gledhill BoilerMate BP User manual

Design, Installation & Servicing Instructions
Models covered in this manual
BoilerMate BMBP 125
BoilerMate BMBP 145
BoilerMate BMBP 185
BoilerMate BMBP 215
BoilerMate BMBP 225
BoilerMate BP
Mains pressure hot water thermal store for use with gas or oil boilers

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
Notes
Terms & Conditions 28
BENCHMARK
Commissioning Checklist 30
Service Record 31
ISSUE 3: JANUARY 2014
The Gledhill BoilerMate BP range is a WBS
listed product and complies with the HWA
Specication for integrated 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.
Gas Safe operates a Self Certication Scheme for gas heating appliances.

Page 3
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.
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 Electrical Installations
Water Regulations
British Standards
BS6798, BS5449, BS5546, BS5440:1, BS5440:2, CP331:3, BS6700, BS5258, BS7593 and
BS7671.
A suitably competent person as stated in the Gas Safety Regulations must install the
BoilerMate and carry out any subsequent maintenance/repairs. In fact, the front panel
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 notiable to Building Control.
The BoilerMate BP 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 and 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
water only thermal store. It is designed for 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
this manual. When it is used in a sealed heating
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 ow 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 inside the thermal store. The
outlet temperature of the domestic hot water
is regulated by a thermostatic blending valve
which is factory set at 55±3°C .
Because the BoilerMate BP does not require
a safety discharge from a temperature and
pressure (T&P) valve, the installations in
buildings will be easier and will not suer the
problems associated with using the PVCu soil
stacks to take discharge from the unvented
cylinders.
The BoilerMate BP is supplied as an F&E cistern
and ball valve to be tted by the installer.
DESIGN
INTRODUCTION

Page 4
Standard Equipment
The standard conguration of the BoilerMateBP
is shown opposite and it is supplied with the
following factory tted equipment: -
1 Thermostatic dhw blending valve – set at 55°C
2 Store thermostat – set at 75°C
3 Feed and expansion cistern complete with
ball valve and oat (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
The position of the pipe connections is shown
opposite and the connection sizes are listed in table 1.
C1 Mains cold water inlet
C2 Hot water outlet
C3 Primary heat exchanger ow
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
cistern using the pipework assembly provided.
Do not alter or connect any pressure-relief
device to the vent pipe of this water heater.
All factory made joints should be checked after
installation in case they have been loosened
during transit.
The ttings for the feed and expansion cistern
should be installed in a position to suit the
particular location and the cistern tted on its
supports/base.
The cold feed/expansion and safety open vent
should be installed between the appliance and
the feed and expansion cistern.
Figure 1
C2
C5 C6
1
C7
C1
C4
C3
2
C8
DESIGN
TECHNICAL DATA

Page 5
* Provisional gures only
Notes:-
1. The ow rates are based on a 35°C temperature rise and assume 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 ow 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
DESIGN
TECHNICAL DATA

Page 6
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: 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 top up
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 fill option is chosen, the
heights 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.
DESIGN
TECHNICAL DATA

Page 7
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 Store thermostat
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 Store thermostat
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.
DESIGN
TECHNICAL DATA

Page 8
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 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 15mm cold water supply and a
22mm warning / overow pipe.
Note: All dimensions are shown in mm and
are to the centre line of pipework.
Connection Details/Dimensions For Top Of Unit
Figure 5
570 (595 including the door/clock)
580
58
117
370 - Cold Feed/Expansion
330 - Open Vent
Connection Details/Dimensions For Bottom Of Unit
570 (595 including the door/clock)
560
545
525
370 - Mains Cold Water Inlet
485 - Hot Water Outlet
130
Boiler Flow and Return
DESIGN
TECHNICAL DATA

Page 9
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
DESIGN
TECHNICAL DATA

Page 10
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 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
minimum dynamic pressures at the cold connection to the BoilerMate BP at the time of
the maximum calculated simultaneous demand. Particular consideration should also
be given to available pressures in the case of 3 storey properties. 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.
No check valve or similar device should be tted on the cold water supply branch to
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”.
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.
If scale should ever become a problem the
BoilerMate BP heat exchanger can be descaled
in situe. Contact the Technical Helpline for
more details.
The hot water ow 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
should be calculated using procedures dened
in BS 6700.
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 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
DESIGN
SYSTEM DETAILS

Page 11
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, 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 sucient for a small
1bathroom dwelling (depending upon the ow rate available), but the minimum
recommended size for new dwellings is 22mm (25mm MDPE). For the BMBP 225
model we recommend a 28mm (32mm MDPE) supply pipe.
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-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. If an external hose tap is provided this should be branched in 15mm pipework
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 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 of 2-3 bar, or the dwelling is 3 storey. Details of suitable
ow regulators are provided in Appendix.
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.
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. 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 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 BP 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 fitted 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 off
pipework is excessive the delivery time may
be unacceptable before hot water is available at
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.
DESIGN
SYSTEM DETAILS

Page 12
Heating System
General – Sealed And Open Vented Heating Systems
The BoilerMate BP is suitable for both an open vented and a sealed heating systems
shown schematically in gures 9 and 10 respectively. The system components can be
installed inside the appliance case as shown in gures 3 and 4.
Although, the heating system can be either open vented or sealed, the thermal store
must always be open vented as shown in gures 9 & 10 and also: -
• The combined cold feed and open vent pipe arrangement must not be used.
• No valve should be tted 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.
The boiler must be set to operate at nominal 82°C ow which usually corresponds to
maximum boiler control thermostat setting.
It is recommended that an automatic bypass is tted to compensate for pressure and
hence the ow rate changes in the heating circuit e.g. when the thermostatic radiator
valves close. The bypass valve must be set by the installer to suit the system i.e. to
provide minimum ow required for the boiler when all TRVs 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
DESIGN
SYSTEM DETAILS

Page 13
Heating System
Pipe Sizing And Materials – Sealed And Open Vented Heating Systems
All the recommendations with regard to heating systems in this manual are generally
based n BS/EN Standard copper pipework and ttings. 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.
• The design criterion of the plastic system is at least equivalent to the use of BS/En
Standard copper pipework and ttings.
• We always recommend the barrier pipe for these systems.
• The F & E cistern supplied with the thermal store can be tted remotely up 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
system should be sized to achieve either 11°C rise across the boiler or the maximum
temperature rise specied 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 gure 6 and this
can be used for sizing the pump and the primary pipe work.
Boiler Size
The minimum total boiler power required is the sum of the power required for space
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
DESIGN
SYSTEM DETAILS

Page 14
Expansion Vessel 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
Open Vented Heating Systems
The layout of a typical open vented ‘Y Plan’ heating system is shown in gure 8. The
BoilerMate BP is equally suitable for‘S’and ‘W’ plan heating system layouts.
The ow pipe from the boiler should rise continuously up to the vent pipe to facilitate
venting. The heating circuit is taken directly from the boiler and is piped in the
conventional manner.
The F & E cistern supplied with the thermal store can be tted remotely up to 6m above
the base of the BoilerMate BP. If this cistern is used for the central heating as shown
in gure 8, then the water level in the F&E cistern should be at least 250mm above
the highest point on the system including the radiators and must be high enough to
provide the minimum head required by the boiler being used.
Sealed Heating Systems
The layout of a typical sealed‘Y Plan’heating system is shown in gure 9.The BoilerMate
BP is equally suitable for ‘S’ and ‘W’ plan heating system layouts. A boiler used in a
sealed heating system must be suitable for this application i.e. must be tted with an
overheat cut-out thermostat.
It is recommended that the F&E cistern (for the store) is tted at a high level in the
same cupboard as the BoilerMate BP. However it can be tted remotely up to 6m
above the base of the BoilerMate BP.
The F&E cistern overow/warning pipe should be installed in a material suitable for a
heating system feed and expansion cistern in accordance with BS5449.
There shall be no permanent connection to the mains water supply for lling the
system even through a non-return valve without the approval of the Local Water
Authority. An approved lling loop is required with for lling the system, which should
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.
The table below can be used for sizing the heating system expansion vessel. The
water content of the primary heat exchanger is listed in table 1 and a gure 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 ow temperature of 93°C.The expansion
vessel must be suitable to accommodate the
change in volume of the water in the system
when heated from 10°C to 110°C a sspecied
in BS 5449:1990clause 16.2.
The minimum system pressure should not be
less than the static head plus 0.5bar i.e. the
height of the highest point in the system above
the expansion vessel plus a margin of 0.5 bar.
DESIGN
SYSTEM DETAILS

Page 15
The appliance is designed to be installed in an airing/cylinder cupboard and the
relevant minimum dimensions are provided in the Technical Data section.
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 tted after installation. Noventilation is normally required to the cupboard.
If the unit needs to be stored prior to installation it should be stored upright in a dry
environment and on a level base/oor.
Installation and maintenance access is needed to the front of the appliance and
above the 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
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 oor 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 the
Technical Data section.
The appliance is designed to operate as quietly as practicable. However, some noise
(from pumps etc) is inevitable in any heating system. This will be most noticeable
in cupboards formed on bulkheads, or at the mid span of a suspended oor. In these
cases the situation can be improved by placing the appliance on a suitable sound
deadening 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 housing the BoilerMate BP. The dimensions
and clearances are provided in the Technical Data section. 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/overow pipe and the ballvalve supply from the mains cold water
system if the automatic ll version appliance is being tted.
Note: The standard appliance is supplied with a cistern but without a ballvalve
and overow connector.
INSTALLATION
SITE REQUIREMENTS

Page 16
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
Electrical Wiring
1 An electrical supply must be available
which is correctly earthed, polarized and in
accordance with the latest edition of the IEE
requirements for electrical Installations BS 7671.
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 xed 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 tted for
heating domestic hot water in case the
boiler fails. The immersion heater control
thermostat must be set at 75°C.The wiring of
the immersion heater must be in accordance
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 gure 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
fuse and a double pole local isolating switch
(see gures 12 and 13)
INSTALLATION
INSTALLATION

Page 17
Preparation/placing the appliance in
position.
Details of the recommended positions for
termination of the rst x pipework are provided
in theTechnical Data section. 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.
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.
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 the Technical Data section.
For further information on manual handling
See Appendix.
Note: Although the above guidance is provided
any manual handling/lifting operations will
need to comply with the requirements of
the Manual Handling Operations Regulations
issued by the H.S.E.
The appliance can be moved using a sack truck
on the rear face although care should be taken
and the route should be even.
In apartment buildings containing a number
of storeys we would recommend that the
appliances are moved vertically in a mechanical
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.
INSTALLATION
INSTALLATION

Page 18
It is normally envisaged that the feed and expansion cistern will be located in the same
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 tting the cistern at a higher level this must not be tted 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 ll version appliance is used the overow/warning pipe shall have
a continuous fall, be tted to discharge clear of the building and be sited so that
any Overow can be easily observed. It shall also be installed in a size and material
suitable for use with heating feed and expansion cisterns in accordance with BS 5449
and should not have any other connections to it.
INSTALLATION
INSTALLATION

Page 19
Open the incoming stop valve and ll the domestic mains cold and hot water systems.
Check and adjust as necessary the expansion vessel air pressure to the gure specied
(normally 1.5 bar).
Fill the whole of the primary heating system with potable water through the lling
loop provided adjacent to the boiler to the pressure required (normally 1.5 bar).
During lling 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 ush
and rell.
Check the water level in the feed and expansion cistern and adjust the ballvalve if tted.
Check the warning pipe (if tted) is installed correctly, has a continuous fall and is not
blocked i.e. discharges water freely.
Check the whole of the primary heating and domestic hot and cold distribution
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
It is very important to ensure that the Primary system is cleaned using a suitable
cleansing agent such as Sentinel X300 or Fernox Superoc to ensure that any
ux residues/installation debris are removed.
The volumes/concentration should be calculated in accordance with the
manufacturers instructions allowing the volume for the primary coil shown in the
Table in the Technical Data section.
Primary Water System Treatment
Although the BoilerMate BP has no special water treatment requirements, the radiators
and other parts of the circuit will benet from the application of a scale and corrosion
inhibitor such as Sentinel X100 or a Protector such as Fernox MB1.
The volumes/concentration should be calculated in accordance with the
manufacturers instructions allowing the volume for the primary coil shown in the
Table in the Technical Data section.
Powerushing/cleaning Of The Heating System
If it is proposed to ‘powerush’ the heating system we would recommend that the
process used should always comply fully with the manufacturers instructions for the
powerushing equipment being used.
If in any doubt please consult our Technical Helpline.
NOTE: With sealed heating systems air is
released from the water during the rst few
weeks of operation. This must be vented and
the system repressurised.
Commissioning Domestic Hot Water System
The hot water ow temperature should settle
at about 55°C. Close this tap and open the hot
bath tap at maximum ow rate and record the
ow rate and the hot water temperature in the
‘Benchmark’ commissioning checklist.
Hand over to User
(a) Explain how to operate the heating and
hot water controls to the user. This should
include setting ‘on’ and ‘o’ times and the
room temperature on the room thermostat
as well as the use of thermostatic radiator
valves.
(b) Advise on boiler operation and maintenance
advised in the boiler manual.
(c) Handover appliance and room thermostat
user instructions and put the completed
“Benchmark” checklist within this manual
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.
At the time of commissioning, complete all
relevant sections of the Benchmark Checklist
located on the inside back pages of this
document.
This must be completed during
commissioning and left with the product
to meet the Warranty conditions offered
by Gledhill.
These Instructions should be placed along with
the component manufacturers instructions in
the pocket provided. The front panel should
then be retted.
INSTALLATION
COMMISSIONING

Page 20
Important Do’s and Don’ts
DO check the incoming mains water pressure and ow rate are adequate. (The
preferred range of mains pressure is 2-3bar).
DO check that all plumbing and electrical connections are in accordance with
the labelling on the thermal store.
DO check and ensure the air pressure side of the expansion vessel is set at 1.0 bar (or
as specied) - sealed heating system only.
DO ensure that if the BoilerMate BP is tted on a sealed primary (i.e. closed) system,
then the boiler is suitable (i.e. tted with an overheat thermostat)
DO adjust the ballvalve so that the water level in the appliance F & E cistern when the
system is cold is correct and does not overow 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 nally lled, to the point where the warning/overow pipe will cope with
the discharge arising from a ballvalve failure.
DO check that the F & E cistern is not more than 6m above the base of the BoilerMate
appliance.
DO make sure that 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 overow/warning pipe (if tted) 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 dierence across the ow 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
components are available from Gledhill during
the in-warranty period (normally 12 months).
After this, spares can be obtained direct from
Gledhill using the ‘Speed Spares’ service, or
through any of the larger plumbers merchants/
specialist heating spares suppliers.
Help and advice is also available from the
Technical Helpline on 01253 474584. Please
note this is a premium rate line and will be
charged accordingly.
However, all components are readily accessible
and can be changed quickly and easily by the
installer using common plumbing practice.
SERVICING
SERVICE / CHANGE COMPONENTS