option of ‘Switch’ which will provide a 9kW
electrical emergency backup in case of failure
ofthemainheatsource. Seesection1.3System
Remote
F&E tank
Full bore automatic bypass valve NOT REQUIRED
unless the heating system incorporates
mechanical thermostatic control valves e.g.
T.R.V's to all radiators or 2 port zone valves.
Primary flow
Primary
return
BM
2000
Boiler
Warning/overflow
pipe
Cold feed
Mains cold
water
OpenVent

Page 5
BOILERMATE 2000
1.2TECHNICAL DATA
Notes:-
1. The BoilerMate 225 appliance is suitable for use in large properties because it produces the same‘peak hour output’as a typical
350-400 litre unvented cylinder. [Ask for report - Unvented v’s IntegratedThermal Storage]. [Please note that this model requires
a larger cupboard and a 686mm wide door]. For properties requiring the BM 225 the incoming main should be 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 many cases, properties of this size will benefit from having 2 smaller sized appliances located adjacent to the areas of
peak hot water use. This will allow 2 heating zones to be provided and remove the need to provide a secondary circulation
on the hot water system.
2. Plastic feed and expansion cistern will be supplied separately including ballvalve,float and overflow fitting.
3. The flow rates are based on a 35°C temperature rise and assume normal pressure and adequate flow to the appliance. The actual
flow rate from the appliance is automatically regulated to a maximum of 28 litres/min.
4. Models will be available in Hard and Soft water versions (suffixed‘H’or‘S’).
5. Unit is supplied on a 100mm high installation base.
6. Thedomestichotwateroutlettemperatureisautomaticallyregulatedtoapproximately55°C atthebathflowrateof18litres/min
recommended by BS 6700. The temperature is not user adjustable.
1.0 DESIGN
ledoM 521MB 541MB 581MB 012MB 522MB
)ytpme(thgieWgk85gk16gk56gk67gk88
)lluf(thgieWgk371gk681gk512gk642gk872
pmuPWHD05/51sofdnurG05/51sofdnurG05/51sofdnurG05/51sofdnurG05/51sofdnurG
pmuPgnitaeH05/51sofdnurG05/51sofdnurG05/51sofdnurG06/51sofdnurG06/51sofdnurG
pmuPrelioB05/51sofdnurG05/51sofdnurG05/51sofdnurG06/51sofdnurG06/51sofdnurG
epipgnitaeh/yramirP snoitcennoc mm22mm22mm22mm82mm82
epipWHD&WCM snoitcennoc mm22mm22mm22mm22mm22
noisnapxe/deefdloC noitcennoc mm51mm51mm51mm51mm51
tnevnepoytefaS noitcennoc mm22mm22mm22mm22mm22
rof(nruteryramirP moorhtabesuremmus )liarlewot mm51mm51mm51mm51mm51
noitcennoCniarD''½R''½R''½R''½R''½R
daeHmumixaMsretem01sretem01sretem01sretem01sretem01
etarwolfretawtoHnim/stl53otpunim/stl53otpunim/stl53otpunim/stl53otpunim/stl53otpu
ezisreliobxaMk51W k02W k52W k03W k53W
'hctiwS'Wk9Wk9Wk9Wk9Wk9
sepytgnillewDlacipyT
smoordeB3-13-24-25-36-4
smoorhtaB11212234
rewohsetius-nE12142420

Page 6
1.2TECHNICAL DATA
Standard Equipment
The standard configuration of the BoilerMate
2000isshownopposite.TheApplianceControl
Board (A.C.B.),mounted inside the appliance,
controlstheoperationofthecompletesystem.
The A.C.B. is pre-wired to a terminal strip
where all electrical connections terminate. It
is supplied with the following factory fitted
equipment:-
1. Boiler pump
2. Domestic hot water primary
(plate heat exchanger) pump
3. Space heating pump
4. Hard water appliance control board
(A.C.B.)
5. Electro-mechanical clock to control the
space heating (in conjunction with room
thermostat - if fitted)
6. Plate heat exchanger
7. DHWS temperature sensor
8. PHE return sensor
9. Store temperature sensor
10. Y type strainer/flow regulator
11. A feed and expansion cistern
completewithballvalve,overflow
fittingandcoldfeed/openventpipework
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
for heating and hot water in the event
of a boiler fault.
* A seven day digital clock/programmer
to control the space heating (in
conjunction with a room thermostat if
fitted).
* A kit to site the clock/programmer
remotely.
* A no clock option - because of the
design of the appliance it should not be
necessary to fit anything other than a
single channel clock to control the
heating system.
* Hotandcoldwatermanifoldsforusewith
plastic pipework.
1.0 DESIGN
Appliance Control Board
A.C.B.
Electro-mechanical clock
programmer
Digital clock programmer ‘Switch’

Page 7
BOILERMATE 2000
B
D
600mm min clear opening - if
located directly in front of the
appliance. Maintenance
access
Min maintenance
access to comply with
theWater Regulations
CUPBOARD
E
C
300mm
420mm
280mm
600mm 100mm
*350mm
F
A
F & E Cistern
F & E Cistern
plan
1.0 DESIGN
1.2TECHNICAL DATA
Note: The Appliance dimensions above do not allow for
the100mm high installation base
The following table of minimum cupboard dimensions only
allowtheminimumspacerequiredfortheappliance(including
the F & E cistern) and any extra space required for shelving etc
in the case of airing cupboards etc must be added.
SNOISNEMIDECNAILPPA
ledoM thgieH htdiW htpeD
ABC
521MBmm0411mm595mm595
541MBmm0411mm595mm595
581MBmm0531mm595mm595
012MBmm0051mm595mm595
522MBmm0551mm056mm595
SNOISNEMIDDRAOBPUCMUMINIM
ledoM thgieH htdiW htpeD
FDE
521MBmm0981mm007mm006
541MBmm0981mm007mm006
581MBmm0012mm007mm006
012MBmm0522mm007mm006
522MBmm0032mm057mm006
Note: The above dimensions are based on the Appliance and
the F & E cistern being in the same cupboard.
The BM 225 is wider than the other sizes and requires
a minimum 686mm wide door and a 750mm wide
cupboard.

Page 8
1.0 DESIGN
1.2 TECHNICAL DATA
Cut out area through
base of unit - showing
recommended pipework
riserpositions.
120
408
595 (650)
595
555
REAR
PLAN
475
455
Safety/OpenVent Cold feed/Expansion
REMOVABLE FRONT ACCESS PANEL
325
405 450
(490)
365
(390)
295
(325)
230
(245)
195
(230)
130
(155)
55
(70)
TOP
BoilerFlow
BoilerReturn
HeatingReturn
Primary Return
Summer use bathroom circuit
Heating Flow
HotSupply
Cold Mains Supply
Suggestedlocation for 15mm
coldmains feed tothe 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 subject to a tolerance of
+/- 20mm in any direction.A 15mm cold water supply and a 22mm
warning / overflow pipe will also be required for the separate feed and
expansion tank.
Dimensions in brackets apply to the 225 model only
45
70

Page 9
BOILERMATE 2000
1.2 TECHNICAL DATA
AWAITING HOTWATER 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
1.3 SYSTEM DETAILS
Hot and ColdWater System
General
A schematic layout of the hot and cold water services in a typical small dwelling is
shownbelow. BoilerMate2000willoperateat mains pressuresaslowas1barandas
highas5baralthoughtherecommendedrangeis2-3bar. Ifthemanifolds(availableas
anoptionalextra)arebeingusedtheinletpressuretothemanifoldmustbeaminimum
of 2 bar. It is also important to check that all other equipment and components in
thehotandcoldwatersystem arecapable of acceptingthemains pressureavailable
tothe property. Ifthe mains pressurecan rise above5bar or the maximumworking
pressureofanyitemofequipmentorcomponenttobefittedinthesystemapressure
limiting (reducing) valve set to 3 bar will be required.
Ifyouencountera situation wherethewaterpressureis adequatebutflowratesare
poor please contact our technical helpline for details of an effective solution.
Note: Each BoilerMate 2000 is fitted with a strainer and flow regulator on the cold
mainssupply connection. If the supply pressureis lessthan 2 bar or if the manifolds
(available as an optional extra) are being used or if all taps are provided with flow
regulators the flow 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 comply with the Benchmark Guidance Note forWaterTreatment in Heating and
HotWater Systems the installer should 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%$ATPRESSURES
BELOWBARUNLESSANY
COMPONENTSHAVEALOWER
MAXIMUMWORKING
PRESSURE
3ECOND
DWELLING
-#73
SUPPLYPIPE
3INK
/PENVENT
7ARNINGOVERFLOW
PIPE
#OLDFEED
EXPANSION
(AND
BASIN
7#FITTED
WITH"3
BALLVALVE
"ATH
"-
3CALEINHIBITOR
)&2%15)2%$
3HOWER
(
AA A
A
AA A
#(# (# #
36
#HECKVALVE./42%15)2%$UNLESS
CHEMICALWATERTREATMENTUNITISFITTED
gAgFLOWREGULATORRECOMMENDEDFORBETTER
BALANCEOFHOTANDCOLDWATERSUPPLIES
$OUBLECHECKVALVE./42%15)2%$UNLESSSUPPLY
PIPESERVICESMORETHANONEDWELLING
&%#ISTERN
#OLDMAINS
SUPPLY
When specifying this appliance we would
recommend that for hardness levels above
200ppm(mg/l) a hardwater appliance isused.
For hardness levels above 250ppm (mg/l) we
would recommend that some form of in-line
scaleinhibitor/reducerisrecommendedbyone
oftheWaterTreatmentcompanieslistedinthe
Benchmark Guidance Note (see Appendix C).”
The hot water flow rate from the BoilerMate
2000 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
shouldbecalculatedusingproceduresdefined
in BS 6700.
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 6700. This
could be up to 80ltr/min in some properties.

Page 11
BOILERMATE 2000
1.3 SYSTEM DETAILS
Hot and ColdWater 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 6700. 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 of 2-3 bar.
1. A 15mm copper or equivalent external service may be sufficient for a
small 1bathroom dwelling (depending upon the flow 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
should be run in 22mm pipe. The cold main and hot draw-off should also
be run in 22mm as far as the branch to the bath tap.
3. The final 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 fitting appropriate flow regulators to each hot and cold outlet. This is
particularlyrelevantwherethewaterpressuresareabovetherecommended
water pressure range of 2-3 bar. Details of suitable flow regulators are
provided in Appendix A.
Note: Ifmanifolds(availableas an optional extra) are being used suitable flow
regulators are automatically provided in the manifold and do not need to be
provided at each outlet - See Appendix B for further details.
All the recommendations with regard to pipework systems in this manual are
generally based on the use of BS/EN Standard copper pipework and fittings.
However,wearehappythatplasticpipeworksystemscanbeusedinplaceofcopper
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 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 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
dynamicchangesparticularlywhenotherhotandcoldtaps/showersareopened
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
expensivethanamanualshowerwestronglyrecommendtheuseofthermostatic
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 flow/pressure outlets please discuss with the Gledhill technical department.
1.0 DESIGN
Thehotwatersupplytoashower-mixingvalve
shouldbefedwhereverpracticaldirectly from
the BoilerMate 2000 or be the first draw-off
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 fitted with the necessary
check valves to provide back-syphonage
protection in accordance with the Water
Regulations.
Thesupplyofhotandcoldmainswaterdirectly
toabidetispermittedprovidedthatitisofthe
over-rim flushing type and that a type ‘A’air
gap is incorporated.
Hot and ColdWater System.
Ifthelengthofthehotwaterdrawoffpipework
isexcessiveand the deliverytime will bemore
than 60 seconds before hot water is available
atthetap,youmaywishtoconsiderusingtrace
heatingtothe hot waterpipeworksuchas the
RaychemHWATsystem. PleaseconsultGledhill
Technical Department for further details.
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.

Page 12
1.0 DESIGN
Heating System
General
A schematic layout of the heating system in a
typical small dwelling is shown opposite.
The flow and return from the boiler must
always run directly to the BoilerMate 2000
and the flow should rise continuously to
facilitate venting. The heating circuit is taken
from the BoilerMate 2000 and is piped in the
conventional manner.
The BoilerMate 2000 is only suitable for an
open vented system.
The F & E cistern can be fitted remotely up to
10m above the base of the BoilerMate 2000
i.e. the maximum static pressure in the store
must not exceed 1 bar.
If any radiators are located above the level
of the BoilerMate 2000 the system should
be designed so that gravity circulation does
not occur when the heating pump is not
running. To be certain of preventing this it is
recommendedthatacheckvalve,orvalves,are
fitted on the vertical flowpipes.
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 headroom is restricted
(e.g.in a flat).
Range rated boilers can be used but should
always be set at the highest output. The
system efficiency will not be impaired while
the recovery rate will be improved.
It is not necessary to provide a boiler bypass
on the primary circuit with thermal storage
appliances (i.e. between the boiler and the
thermal store.)
Remote
F&E tank
Full bore automatic bypass valve NOT REQUIRED
unless the heating system incorporates
mechanical thermostatic control valves e.g.
T.R.V's to all radiators or 2 port zone valves.
Primary flow
Primary
return
BM
2000
Boiler
Warning/overflow
pipe
Cold feed
Mains cold
water
OpenVent

Page 13
BOILERMATE 2000
1.0 DESIGN
1.3 SYSTEM DETAILS
Pipe Sizing/Materials
The primary pipework connecting the boiler and the thermal store should be sized
to achieve a maximum of 8°C rise across the boiler or the maximum temperature
rise specified by the boiler manufacturer,whichever is smaller,but in any instance it
should not be less than 22mm copper tube.
Note: There should be no valves in the pipework connecting the boiler to the
BoilerMate 2000.
The heating circuit operates on the normal primary boiler temperatures i.e. 82°C
flow and 71°C return. Therefore any traditional hot water radiators or convectors
can be used with this system and no special over-sizing of the heat emitters is
necessary.
All the recommendations with regard to pipework systems in this manual are
generally based on the use of BS/EN Standard copper pipework and fittings.
However, we are happy that plastic pipework systems can be used in place of
copperinternallyaslongasthechosensystemisrecommendedforuseondomestic
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
Itisalsoessentialthatifanalternativepipework
material/system is chosen the manufacturer
confirms that the design criteria of the new
systemisatleastequivalenttotheuseofBS/EN
Standard copper pipework and fittings.
Boiler Size
It is only necessary to calculate the heating
requirements in accordance with BS 5449. The
allowances shown below should be added
for domestic hot water. The control system
automatically gives priority to hot water when
necessary.
Boiler Sited Below BoilerMate 2000
Any boiler can be used when the flow pipe
from the boiler to the BoilerMate 2000 rises
continuously. No valve shall be fitted in the
primary flow or open vent.
toHcitsemoDrofecnawollA retaW
ledoM)Wk(
521MB2
541MB3
581MB3
012MB5.3
522MB4

Page 14
1.0 DESIGN
1.3 SYSTEM DETAILS
Anyboilerusedmustbefittedwithanoverheat
thermostat i.e. it must be suitable for use in
a sealed system.
The F & E cistern must be fitted at a height
whichwillprovidetheminimumheadrequired
for the boiler and must be at least 250mm
above the highest point of the system.
TheheightofthewaterlevelintheF&Ecistern
fromthebaseofthestoreshouldbenogreater
than 10m.
A gravity check valve should be fitted in the
boiler return pipework to prevent gravity
circulation between the BoilerMate 2000 and
the boiler during dormant periods.
An automatic air vent will be required on the
flow adjacent to the 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.
TheheightofthewaterlevelintheF&Ecistern
must provide the minimum head required by
the boiler and must be at least 250mm higher
than the highest point of the system.
Boiler sited above the BoilerMate
Heating System
&%#ISTERN
&%#ISTERN
0RIMARYFLOW
0RIMARYFLOW
0RIMARYRETURN
0RIMARYRETURN
"OILER
"OILER
!6
#6
!6!UTOMATICAIRVENT
#6'RAVITYCHECKVALVE
&%#ISTERN
&%#ISTERN
0RIMARYFLOW
0RIMARYFLOW
0RIMARYRETURN
0RIMARYRETURN
"OILER
"OILER
!6 !6
!6!UTOMATICAIRVENT

Page 15
BOILERMATE 2000
1.0 DESIGN
1.3 SYSTEM DETAILS
Connection of Bathroom Radiator/
Towel-Rail for Summer use
Ifapumpedcircuitisrequiredforthebathroom
radiator/towel rail, the flow pipework can be
teedanywhereinto the primary flowbetween
the boiler and the BoilerMate. The return
pipework can be connected into the 15mm
copperblankedconnectionprovidedadjacent
to the boiler pump. We recommend any
radiators/towelrailsonthiscircuitareprovided
with T.R.V.’s and that the total heat output of
the radiators/towel rails is not more than 5%
of the boiler output.
The radiators will only get hot when the
boiler is firing.
Itisimportantthattheflowratesthroughthese
radiatorsisadjusted to the minimum required
atthelockshieldvalveson theradiators. Ifthis
isnotdonetheperformanceoftheBoilerMate
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
radiatorcanbefittedwithaT.R.V.ifrequiredas
longasthisissuitableforgravitycirculationi.e.
low resistance type.
Heating System
TheheightofthewaterlevelintheF&Ecistern
must provide the minimum head required by
the boiler and must be at least 250mm higher
than the highest point of the system.
TheheightofthewaterlevelintheF&Ecistern
must provide the minimum head required by
the boiler and must be at least 250mm higher
than the highest point of the system.
F & E Cistern
BM 2000
Boiler
Radiator
F & E Cistern
BM 2000
D.V.
D.V.:Drain valve

Page 16
1.3 SYSTEM DETAILS
Heating System
Method of connecting two BoilerMates to one heat source.
If the primary flow and return pipework continuously rises from the boiler to the
BoilerMatethe recommendedmethod for connecting two BoilerMatesto oneheat
source is to fit the BoilerMates as normal but to provide a single check valve on the
branch immediately after each primary pump.
Theheatingandhotwaterfromeachappliancemustserveseparatezones/bathrooms
withintheproperty.
The electrical supplies from each appliance to the boiler will need twinning so that
the boiler will operate on a call from either/both appliances.
Both primary pumps and the primary pipework sizes should be checked to ensure
that they are adequate for the 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,
Gledhillwillthensupplyasuitableventassemblyforfittingonthesafety/openvent
connection and a blank for the cold feed connection of each BoilerMate 2000, in
lieu of the F & E cistern normally 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 BoilerMate
appliance.
The single F & E cistern will need to be provided,(by the installer) and be suitable
for the size of the total system installed.
For further details please ring the Gledhill Technical helpline.
1.0 DESIGN

Page 17
BOILERMATE 2000
1.3 SYSTEM DETAILS
‘Switch’
The BoilerMate 2000 can be ordered with
the option of ‘Switch’ which provides a 9kW
electrical emergency back up in the case of
failure of the main heat source i.e.gas boiler.
This must NOT be used to provide hot
water only in summer if the main system is
working correctly.
If Switch is ordered the electrical supply will
need to take account of the increased load.
Full details of the requirements are provided
in Section 2.1 Site Requirements and 2.2
Installation.
Otherwise the design requirements are the
same as the standard appliance.
Switchcanoperateon‘hotwater’or‘hotwater
and 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
manuallyswitchedbacktothe‘hotwater’only
position.
It also means that wherever Switch is
being used the normal domestic hot water
temperaturecontrols are over-ridden. Initially
dependent on the flowrate/store temperature
hot water can be delivered at the tap at
temperatures as high as 75°C. A warning
notice to this effect is provided in the front
of the appliance.
However,oncetheinitialstoretemperaturehas
been reduced the Switch element thermostat
will reduce the temperature at the tap to no
morethan65°C. Fulldetailsof how to operate
thesystemareprovidedonalabelfixedtothe
front of the appliance.
1.0 DESIGN

Page 18
Electrical Supply requirements for BoilerMate2000 with Switch
2.0 INSTALLATION
2.1 SITE REQUIREMENTS
The appliance is designed to be installed in an airing/cylinder cupboard and the
relevant minimum dimensions are provided in section 1.2Technical Data.
Because of the ease of installation we recommend that the cupboard construction
is completed and painted before installation of the appliance. The cupboard door
can be fitted after installation.
If the unit needs to be stored prior to installation it should be stored upright in a
dry environment and on a level base/floor.
Installationandmaintenanceaccessisneeded to the front of the appliance and
abovethe F & E cistern. SeeTechnical Data section for further details.
The minimum dimensions contained in section 1.2 Technical Data allow for the
passage/connection of pipes to the appliance from any direction as long as the
appliance is installed on the installation base provided. If the installation base is
not used extra space may be needed to allow connection to the pipework and the
whole of the base area should be continuously supported on a material which will
not easily deteriorate if exposed to moisture.
The floor of the cupboard needs to be level and even and capable of supporting
the weight of the appliance when full. Details of the weight when full is provided
in section 1.2 Technical Data.
Theapplianceisdesignedtooperateasquietlyaspracticable. However,somenoise
(from pumps etc) is inevitable in any heating system. This will be most noticeable
in cupboards formed on bulkheads,or atthe mid spanof a suspendedfloor. In these
cases the situation can be improved 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 high level in the cupboard housing the BoilerMate 2000. The
dimensions and clearances are provided in section 1.2 Technical Data. The location
will need to provide a suitable route for the cold feed and expansion pipe as well
as the open safety vent pipe. The location will also need to provide a suitable
route and discharge position for the warning/overflow pipe and the ballvalvesupply
fromthemainscoldwatersystem.
An electrical supply must be available which is
correctly earthed,polarized and in accordance
with the latest edition of the IEE requirements
forelectricalInstallationsBS7671.
The electrical mains supply needs to be
230V/50Hz.
Connectionmustbemadeusingadouble-pole
linked isolator with a contact separation of
3mm in both poles which is located within 1m
of the appliance. The supply must only serve
the appliance.
The supply to the standard appliance shall be
fused at 3 amp.
If the ‘Switch’ electrical emergency backup
is being provided, the minimum breaking
capacity of the main isolation switch and
cable sizes/lengths at 230V shall follow the
recommendations in the table below.
Nominal
full load
current
Min rating of
isolating
switch Cable size
Max.recommended
cable run-based on
9.2V drop and 0.4
second disconnection
time using a type
1 or B breaker
41.0 Amps 45 Amps 10 mm249 metres
Recommended circuit
protection device - based on
0.4 second disconnection
time
45 A type 1 - MCB to BS 3871
45A type B circuit breaker to BS EN
60898

Page 19
BOILERMATE 2000
2.2 INSTALLATION
2.0INSTALLATION
HANDLING
When lifting the unit work with someone of similar build
and height if possible.
Choose one person to call the signals.
Lift from the hips at the same time,then raise the unit to
the desired level.
Move smoothly in unison.
Preparation/placing the appliance in
position.
Details of the recommended positions for
termination of the first fix pipework are
provided in section 1.2 Technical Data. The
pipework can be located or its position
checked using the template provided with
each appliance. If these have been followed
installation is very simple and much quicker
than any other system.
Theapplianceissuppliedshrinkwrappedona
timber installation base. Carrying handles are
also provided in the back of the casing.
Thefeedandexpansioncisterncompletewith
ballvalve, cold feed/expansion and overflow/
warning fittings are provided in a separate
box.Ifflexibleconnections havebeen ordered
thesewillalsobeinsidethefeedandexpansion
cistern.
The appliance should be handled carefully to
avoiddamageandtherecommendedmethod
is shown opposite. Before installation the
site requirements should be checked and
confirmedasacceptable.Theplasticcoverand
protectivewrappingshould beremovedfrom
the appliance the installation base (provided)
placedinposition.
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 of the pipework and electrical
supplies. The feed and expansion cistern
support shall be installed ensuring that the
base is fully supported and the working
head of the appliance is not exceeded and
the recommended access is provided for
maintenance- see section1.2Technical Data.
Note:Althoughtheaboveguidanceisprovided
any manual handling/lifting operations will
need to comply with the requirements of
the Manual Handling Operations Regulations
issued by the H.S.E.
Theappliancecanbemovedusingasacktruck
ontherearfacealthoughcareshouldbetaken
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.
A specific manual handling assessment is shown in Appendix D
at the rear of this manual.

Page 20
The position of the pipework connections is
shown opposite.The connection sizes and
dimensions are listed in Section 1.2 Technical
Data.
All the connections are also labelled on the
appliance. It is essential that the pipework is
connected to the correct connection.
The connections can be hard piped but we
recommend the use of flexible connections
(available as an optional extra).
If using push fit connectors with the flexible
hose kits it is important to check that they
are compatible. Written approval has already
been obtained for:-
Hepworth - Hep2O BiTite
John Guest - Speedfit
Yorkshire -Tectite
However, as similar assurances cannot be
obtained for Polypipe fittings we cannot
recommend their use.
Connections A, B, C, F and H are plain ended
copper pipe.
Connections D, G and I are compression
fittings.
Connection E is blanked 15mm copper pipe
Connection J is RC½ (½ 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 connections
Note: The safety open vent and cold feed/
expansion should be connected to the
F & E cistern using the pipework assembly
provided.
All factory made joints should be checked
after installation in case they have been
loosened during transit.
The fittings for the feed and expansion cistern
should be installed following the instructions
provided by the manufacturer in a position
to suit the particular location and the cistern
fitted on its supports/base.
Thecoldfeed/expansionand safety openvent
shouldbeinstalledbetweentheapplianceand
the feed and expansion cistern.
AB
CDEFGHI J