gledhill BoilerMate BMBP 125 User guide

Design, Installation
& Servicing Instructions
Model Numbers
BoilerMate BMBP 125
BoilerMate BMBP 145
BoilerMate BMBP 185
BoilerMate BMBP 215
BoilerMate BMBP 225
All models comply with the HotWater Association
specification for thermal stores
For a sealed or an open vented
central heating and mains
pressure hot water supply system
incorporating a thermal store

Page 2
CONTENTS
Section Page
DESIGN
Introduction 3
Technical Data 4
System Details 10
INSTALLATION
Site Requirements 15
Installation 16
Commissioning 19
SERVICING
Annual Service 20
Changing Components 20
Short Parts List 21
Fault Finding 22
APPENDIX
Appendix A 23
Appendix B 24
Appendix C 25
Terms & Conditions 26
ISSUE 1:12-08
The Gledhill BoilerMate BP range is a WBS
listed product and complies with the HWA
Specificationforintegratedthermal 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’sfirstpriorityistogiveahighquality
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.
Building Regulations and Benchmark Commissioning
TheBuildingRegulations(England&Wales)requirethat the installation of aheating
appliance be notified to the relevant Local Authority Building Control Department.
From 1st April 2005 this can be achieved via a Competent Person Self Certification
Scheme as an option to notifying the Local Authority directly. Similar arrangements
will follow for Scotland and will apply in Northern Ireland from 1st January 06.
CORGI operates a Self Certification Scheme for gas heating appliances.
Thesearrangementsrepresentachangefromthesituationwherebycompliancewith
theBuildingRegulationswasacceptediftheBenchmarkLogbookwascompletedand
this was then left on site with the customer).
Withtheintroductionofaselfcertificationscheme,theBenchmarkLogbookisbeing
replacedbyasimilardocumentintheformofacommissioningchecklistandaservice
interval record is included with all gas appliance manuals. However, the relevant
Benchmark Logbook is still being included with all Thermal Storage products and
unvented cylinders.
Gledhill fully supports the Benchmark aims to improve the standards of installation
andcommissioningofcentralheatingsystemsintheUKandtoencouragetheregular
servicing of all central heating systems to ensure safety and efficiency.
Building Regulations require that the heating installation should comply with the
manufacturer’s instructions. It is therefore important that the commissioning check
listiscompletedbythecompetentinstaller.Thischecklistonlyappliestoinstallations
in dwellings or some related structures.

Page 3
INTRODUCTION
DESIGN
These instructions should be read in conjunction with the Installation and Servicing
Instructions issued by the manufacturers of the heat source e.g. the boiler used.
Anywaterdistributionandcentralheatinginstallationmustcomplywiththerelevant
recommendations of the current version of the Regulations and British Standards
listed below:-
Gas Safety Regulations
Building Regulations
I.E.E. Requirements for Electrical Installations
Water Regulations
British Standards
BS6798,BS5449, BS5546, BS5440:1, BS5440:2, CP331:3, BS6700, BS5258, BS7593 and
BS7671.
Asuitably competentperson as statedin theGasSafety Regulationsmust install the
BoilerMateandcarryoutanysubsequentmaintenance/repairs.Infact,thefrontpanel
is secured by 2 screws and should only be removed by a competent trades person.
The manufacturer’s notes must not be taken as overriding statutory obligations.
The BoilerMate BP is suitable for use with either a sealed primary or an open vented
central heating system.
The BoilerMate BP is not covered by section G3 of the current Building Regulations
and is therefore not notifiable to Building Control.
TheBoilerMateBPisnotintendedforusebypersons(includingchildren)withreduced
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 specification 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,
selectionor specification orforthe effectiveness ofaninstallation containing oneof
our products unless we have been specifically requested to do so.
Allgoodsaresold subject to our ConditionsofSaleand Warranty Terms, which
are set out at the rear of this manual.
In the interest of continuously improving the BoilerMate BP 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.
Description
The BoilerMate BP is an indirectly heated hot
wateronly thermalstore. Itis designedfor use
with a remote gas or oil boiler and is suitable
for both open vented and sealed heating
systems as long as they comply with the
recommendations of contained in the rest of
thismanual.Whenitisusedinasealedheating
system, the boiler should also be suitable for
the sealed heating systems.
An important feature of this concept is that
the hot water can be supplied directly from
the mains at high flow rates without the need
for temperature and pressure relief valves or
expansion vessels. This is achieved by passing
the mains water through the heat exchangers
insidethethermalstore.Theoutlettemperature
of the domestic hot water is regulated by a
thermostatic blending valve which is factory
set at 55±3°C .
Because the BoilerMateBP does not require
a safety discharge from a temperature and
pressure (T&P) valve, the installations in
buildings will be easier and will not suffer the
problems associated with using the PVCu soil
stacks to take discharge from the unvented
cylinders.
TheBoilerMateBPissuppliedasanF&Ecistern
and ball valve to be fitted by the installer.

Page 4
DESIGN
TECHNICAL DATA
Standard Equipment
ThestandardconfigurationoftheBoilerMateBP
is shown opposite and it is supplied with the
following factory fitted equipment: -
1 Thermostaticdhwblendingvalve–setat55°C
2 Miniexpansionvessel–chargepressure2.5bar
3 Store thermostat – set at 75°C
4 Feedand expansion cistern completewith
ball valve and float (not shown) – loose, to
be piped by the installer
Factory Fitted Optional Equipment
A1 Electronic scale prevention device
Supply Only Optional Equipment
Immersion heater
Pipe Connections
Thepositionofthepipeconnectionsisshownopposite
andtheconnection sizesarelisted intable1.
C1 Mains cold water inlet
C2 Hot water outlet
C3 Primary heat exchanger flow
C4 Primary heat exchanger return
C5 Open vent
C6 Cold feed
C7 Drain
C8 Immersion heater boss
All the connections are also labelled on the
appliance. It is essential that the pipework is
connected to the correct connection.
Note: The safety open vent and cold feed/
expansion must be connected to the F & E
cisternusingthepipeworkassemblyprovided.
Do not alter or connect any pressure-relief
devicetotheventpipeofthiswaterheater.
Allfactorymadejointsshouldbechecked after
installation in case they have been loosened
during transit.
The fittings for the feed and expansion cistern
should be installed in a position to suit the
particular location and the cistern fitted on its
supports/base.
Thecold feed/expansionand safety openvent
shouldbeinstalledbetweentheapplianceand
the feed and expansion cistern.
Figure 1
C2
C5 C6
1
C7
C1
C4
C3
3
C8
2

Page 5
TECHNICAL DATA
DESIGN
* Provisional figures only
Notes:-
1. Theflow ratesarebased on a 35°C temperatureriseandassume normal dynamic
pressure of 2.0 bar at the appliance.
2. Unit is supplied on a 100mm high installation base.
3. The domestic hot water outlet temperature is automatically regulated to
approximately 55°C.
Model BMBP 125 BMBP 145 BMBP 185 BMBP 215 BMBP 225
Nominal volume (l) 125 130 153 168 190
Weight (empty) (kg) 53 55 61 67 75
Weight (full) (kg) 183 185 214 235 265
Primary/heating pipe
connections 22mm 22mm 22mm 28mm 28mm
MCW & DHW pipe
connections 22mm 22mm 22mm 22mm 22mm
Cold feed/expansion
connection 15mm 15mm 15mm 15mm 22mm
Safety open vent
connection 22mm 22mm 22mm 22mm 22mm
Drain connection R ½” R ½” R ½” R ½” R ½”
Maximum Head
Thermal Store 6 meters 6 meters 6 meters 6 meters 6 meters
Maximum pressure
heating circuit 3 bar 3 bar 3 bar 3 bar 3 bar
Volume of primary
heat exchanger 4.9 litres 4.9 litres 5.5 litres 5.5 litres 6.1 litres
Primary heat exchanger
rating(kW)*15 17 25 25 30
Heat loss factor
(kWh/24h)*1.48 1.57 1.65 1.72 1.85
Hot water flow rate
(l/m) up to 18 18 18 22 22
Typical Dwelling Types
Bedrooms 1-3 2-3 2-4 3-5 4-6
Bathrooms 1 1 2 1 2 1 2
En-suite shower 1 2 1 4 2 4 3
Table 1

Page 6
DESIGN
TECHNICAL DATA
Appliance Dimensions
Model Height
(A) Width (B) Depth (C)
BMBP 125 1262 580 595
BMBP 145 1262 580 595
BMBP 185 1423 580 595
BMBP 215 1584 580 595
BMBP 225 1784 580 595
B
E
C
BoilerMate BP
Top up
cistern
Top up
cistern
300 *350A100
D
F
Maintenance
access
Figure 2
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.
Minimum Cupboard Dimensions
Model Height
(D) Width (E) Depth (F)
BMBP 125 2012 680 600
BMBP 145 2012 680 600
BMBP 185 2173 680 600
BMBP 215 2334 680 600
BMBP 225 2534 680 600
Note:TheAppliancedimensionsabovedonot
allow for the100mm high installation base.
The following table of minimum cupboard
dimensions only allow the minimum space
requiredfortheappliance(includingthetopup
cistern). Any extra space required for shelving
etc in the case of airing cupboards etc must
be added.
Note: Theabovedimensionsare basedon the
Applianceand theTop up cistern (fittedwith a
ballvalve) being in the same cupboard.
Ifthemanualfilloptionischosen,theheights
shown above can be reduced by 125mm.
If pipework needs to rise vertically adjacent
to the appliance the width/depth will need
increasing to accommodate this.

Page 7
TECHNICAL DATA
DESIGN
2
5
3
1
4
7
6
Figure 4
2
5
3
1
4
6
Figure 3
Example installation of a‘Y’plan system
1 Pump
2 Storethermostat
3 Bypass valve
4 Manual air vent
5 3-port mid position valve
6 Wiring centre
Note: All components to be supplied by the
installer.
Example installation of an‘S’plan system
1 Pump
2 Storethermostat
3 Bypass valve
4 Manual air vent
5 Central heating zone valve
6 Hot water zone valve
7 Wiring centre
Note: All components to be supplied by the
installer.

Page 8
DESIGN
TECHNICAL DATA
PLAN OF APPLIANCE CONNECTIONS
The BoilerMate BP 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. All pipe positions
are approximate and subject to a tolerance of
+/- 10mm in any direction. Space will also be
required for a 15mm cold water supply and a
22mm warning / overflowpipe.
Note: All dimensions are shown in mm and
are to the centre line of pipework.
Connection Details/Dimensions ForTop Of Unit
Figure 5
570 (595 including the door/clock)
580
58
117
370 - ColdFeed/Expansion
330 - OpenVent
Connection Details/Dimensions For Bottom Of Unit
570 (595 including the door/clock)
560
545
525
370 - MainsColdWaterInlet
485 - HotWaterOutlet
130
BoilerFlowandReturn

Page 9
TECHNICAL DATA
DESIGN
Pressure loss across the primary heat exchanger
Primary flow rate (l/s)
0.1 0.2 0.3 0.4 0.5 0.6 0.7 0.8
Pressure loss (mWG)
6
5
4
3
2
1
0
BMBP125, BMBP145 BMBP225 BMBP185, BMBP215
Figure 6
Pressure drop across the DHW heat exchanger
DHW flow rate (l/min)
51015202530
Pressure loss (bar)
4.0
3.5
3.0
2.5
2.0
1.5
1.0
0.5
0
BMBP125, BMBP145 BMBP185, BMBP215, BMBP225
Figure 7

Page 10
DESIGN
SYSTEM DETAILS
Hot and ColdWater System
General
A schematic layout of the hot and cold water services in a typical small dwelling is
shown below.BoilerMate BP will operate at mains pressures as low as 1 bar and as
high as 5 bar although the recommended range is 2-3 bar.These pressures are the
minimumdynamicpressuresatthecoldconnectiontotheBoilerMateBPatthetime
ofthemaximumcalculatedsimultaneousdemand.Particularconsiderationshouldalso
begiven toavailablepressures inthe case of 3 storeyproperties. It isalso important
tocheckthatallother equipmentandcomponentsin thehotandcoldwater 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 fitted in the system a pressure limiting (reducing)
valve set to 3 bar will be required.
Nocheck valveor similar device should be fittedonthe cold water supply branchto
the BoilerMate BP.
The Building Regulations L1A,L1B and the requirements set out in the Domestic
Heating Compliance Guide 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”.
Tocomplywiththisrequirementthehardnessofthemainswatershouldbecheckedby
theinstallerandifnecessarytheoptionalfactoryfittedin-linescaleinhibitorshouldbe
specified at the time of order for hardness levels between 200 and 300 ppm (mg/l).
Wherethewaterisveryhardie300ppm(mg/l)andabovethe optionalpolyphosphate
type,inhibitor shouldbespecified at the time oforder. However,this willneed to be
fitted by the installer at a suitable point in the
cold water supply to the appliance.
If scale should ever become a problem the
BoilerMateBPheatexchangercanbedescaled
insitue.ContacttheTechnicalHelplineformore
details.
The hot water flow rate from the BoilerMate
BP 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.
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 8
Typical hot and cold water distribution
BOILERMATE BP
Check valve
NOT REQUIRED unless
chemical water
treatment unit is fitted
a
Top up cistern

Page 11
SYSTEM DETAILS
DESIGN
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 6700. This is particularly important in a large property
with more than one bathroom.
However,thefollowingruleofthumbguidelinesshouldbeadequateformostsmaller
propertytypes as longas water pressuresare within therecommended range of2-3
bar.
1. A 15mm copper or equivalent external service may be sufficient for a small
1bathroomdwelling(dependingupontheflowrateavailable),buttheminimum
recommendedsizefornewdwellingsis22mm(25mmMDPE). FortheBMBP225
model we recommend a 28mm (32mm MDPE) supply pipe.
2. TheinternalcoldfeedfromthemainincomingstoptaptotheBoilerMate
shouldberunin22mmpipe. Thecoldmainandhotdraw-offshouldalso
be run in 22mm as far as the branch to the bath tap.
3. Thefinalbranchestothehandbasinsandsinksshouldbein10mmandto
the baths and showers in 15mm. (1 metre minimum)
4. Ifanexternalhosetapisprovidedthisshouldbebranchedin15mmpipework
from the cold pipework as near to the incoming mains as possible.
5. 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
waterpressurerangeof2-3bar,orthedwellingis3storey. Detailsofsuitable
flow regulators are provided in Appendix.
Alltherecommendationswithregardtopipeworksystemsinthismanualaregenerally
based on the use of BS/EN Standard copper pipework and fittings.
However,wearehappythatplasticpipeworksystemscanbeusedinplaceofcopper
internallyaslongasthechosensystemisrecommendedforuseondomestichotand
coldwatersystemsbythemanufacturerandisinstalledfullyinaccordancewiththeir
recommendations.
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. These must be used in 3 storey properties where
the impact on pressure/temperature of opening another tap in the system is
greater than normal.
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.
The hot water supply to a shower-mixing valve should be fed wherever practical
directly from the BoilerMate BP 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
toabidetispermitted providedthatitisof the
over-rim flushing type and that a type ‘A’ air
gap is incorporated.
Hot and Cold Water System.
If the length of the hot water draw off
pipework is excessive the delivery time may
beunacceptablebeforehotwaterisavailableat
the tap, you may wish to consider using either
trace heating to the hot water pipework such
as the Raychem HWAT system or secondary
circulation. Please consult Gledhill 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
DESIGN
SYSTEM DETAILS
Heating System
General – Sealed And OpenVented Heating Systems
The BoilerMate BP is suitable for both an open vented and a sealed heating systems
shownschematicallyinfigures9and10respectively.Thesystemcomponentscanbe
installed inside the appliance case as shown in figures 3 and 4.
Although,theheatingsystemcan beeither openventedor sealed,thethermalstore
must always be open vented as shown in figures 9 & 10 and also:-
• The combined cold feed and open vent pipe arrangement must not be used.
• No valve should be fitted in the safety open vent and which must be a minimum
of 22mm copper pipe or equivalent.
The BoilerMate BP is designed to be installed with condensing or non condensing
oil or gas boiler which is capable of delivering hot water at a minimum temperature
of 80°C.
Theboilermustbe settooperateat nominal82°Cflowwhichusuallycorrespondsto
maximum boiler control thermostat setting.
Itisrecommendedthatanautomaticbypassisfittedtocompensateforpressureand
hencetheflowratechangesintheheatingcircuite.g.whenthethermostaticradiator
valves close.The bypass valve must be set by the installer to suit the system i.e.to
provide minimum flow required for the boiler when allTRVs are closed.
hot
water
cold
mains
CH-Flow
F&E Cistern
CH-Return
mixing
valve
Immersion
heater
Boiler
hot
water
cold
mains
CH-Flow
F&E Cistern
CH-Return
mixing
valve
Immersion
heater
Sealed system kit
Boiler
PRV
Open vented heating system Sealed heating system
Figure 10Figure 9

Page 13
SYSTEM DETAILS
DESIGN
Heating System
Pipe Sizing And Materials – Sealed And OpenVented Heating Systems
Alltherecommendationswithregardtoheatingsystemsinthismanualaregenerally
based n BS/EN Standard copper pipework and fittings.However we are happy that
plastic pipework system can be used in place of copper as long as long as the:-
• The chosen system is recommended for use in domestic heating systems
by the manufacturers and it is installed fully in accordance with their
recommendations.
• Thedesigncriterionof theplastic systemisat leastequivalenttotheuseofBS/En
Standard copper pipework and fittings.
• We always recommend the barrier pipe for these systems.
• TheF & E cistern supplied with the thermalstorecan be fitted remotelyup to 6m
above the base of the BoilerMateBP i.e.the maximum static pressure in the store
must not exceed 0.6bar.
The primary pipework connecting the boiler,the thermal store and central heating
systemshould be sizedto achieve either11°C rise across theboileror the maximum
temperature rise specified by the boiler manufacturer;which ever is smaller.But in
any case should not be less than 22mm copper tube or equivalent.
The pressure loss through the primary heat exchanger is shown in figure 6 and this
can be used for sizing the pump and the primary pipe work.
Boiler Size
Theminimumtotalboilerpowerrequiredisthe sumofthepowerrequiredforspace
heating which should be calculated in accordance with BS 5449 and the power
required for producing hot water which can be read from table below.
Minimum Boiler Power Required for Producing DHW
BoilerMate BP Model Y or S plan control
systems (without hot
water priority)
W plan control system
(with hot water
priority)
BMBP 125 3 0
BMBP 145 3 0
BMBP 185 4 0
BMBP 215 4 0
BMBP 225 5 0

Page 14
DESIGN
SYSTEM DETAILS
ExpansionVessel Requirements
Safety valve setting
(bar) 3.0
Vessel charge
pressure (bar) 0.5 1.0 1.5
Initial system
pressure (bar) 0.5 1.0 1.5 2.0 1.0 1.5 2.0 1.5 2.0
Total System
Volume (l)Expansion Vessel Volume (l)
25 2.1 3.5 6.5 13.7 2.7 4.7 10.3 3.9 8.3
50 4.2 7.0 12.9 27.5 5.4 9.5 20.6 7.8 16.5
75 6.3 10.5 19.4 41.3 8.2 14.2 30.9 11.7 24.8
100 8.4 14.0 25.9 55.1 10.9 19.0 41.2 15.6 33.1
125 10.4 17.5 32.4 68.9 13.6 23.7 51.5 19.5 41.3
150 12.5 21.0 38.8 82.6 16.3 28.5 61.8 23.4 49.6
Heating System
OpenVented Heating Systems
The layout of a typical open vented‘Y Plan’heating system is shown in figure 8.The
BoilerMate BP is equally suitable for‘S’and‘W’plan heating system layouts.
Theflowpipefromtheboilershouldrisecontinuouslyuptotheventpipetofacilitate
venting. The heating circuit is taken directly from the boiler and is piped in the
conventional manner.
TheF&Ecisternsuppliedwiththethermalstorecanbefittedremotelyupto6mabove
the base of the BoilerMate BP.If this cistern is used for the central heating as shown
in figure 8,then the water level in the F&E cistern should be at least 250mm above
thehighestpointonthesystemincludingtheradiatorsandmustbehighenoughto
provide the minimum head required by the boiler being used.
Sealed Heating Systems
Thelayoutofatypicalsealed‘YPlan’heatingsystemisshowninfigure9.TheBoilerMate
BP is equally suitable for‘S’and‘W’ plan heating system layouts.A boiler used in a
sealedheatingsystemmustbesuitableforthisapplicationi.e.mustbefittedwithan
overheat cut-out thermostat.
It is recommended that the F&E cistern (for the store) is fitted at a high level in the
same cupboard as the BoilerMate BP. However it can be fitted remotely up to 6m
above the base of the BoilerMate BP.
TheF&Ecisternoverflow/warningpipeshouldbeinstalledinamaterialsuitablefora
heating system feed and expansion cistern in accordance with BS5449.
There shall be no permanent connection to the mains water supply for filling the
system even through a non-return valve without the approval of the Local Water
Authority.Anapprovedfillingloopisrequiredwithforfillingthesystem,whichshould
be disconnected after commissioning the system.This should be located adjacent
to the boiler along with a suitable expansion vessel,pressure gauge,pressure relief
valve.
Thetablebelowcanbeusedforsizingtheheatingsystemexpansionvessel.Thewater
content of the primary heat exchanger is listed in table 1 and a figure of 4.5 l/kW of
installed radiator capacity can be used for a preliminary assessment of the water
content of the heating system.
The expansion vessel requirements shown in
table below are based on a maximum boiler
flowtemperatureof93°C.Theexpansionvessel
must be suitable to accommodate the change
in volume of the water in the system when
heated from 10°C to 110°C a sspecified in BS
5449:1990clause 16.2.
The minimum system pressure should not be
less than the static head plus 0.5bar i.e. the
heightofthehighestpointinthesystemabove
the expansion vessel plus a margin of 0.5 bar.

Page 15
SITE REQUIREMENTS
INSTALLATION
The appliance is designed to be installed in an airing/cylinder cupboard and the
relevant minimum dimensions are provided in theTechnical Data section.
Becauseoftheease ofinstallationwerecommendthat thecupboardconstruction is
completedand painted beforeinstallation of the appliance. Thecupboard door can
be fitted after installation.Noventilationisnormallyrequiredtothecupboard.
If theunit needs to bestoredprior toinstallation it should be storedupright in a dry
environment and on a level base/floor.
Installationandmaintenanceaccessisneeded to the front of the appliance and
abovethe F & E cistern.See Technical Data section for further details.
The minimum dimensions contained in the Technical Data section allow for the
passage/connection of pipes under the appliance from any direction as long as the
appliance is installed on the installation base provided.If the installation base is not
usedextraspacemaybeneededtoallowconnectiontothepipeworkandthewhole
ofthebaseareashouldbecontinuouslysupportedonamaterialwhichwillnoteasily
deteriorate if exposed to moisture.
Thefloor of thecupboard needs tobe leveland evenandcapable of supportingthe
weight of the appliance when full.Details of the weight when full is provided in the
Technical Data section.
Theappliance is designed tooperate as quietly aspracticable. However,some noise
(from pumps etc) is inevitable in any heating system.This will be most noticeable in
cupboardsformedonbulkheads,oratthemidspanofasuspendedfloor. Inthesecases
thesituationcanbeimprovedbyplacingtheapplianceonasuitablesounddeadening
material (i.e.carpet underlay or similar).
A suitable location will be needed for the separate feed and expansion cistern. This
will often be at high level in the cupboard housingthe BoilerMateBP. The dimensions
and clearances are provided in theTechnical Data section. The location will need to
provide a suitable route for the cold feed and expansion pipe as well as the open
safetyventpipe. Thelocationwillalsoneed toprovidea suitablerouteanddischarge
positionforthewarning/overflowpipeandtheballvalvesupplyfromthemainscoldwater
system if the automatic fill version appliance is being fitted.
Note: Thestandardappliance is supplied with a cistern but without a ballvalve
and overflow connector.

Page 16
INSTALLATION
INSTALLATION
Figure 11
2-pole isolator
switch fused at 3A
3 core flex
(0.75mm2minimum)
Clamp
Scale
inhibitor PCB
Mains supply
230Vac, 50Hz
N
EL
Figure 13
L N E
230V ac 50Hz
supply
L N on off on off
-- CH -- -- HW -- N E L SL
L N E
L N E SL L N E
Boiler terminals
Pump
Boiler supply
grey
orange
Programmer Room
thermostat
Store
thermostat
Local double pole
Fused isolator
System
Pump
CH
Zone valve
Wiring
centre 12345678910 11 12
5A
grey orange
HW
Zone valve
E C 1 2
BoilerMate BP Generic ‘S Plan’ wiring diagram
Figure 12
L N E
230V ac 50Hz
supply
L N on off on off
-- CH -- -- HW --
E C 1 2
N E L SL
L N E
L N E SL L N E
Boiler terminals
Pump
Boiler supply
grey
grey
white
white
orange
BoilerMate BP Generic ‘Y Plan’ wiring diagram
Programmer Room
thermostat
Store
thermostat
Local double pole
Fused isolator
System
Pump
3-Port
Flow-share valve
Wiring
centre 12345678910 11 12
6A
ElectricalWiring
1 An electrical supply must be available
which is correctly earthed,polarized and in
accordancewiththelatesteditionoftheIEE
requirementsforelectricalInstallationsBS7671.
2 The electrical mains supply needs to be
230V/50Hz.
3 A means for disconnection from the supply
mains having a contact separation in all
poles that provides full disconnection
under over voltage category III conditions
must be incorporated in the fixed wiring in
accordance with the wiring rules.This shall
be located within 1m of the appliance and
only serve the appliance.
4 An optional 3kW 230Vac immersion heater
complete with a thermostat and overheat
cutout with manual reset can be fitted for
heating domestic hot water in case the
boiler fails.The immersion heater control
thermostatmustbesetat75°C.Thewiringof
theimmersionheatermustbeinaccordance
with the relevant IEE wiring regulations as
the circuit must be protected by a suitable
fuse and a local double pole isolator.
5 If an optional scale inhibitor device is
fitted then a 3 core flex from the local 2-
pole isolator fused at 3A should be used
to connect 230Vac 50 hz supply to the
controller terminals (see figure 11).
6 The 230Vac 50hz supply to the system
wiring centre must be in accordance with
the relevant IEE Wiring Regulations on the
circuit must be protected by a suitable 5A
fuseandadoublepolelocalisolatingswitch
(see figures 12 and 13)

Page 17
INSTALLATION
INSTALLATION
Preparation/placing the appliance in
position.
Details of the recommended positions for
terminationofthefirstfixpipeworkareprovided
intheTechnicalDatasection.Thepipeworkcan
be located or its position checked using the
templateprovidedwitheachappliance. Ifthese
have been followed installation is very simple
and much quicker than any other system.
The appliance is supplied shrink wrapped on
a timber installation base with the F&E cistern
on top of the unit. Carrying handles are also
provided in the back of the casing.
The appliance should be handled carefully
to avoid damage and the recommended
method is shown opposite. Before installation
the site requirements should be checked and
confirmed as acceptable. The plastic cover
and protective wrapping should be removed
from the appliance and the installation base
(provided) and placed in position.
Theappliancecanthenbeliftedintopositionin
the cupboard on top of the base and the front
panelremovedbyunscrewingthe2screwsand
liftingthedoorupandout,readyforconnection
ofthepipeworkandelectricalsupplies.Thefeed
andexpansioncisternsupportshallbeinstalled
ensuringthatthebaseisfullysupportedandthe
workingheadoftheapplianceisnotexceeded
and the recommended access is provided for
maintenance - see theTechnical Data section.
For further information on manual handling
See Appendix.
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.
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.
Larger units may require a team lift.
A specific manual handling assessment is shown in Appendix
at the rear of this manual.

Page 18
INSTALLATION
INSTALLATION
Itisnormallyenvisagedthatthefeedandexpansioncisternwillbelocatedinthesame
cupboard as the BoilerMate appliance itself to maintain a dry roof space.However,if
it is necessary,the cistern can be installed in the roof space.
Note: When fitting the cistern at a higher level this must not be fitted more than 6
metres above the base of the BoilerMate BP appliance.
Obviously, if installed in the roof space the feed and expansion cistern and any
pipework will need to be adequately insulated to protect against frost damage.
If the automatic fill version appliance is used the overflow/warning pipe shall have
a continuous fall, be fitted to discharge clear of the building and be sited so that
any Overflow can be easily observed. It shall also be installed in a size and material
suitableforusewithheatingfeedandexpansioncisternsinaccordancewithBS5449
and should not have any other connections to it.

Page 19
COMMISSIONING
INSTALLATION
Opentheincoming stopvalveand fillthedomestic mainscoldandhotwater systems.
Checkandadjustasnecessarytheexpansionvesselairpressuretothefigurespecified
(normally 1.5 bar).
Fill the whole of the primary heating system with potable water through the filling
loop provided adjacent to the boiler to the pressure required (normally 1.5 bar).
During filling vent air as necessary from the high points of the system including the
manual air vents provided on the appliance and the feed to the expansion vessel.
Fill the appliance i.e. BoilerMate BP through the feed and expansion cistern flush
and refill.
Check the water level in the feed and expansion cistern and adjust the ballvalve if
fitted.
Checkthewarningpipe(iffitted)isinstalledcorrectly,hasacontinuousfallandisnot
blocked i.e. discharges water freely.
Checkthe wholeoftheprimaryheatingand domestichotandcolddistribution
system, including the boiler and BoilerMate BP, for leaks.
It is essential that all systems function properly for optimum performance.
To achieve this, the primary system should be commissioned in accordance with
good practice and generally in accordance with the requirements of BS 6798, BS
5449 and BS 7593.
Full details of the requirements are given in PAS 33:1999 under Section 10
Commissioning.
When using either cleansing or corrosion inhibitor chemical, the manufacturers
instructions must be followed.
Cleansing the Primary System
ItisveryimportanttoensurethatthePrimarysystemiscleanedusingasuitable
cleansing agent such as Sentinel X300 or Fernox Superfloc to ensure that any
flux residues/installation debris are removed.
Thevolumes/concentrationshouldbecalculatedinaccordancewiththemanufacturers
instructions allowing the volume for the primary coil shown in the Table in the
Technical Data section.
Primary Water System Treatment
AlthoughtheBoilerMateBPhasnospecialwatertreatmentrequirements,theradiators
andotherpartsofthecircuitwillbenefitfromtheapplicationofascaleandcorrosion
inhibitor such as Sentinel X100 or a Protector such as Fernox MB1.
Thevolumes/concentrationshouldbecalculatedinaccordancewiththemanufacturers
instructions allowing the volume for the primary coil shown in the Table in the
Technical Data section.
Powerflushing/cleaning Of The Heating System
If it is proposed to ‘powerflush’ the heating system we would recommend that the
processusedshouldalwayscomplyfully withthe manufacturersinstructions forthe
powerflushing equipment being used.
If in any doubt please consult our Technical Helpline.
NOTE: With sealed heating systems air is
releasedfrom thewaterduringthefirstfew
weeksofoperation.Thismustbeventedand
the system repressurised.
Commissioning Domestic Hot Water
System
The hot water flow temperature should settle
at about 55°C. Close this tap and open the hot
bathtap atmaximum flowrate and recordthe
flowrateandthehotwatertemperatureinthe
‘Benchmark’ logbook.
Hand over to User
(a)Explain how to operate the heating and
hot water controls to the user. This should
include setting ‘on’ and ‘off’ times and the
roomtemperatureonthe roomthermostat
as well as the use of thermostatic radiator
valves.
(b)Adviseonboileroperationandmaintenance
advised in the boiler manual.
(c) Handover appliance and room thermostat
user instructions and put the completed
“Benchmark” logbook and the appliance
instruction manual in the pocket on the
inside of the appliance front panel.
(d)DON’T place any clothing or other
combustible materials against or on top of
this appliance.
This product is covered by the ‘Benchmark’
scheme and a separate commissioning/
service log book is included with this
product. This must be completed during
commissioning and left with the product
to meet the Warranty conditions offered
by Gledhill.
TheseInstructionsshouldbeplacedalongwith
the component manufacturers instructions in
the pocket provided. The front panel should
then be refitted.

Page 20
SERVICING
ANNUAL SERVICE/CHANGING COMPONENTS
Important Do’s and Don’ts
DO check the incoming mains water pressure and flow rate are adequate. (The
preferred range of mains pressure is 2-3bar).
DOcheckthatall plumbingandelectricalconnectionsareinaccordancewith
the labelling on the thermal store.
DOcheckandensuretheairpressuresideoftheexpansionvesselissetat1.0bar(or
as specified) - sealed heating system only.
DO ensure that if the BoilerMate BP is fitted on a sealed primary (i.e. closed) system,
then the boiler is suitable (i.e. fitted with an overheat thermostat)
DO adjustthe ballvalveso that thewater levelin the applianceF &E cistern when the
system is cold is correct and does not overflow when the appliance is at maximum
temperature
DO turn down the servicing valve for the ballvalve in the F & E cistern, once the
system is finally filled, to the point where the warning/overflow pipe will cope with
the discharge arising from a ballvalve failure.
DOcheckthattheF&Ecisternisnotmorethan6mabovethebaseoftheBoilerMate
appliance.
DO makesurethat there is adequate clearance above the appliance F & E cistern to
service the ballvalve.
DO ensure that the boiler thermostat is set to maximum for all boilers.
DO insulate any exposed pipework in the BoilerMate BP cupboard.
DO plumb the overflow/warning pipe (if fitted) in a 20mm internal diameter pipe
material which is suitable for use with a heating F & E cistern, in accordance with
BS 5449 (such as copper) and ensure it has a continuous fall and discharges in a
conspicuous external position.
DO check that the primary system pressure does not exceed 2 bar when the whole
of the system is up to temperature.
DO check the pump settings. The boiler/heating pump should be set to give a
temperature difference across the flow and return of not more than 11°C or as
recommended by the manufacturers.
DO ensure that the bypass valve for the heating system is set correctly.
DON’T use a combined feed and vent on BoilerMate BP installations.
DON’T place any clothing or other combustible materials against or on top of this
appliance.
No annual servicing of the BoilerMate BP is
necessary.
Free of charge replacements for any faulty
componentsareavailablefromGledhillduring
the in-warranty period (normally 12 months).
After this,spares can be obtained direct from
Gledhill using the ‘Speed Spares’ service, or
throughanyofthelargerplumbersmerchants/
specialist heating spares suppliers.
Help and advice is also available from the
Technical Helpline on 0906 611 0005. Please
note this is a premium rate line and will be
charged accordingly.
However,allcomponentsarereadilyaccessible
and can be changed quickly and easily by the
installerusing commonplumbing practice.