Boiler Mate CP Manual
User Manual: BoilerMate CP Manual
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Page Count: 40
Design, Installation & Servicing Instructions
Models covered in this manual
BoilerMate CP 120
BoilerMate CP 150
BoilerMate CP 180
BoilerMate CP 220
BoilerMate CP
Mains pressure hot water thermal store for use with central plant boilers
Page 2
Section Page
DESIGN
Introduction 3
Technical Data 5
System Details 9
INSTALLATION
Site Requirements 13
Installation 14
Commissioning 20
Installation Review 21
SERVICING
Annual Service 22
Changing Components 22
Short Parts List 23
Fault Finding 24
ADDENDIX
Addendix A 30
Addendix B 31
Addendix C 32
Notes 33
Terms & Conditions 36
BENCHMARK
Commissioning Checklist 38
Service Record 39
ISSUE 4: FEBRUARY 2016
The Gledhill BoilerMate CP range is a
WBS listed product and complies with
the HWA Specication for hot water only
thermal storage products. The principle was
developed in conjunction with British Gas.
This product is manufactured under an ISO
9001:2008 Quality System audited by BSI.
Gledhill’s rst priority is to give a high quality
service to our customers.
Quality is built into every Gledhill product
and we hope you get satisfactory service
from Gledhill.
If not please let us know.
Benchmark places responsibilities on both manufacturers and installers. The purpose is to
ensure that customers are provided with the correct equipment for their needs, that it is
installed, commissioned and serviced in accordance with the manufacturers instructions
by competent persons and that it meets the requirements of the appropriate Building
Regulations. The Benchmark Checklist can be used to demonstrate compliance with
Building Regulations and should be provided to the customer for future reference.
Installers are required to carry out installation, commissioning and servicing work in
accordance with the Benchmark Code of Practice which is available from the Heating
and Hot Water Industry Council who manage and promote the Scheme. Visit www.
centralheating.co.uk for more information.
For further information on the HWA Charter Statement, please refer to the HWA website
hotwater.org.uk.
Page 3
DESIGN
INTRODUCTION
Any water distribution system/installation must comply with the relevant
recommendations of the current version of the Regulations and British Standards
listed below:-
Gas Safety (Installation and use) Regulations 1998
Building Regulations
Water Supply (Water Fittings) Regulations 1999
Manual Handling Operations Regulations
British Standards
BS EN 806:1-5: BS EN 8558:2011
Requirements for Electrical Installations BS7671:2008 and A2:2013 17th Edition
Most new building work will require the relevant building control body to be notied
prior to the building work commencing. This will not be required if the work is carried
out under a self certication scheme or if the work is not notiable. Full details of the
self certication schemes and work that is not notiable can be obtained from page
9 of Approved Document G, available from www.planningportal.gov.uk.
A suitably competent trades person must install the BoilerMate CP and carry out
any subsequent maintenance/repairs. In fact the appliance front cover is secured
by 2 screws and this should only be removed by a competent trades person. The
manufacturer’s notes must not be taken as overriding statutory obligations.
The Domestic Building Services Compliance Guide 2013 denes, one of the xed
building services, as any part of or controls associated with xed systems for domestic
hot water. All xed building services, including theircontrols, should be commissioned
by testing and adjustment to ensure that they use no more fuel and power than is
reasonable in the circumstances. Where commissioning is required, if it is completed
by a person registered with a competent person scheme, the commissioning notice
will be supplied by that person, otherwise the person carrying out the work must notify
the relevant building control body, that commissioning has taken place in accordance
with the Domestic Heating Compliance Guide.The building control body will then be
able to issue a completion certicate. This applies to England, for other jurisdictions in
the UK, it may be necessary to consult their own building regulations and guidance.
The BoilerMate CP is not intended for use by persons (including children) with reduced
physical, sensory or mental capabilities, or lack of experience or knowledge, unless
they have been given supervision or instruction concerning use of the appliance by
a person responsible for their safety.
Children should be supervised to ensure that they do not play with the appliance.
The information in this manual is provided to assist generally in the selection of
equipment. The responsibility for the selection and specication 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 specication or for the eectiveness of an installation containing one of
our products unless we have been specically requested to do so.
All goods are sold subject to our Conditions of Sale, which are set out at the rear of
this manual.
In the interest of continuously improving the BoilerMate CP range, Gledhill Building
Products Ltd reserve the right to modify the product without notice, and in these
circumstances this document, which is accurate at the time of printing, should be
disregarded. It will however be updated as soon as possible after the change has
occurred.
The Environment
This product has been manufactured using
many recyclable materials, including the
approved HCFC/CFC free polyurethane foam
insulation. At the end of its useful life, it
should be disposed of at a Local Authority
Recycling Centre, to maximise the products full
environmental benets.
Page 4
The BoilerMate CP shown schematically above is designed to provide an improved
method of supplying mains pressure hot water when used with a central plant system.
An important feature of the concept is that hot water can be supplied directly from
the mains at conventional ow rates without the need for temperature and pressure
relief safety valves or expansion vessels. This is achieved by passing the mains water
through a plate heat exchanger. The outlet temperature of the domestic hot water
is maintained by a printed circuit control board, which controls the speed of the
pump circulating the primary water from the store through the plate heat exchanger.
The Domestic Building Services Compliance Guide (2013) provides more detailed
information on the guidance contained in Approval Documents L1A and L1B, guidance
to the Building Regulations. The recommended minimum standards specify that
“where the mains water hardness exceeds 200ppm provision should be made to treat
the feed water to water heaters and the hot water circuit of combination boilers to
reduce the rate of accumulation of lime scale”.
To comply with this requirement the hardness of the mains water should be checked
by the installer and if necessary the optional factory tted in-line scale inhibitor should
be specied 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 specied 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.
This unit uses minimal power in stand by mode,
but can be turned o if required.
Because this product does not require a safety
discharge from a temperature and pressure
relief valve, any installations will be easy to
incorporate into the building and will not suer
from the problems associated with using PVCu
soil stacks to take the discharge from unvented
cylinders.
The heat losses from thermal stores should not
be directly compared with heat losses from
unvented or vented cylinders because they are
treated dierently in SAP. This is because the
unvented and vented cylinders are tested at
65°C and the thermal store at 75°C.
Figure 1.1
1. Boiler ow
2. Backup immersion heater
3. PHE pump
4. Cold Feed
5. CW inlet
6. HW outlet
7. Drain
8. Return from PHE to store
9. Flow from store to PHE
10. Feed and expansion tank
11. Boiler return
12. Flow sensor
13. Thermostat pocket
7
2
13
1
11
3
9
5
8
6
12
4
10
DESIGN
INTRODUCTION
Page 5
Technical Specication BoilerMate CP
Product Stock Code BMSCP120 BMSCP150 BMSCP180 BMSCP220
Energy eciency class B C C D
Heat loss (watts) 43 57 70 93
Height (mm) 1075 1145 1275 1575
Width (mm) 530 560 560 560
Depth (mm) 595 630 630 630
Min cupboard height (mm) 1825 1895 2025 2325
Min cupboard width (mm) 570 600 600 600
Min cupboard depth (mm) 610 645 645 645
Weight (empty) (kg) 48 52 57 65
Weight (full) (kg) 162 198 222 275
Domestic hot water volume (litres) 105 140 160 195
Hot water ow rate (litres/minute) 12.5 12.5 12.5 12.5
Coil rating (kW) 12 16 17 21
Coil surface area (m2) 1.18 1.56 1.92 2.54
Pressure loss of coil (bar) 0.20 0.22 0.22 0.28
Model Selection Guide BoilerMate CP
Dwelling Type
Bedroom 1-2 2-3 2-3 2-4
Bathroom 1 or 1 1 2
En-suite shower rooms 1 1 2 1
Model required BMSCP120 BMSCP150 BMSCP180 BMSCP220
Notes:-
1. Plastic top up cistern will be supplied separately.
2. The ow rates are based on a 35°C temperature rise and assume that recommended
pressures and adequate ow are available at the appliance. The actual ow rate
from the appliance is automatically regulated to a maximum of 15 litres/min.
3. Unit is supplied on a 100mm high installation base.
4. The domestic hot water outlet temperature is automatically regulated to
approximately 55°C, and the temperature is not user adjustable.
Table 1.2
Table 1.1
DESIGN
TECHNICAL DATA
Page 6
Standard Equipment
The standard conguration of the BoilerMate CP
is shown opposite. The Printed Circuit Control
Board, mounted inside the appliance, controls
the production of the domestic hot water.
This is pre-wired to a terminal strip where all
electrical connections terminate. The installer
must t components to control the operation
of the immersion heater. It is supplied with the
following factory tted equipment:-
1. Boiler ow
2. 3kW backup immersion heater
3. Printed Circuit Board
4. Plate heat exchanger
5. Domestic hot water primary (plate heat
exchanger) pump
6. Incoming cold water sensor
7. Strainer and ow regulator
8. Screwed connection for a drain tap
9. Top up cistern complete with cold feed/
open vent pipework assembly is supplied
separately
10. Store sensor
11. Cylinder thermostat
12. Boiler return
13. Flow sensor
Note
The immersion heater is a low watt density
type with incaloy 825 sheaths and are specially
manufactured to suit thermal stores. It is
recommended that any replacements should
be obtained from Gledhill Spares.
The immersion heater is fitted with control
thermostats and overheat thermostats.
Immersion heaters without these components
must not be tted to the unit.
Optional Extra Equipment
• In line scale inhibitor for mains water
services with hardness levels between 200
and 300ppm (mg/l) tted but ready for
wiring by the installer to the suitable 230V
ac supply.
• Polyphosphate scale inhibitor for tting on
site by the installer.
• Ballvalve/overow connector for top up
cistern.
Figure 1.2
6
7
13
4
5
10
11
3
9
2
1
12
8
DESIGN
TECHNICAL DATA
Page 7
Note: The Appliance dimensions above do not
allow for the100mm high installation base.
The following table of minimum cupboard
dimensions only allow the minimum space
required for the appliance (including the F & E
cistern). Any extra space required for shelving
etc in the case of airing cupboards etc must
be added.
Note: The above dimensions are based on the
Appliance and the Top up cistern (tted with a
ballvalve) being in the same cupboard. If the
manual ll method is chosen the heights can
be reduced by 125mm.
If pipework needs to rise vertically adjacent
to the appliance the width/depth will need
increasing to accommodate this.
Appliance Dimensions
Model Height
A
Width
B
Depth
C
BMSCP120 1075 530 595
BMSCP150 1145 560 630
BMSCP180 1275 560 630
BMSCP220 1575 560 630
Minimum Cupboard Dimensions
Model Height
D
Width
E
Depth
F
BMSCP120 1825 570 610
BMSCP150 1895 600 645
BMSCP180 2025 600 645
BMSCP220 2325 600 645
B
E
C
BoilerMate CP
Top up
cistern
Top up
cistern
300 *350A100
D
F
Maintenance
access
Figure 1.3
280
420
*Min maintenance
access to comply with
the Water Regulations
(ballvalve model only)
The minimum
clear opening in
front of the
appliance to be
at least the
same depth as
the appliance.
The cupboard door
opening will need
to take into
account the various
sizes of appliances.
DESIGN
TECHNICAL DATA
Page 8
Plan Of Appliance Connections
The BoilerMate CP units are supplied on an
installation base to allow the pipe runs to
connect to the appliance from any direction.
It is easier if all pipes protrude vertically in the
cut out area shown. Compression or push t
connections can be used. All pipe positions
are approximate and subject to a tolerance of
+/- 10mm in any direction. Space will also be
required for a 22mm cold water supply and a
22mm warning / overow pipe (if the optional
extra ball valve and overow connector have
been specified. If a warning/overflow pipe
is NOT provided the F&E Cistern should be
filled from a temporary hose connection
incorporating a double check valve. This can
be from a temporary hose connection supplied
from a cold water tap or a permanent cold
branch provided adjacent to the Top up Cistern.
The temporary connection must be removed
once the appliance is lled.
Note: All dimensions are shown in mm and
are to the centre line of the pipework.
DESIGN
TECHNICAL DATA
Connection Details/Dimensions For Top Of Unit
Figure 1.4
95
148
156
103
Open Vent (22mm)
Cold Feed (22mm)
Connection Details/Dimensions For Bottom Of Unit
Mains Cold Water Inlet
(15mm/22mm)
Hot Water Outlet
(18mm/22mm)
Boiler Flow and
Return pipework
this side of the unit
70
35
546
558
Page 9
Hot and Cold Water System
General
A schematic layout of the hot and cold water services in a typical small dwelling is
shown below. BoilerMate CP will operate at mains pressures as low as 1 bar and as
high as 5 bar although the recommended range is 2-3 bar dynamic at the appliance.
It is also important to check that all other equipment and components in the hot
and cold water system are capable of accepting the mains pressure available to the
property. If the mains pressure can rise above 5 bar or the maximum working pressure
of any item of equipment or component to be tted in the system, a pressure limiting
(reducing) valve set to 3 bar will be required.
If you encounter a situation where the water pressure is adequate but ow rates are
poor please contact our technical helpline for details of an eective solution.
Note : Each BoilerMate CP is tted with a strainer and ow regulator on the cold mains
supply connection. If the supply pressure is less than 2 bar or if all taps are provided
with ow regulators the ow regulator on the cold inlet should be removed.
No check valve or similar device should be tted on the cold water supply branch to
the BoilerMate CP.
The hot water ow rate from the BoilerMate CP is directly related to the adequacy of the
cold water supply to the dwelling. This must be capable of providing for those services,
which could be required to be supplied simultaneously, and this maximum demand
should be calculated using procedures dened in BS EN 806:1-5: BS EN 8558:2011.
If a water meter is tted in the service pipe, it should have a nominal rating to match
the maximum hot and cold water peak demands calculated in accordance with BS
EN 806:1-5: BS EN 8558:2011. Please note, the BoilerMate CP is tted with a 15 l/m
ow restrictor.
Warning/
overow
pipe
MCWS
Servicing
valve
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’ - ow 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 - tted
with BS1212
ballvalve
C
Figure 1.5
Typical hot and cold water distribution
BOILERMATE CP
Check valve
NOT REQUIRED unless
chemical water
treatment unit is tted
If an auto ll top up is tted, a check valve
can be installed here to prevent
stagnent water from this pipe back owing
into the mains cold water supply
a
Top up cistern
DESIGN
TECHNICAL DATA
Note: The diagram below shows the top up
cistern with ballvalve and warning/overow
pipe which can be supplied as an optional extra
if required. However, the standard preferred
arrangement is for the cistern to be manually
lled from a temporary hose connection tted
with a double check valve.
The cistern must not be tted more than 10
metres above the BoilerMate CP appliance itself.
Page 10
Hot and Cold Water System
Pipe Sizing / Materials
To achieve even distribution of the available supply of hot and cold water, it is
important in any mains pressure system, that the piping in a dwelling should be sized
in accordance with BS EN 806:1-5: BS EN 8558:2011. This is particularly important in
a large property with more than one bathroom.
However, the following rule of thumb guide lines should be adequate for most smaller
property types as long as water pressures are within the recommended range.
1. A 15mm copper or equivalent external service may be sucient for a small 1
bathroom dwelling (depending upon the ow rate available), but the minimum
recommended size for new dwellings is 22mm (25mm MDPE).
2. The internal cold feed from the main incoming stop tap to the BoilerMate CP should
be run in 22mm pipe. The cold main and hot draw-o should also be run in 22mm
as far as the branch to the bath tap.
3. The nal branches to the hand basins and sinks should be in 10mm and to the
baths and showers in 15mm (1 metre minimum).
4. We would recommend that best results for a balanced system are achieved
by tting appropriate ow regulators to each hot and cold outlet. This is
particularly relevant where the water pressures are above the recommended
water pressure range. Details of suitable ow regulators are provided in
Appendix A.
All the recommendations with regard to pipework systems in this manual are generally
based on the use of BS/EN Standard copper pipework and ttings.
However, we are happy that plastic pipework systems can be used in place of copper
internally as long as the chosen system is recommended for use on domestic hot
and cold water systems by the manufacturer and is installed fully in accordance with
their recommendations.
This is particularly important in relation to use of push t connections when using the
optional exible hose kits - see installation section of this manual.
It is also essential that if an alternative pipework material/system is chosen the
manufacturer conrms that the design criteria of the new system is at least equivalent
to the use of BS/EN Standard copper pipework and ttings.
Hot and Cold Water System
If the length of the hot water draw o pipework is excessive and the delivery time
will be more than 60 seconds before hot water is available at the tap, you may wish to
consider using trace heating to the hot water pipework such as the Raychem HWAT
system. Also a conventional pumped secondary circulation system (shown below)
can be used with any model of the BoilerMate CP.
Bath hot water supplies should be limited to
a maximum of 48°C by the use of an inline
blending valve.
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.
Secondary circulation pipework must be
insulated to prevent energy loss in both heated
and unheated areas.
Taps/Shower Fittings
Aerated taps are recommended to prevent
splashing.
Any type of shower mixing valve can be used
as long as both the hot and cold supplies
are mains fed. However all mains pressure
systems are subject to dynamic changes
particularly when other hot and cold taps/
showers are opened and closed, which will
cause changes in the water temperature at
mixed water outlets such as showers. For this
reason and because these are now no more
expensive than a manual shower we strongly
recommend the use of thermostatic showers
with this appliance.
The shower head provided must also be
suitable for mains pressure supplies.
However, if it is proposed to use a ‘whole body’
or similar shower with a number of high ow/
pressure outlets please discuss with the Gledhill
technical department.
The hot water supply to a shower-mixing
valve should be fed wherever practical directly
from the BoilerMate CP or be the rst draw-
o point on the hot circuit. The cold supply
to a shower-mixing valve should wherever
practical be fed directly from the rising mains
via an independent branch. The shower must
incorporate or be tted with the necessary check
valves to provide back-syphonage protection in
accordance with the Water Regulations.
The supply of hot and cold mains water directly
to a bidet is permitted provided that it is of the
over-rim ushing type and that a type ‘A’ air gap
is incorporated.
DESIGN
TECHNICAL DATA
BoilerMate CP
Inline lter &
ow regulator
Single check
valve
Single
check
valve
Pump isolation
valves
Cold water inlet
Plate heat exchanger
Hot water outlets Pipework length and
diameter to suit
property demands
Pipework length and
diameter to suit
recirculation ow rate
approx 1-2 l/min
Cold water sensor
Control
stat
Flow switch
Potable water
expansion vessel
Secondary
circulation
pump
Page 11
DESIGN
SYSTEM DETAILS
Watermeter
Heatmeter
Districtflow
Coldwater
Districtreturn
Programmer
F&ECistern
DHWController
DHWPump
Roomthermostat
Flow sensor
Cylinder
thermostat
Backupimmersionheater
DiverterValve
(notmidposition)
Coldwatertodwelling
DHWtodwelling
CHflowtodwelling
CHreturnfromdwelling
BMS
Boilermate stainless
forDistrictHeating
Coilflowconnection
Coilreturnconnection
Airvalve
Zonevalve
DHW24PlatePHE
The above diagram shows the BoilerMate CP installed to a system where the pumped
supply is adequate to overcome the pressure loss of the BoilerMate CP heat exchanger
coil, the pressure loss over the central heating system components and all other
components tted to it. In addition, all the components tted are able to withstand
the pressure in the district system.
In the above diagram, the cold water supply to the feed and expansion cistern is not
shown, and neither is the overow pipe which may by required if the ball valve is tted
to the F & E cistern. See page 9 for further details. Potentially a temporary lling loop
complying with the water regulations can be installed.
Immersion Heaters
These are 3kW 240V AC heaters and incorporate a control thermostat set at 73°C and
a manually reset energy cut-out which operates at 85°C.
External wiring to the immersion heaters must be in accordance with the relevant IEE
Wiring Regulations and the circuit must be protected by a suitable fuse and a double
pole isolating switch.
The correct method of terminating the wiring to the immersion heater is shown
opposite.
Page 12
DESIGN
SYSTEM DETAILS
Heatmeter
DiverterValve
(notmidposition)
CHflowtodwelling
CHreturnfromdwelling
Heatmeter
DiverterValve
(notmidposition)
CHflowtodwelling
CHreturnfromdwelling
Pumppositiontoovercomepressurelossoncentralheatingcircuit– noadditionalrequirementforsystemexpansionorexcesspressure
District
supply
District
return
District
supply
District
return
Pumppositiontoovercomepressurelossoncentralheatingcircuitandcoil‐ noadditionalrequirementforsystemexpansionorexcesspressure
Coilflowandreturn
Coilflowandreturn
CHBypass
CHBypass
Zonevalve
Zonevalve
Heatmeter
DiverterValve
(notmidposition)
CHflowtodwelling
CHreturnfromdwelling
Heatmeter
DiverterValve
(notmidposition)
CHflowtodwelling
CHreturnfromdwelling
Pumppositiontoovercomepressurelossoncentralheatingcircuit– noadditionalrequirementforsystemexpansionorexcesspressure
District
supply
District
return
District
supply
District
return
Pumppositiontoovercomepressurelossoncentralheatingcircuitandcoil‐ noadditionalrequirementforsystemexpansionorexcesspressure
Coilflowandreturn
Coilflowandreturn
CHBypass
CHBypass
Zonevalve
Zonevalve
Heatmeter
DiverterValve
(notmidposition)
CHflowtodwelling
CHreturnfromdwelling
Pumpandplateheatexchangerpositiontoovercomepressurelossandadditionalexpansionrequirementoncentralheatingcircuit
– noadditionalrequirementforexcessdistrictpressure.
District
supply
District
return
Coilflowandreturn
Plateheatexchanger
Localexpansionsystem
connectionrequired
Heatmeter
DiverterValve
(notmidposition)
CHflowtodwelling
CHreturnfromdwelling
Pumpandplateheatexchangerpositiontoovercomepressureloss,additionalexpansionrequirementandexcessdistrictpressurerequirements
District
supply
District
return
Coilflowandreturn
Plateheatexchanger
Localexpansionsystem
connectionrequiredCHBypass
CHBypass
Zonevalve
Zonevalve
Openventedfeedandexpansion
OrTemp.fillinglooprequired
Openventedfeedandexpansion
OrTemp.fillinglooprequired
Heatmeter
DiverterValve
(notmidposition)
CHflowtodwelling
CHreturnfromdwelling
Pumpandplateheatexchangerpositiontoovercomepressurelossandadditionalexpansionrequirementoncentralheatingcircuit
– noadditionalrequirementforexcessdistrictpressure.
District
supply
District
return
Coilflowandreturn
Plateheatexchanger
Localexpansionsystem
connectionrequired
Heatmeter
DiverterValve
(notmidposition)
CHflowtodwelling
CHreturnfromdwelling
Pumpandplateheatexchangerpositiontoovercomepressureloss,additionalexpansionrequirementandexcessdistrictpressurerequirements
District
supply
District
return
Coilflowandreturn
Plateheatexchanger
Localexpansionsystem
connectionrequiredCHBypass
CHBypass
Zonevalve
Zonevalve
Openventedfeedandexpansion
OrTemp.fillinglooprequired
Openventedfeedandexpansion
OrTemp.fillinglooprequired
In this diagram an additional pump is shown
tted because the pressure loss in the central
heating system is too large for the district pump.
The pump is now tted in the district supply
because the pressure loss over the BoilerMate
CP coil is too large.
Here, the plate heat exchanger has been tted
because the expansion requirements of the
central heating system are to be handled in the
dwelling rather than the whole system, or the
components in the central heating system are
not capable of withstanding the pressure of the
district heating system.
In this instance, the plate heat exchanger
provides a full pressure break between the
district heating system and the dwelling system.
The dwelling system will need to cater for
expansion and circulation requirements. This
may be used where excessive district heating
pressure occurs.
Page 13
The appliance is designed to be installed in an airing/cylinder cupboard and the
relevant minimum dimensions are provided in the Technical Data section of this
manual.
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.
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 Top up cistern. See the Technical Data section of this manual for further details.
The minimum dimensions contained in the Technical Data section of this manual
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 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 of this manual.
The appliance is designed to operate as quietly as practicable. If the plate heat
exchanger pump is noisy when the hot water tap is opened, then check the level
of water in the F & E cistern and vent the pump if necessary. Water hammer may be
caused by loose pipework and/or tap washers and/or washing machine valves.
Cupboard temperatures will normally be slightly higher than in a conventional system
and the design of the cupboard and door will need to take this into account. No
ventilation is normally required to the cupboard.
The separate Top up cistern will need to be located on top of the appliance or at high
level in the cupboard housing the BoilerMate CP. The dimensions and clearances are
provided in the Technical Data section of this manual. The location will need to provide
a suitable route for the cold feed 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/overow pipe and the ballvalve supply from the mains cold water system
(if provided) if these have been ordered as an optional extra.
Note: The standard appliance is supplied with a cistern without a ballvalve/
overow for lling manually.
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.
The electrical mains supply needs to be 230V/50Hz.
The sizes/types of electrical supplies must be as detailed in System Details section
of this manual. 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.
The hot and cold water ‘rst x’ pipework should be terminated 50mm above the
nished oor level in accordance with the dimensions provided in the Technical Data
section of this manual.
INSTALLATION
SITE REQUIREMENTS
Page 14
INSTALLATION
INSTALLATION
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 C
at the rear of this manual.
Preparation/placing The Appliance In
Position.
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 above.
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.
Before installation the site requirements should
be checked and conrmed as acceptable.
The plastic cover and protective wrapping
should be removed from the appliance and the
installation base (provided) 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, the working head of the appliance
is not exceeded and the recommended access
is provided for maintenance - see the Technical
Data section of this manual for details.
Page 15
INSTALLATION
INSTALLATION
Pipework Connections
The position of the pipework connections is
shown opposite. The exact location dimensions
are listed in the Technical Data section of this
manual.
All the connections are also labelled on the
appliance. It is essential that the pipework is
connected to the correct connection.
Connections A and B are plain ended stainless
steel pipe.
Connection C and D compression ttings.
Connection E is RC½ (½ in BSPT internal)
A - 22mm Safety open vent
B - 22mm Cold feed/expansion
C - 22mm Incoming mains cold water
D - 22mm Domestic hot water
E - ½” Drain tap connection
F - 28mm Boiler ow
G - 28mm Boiler return
Note: The safety open vent and cold feed/
expansion must be connected to the top up
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 top up cistern should be
installed following the instructions provided
and the cistern tted on its supports/top of
the appliance.
The cold feed/expansion and safety open vent
should be installed between the appliance and
the top up cistern.
Figure 1.6
C
D
BA
E
G
F
Page 16
INSTALLATION
INSTALLATION
Cold feed / open vent
pipework
(as supplied)
Interconnecting
Pipework
(By Installer)
Figure 1.7
BoilerMate
CP
Feed And Open Vent Pipe
It is normally envisaged that the top up cistern will be located in the same cupboard
as the BoilerMate CP appliance itself to maintain a dry roof space.
The cold feed/open vent pipework assembly (as supplied) should be used to install
the top up cistern directly on top of the appliance.
If it is necessary to locate the cistern in the roof space (or on a higher oor) the cold
feed/open vent pipework assembly (as supplied) should be used to connect to the
top up cistern and pipework site run by the installler to connect this to the appliance.
Obviously, any pipework in the roof space and the feed and expansion cistern will
need to be adequately insulated to protect against frost damage.
Combined Feed And Open Pipe Arrangements Must Not Be Used.
No valves should be tted in the safety open vent which must be a minimum of 22mm
copper pipe or equivalent throughout its length.
The mains cold water supply to the ballvalve (if provided) shall be provided with a
suitable servicing valve.
The overow/warning pipe (if provided) shall have a continuous fall, be tted to
discharge clear of the building and be sited so that any overow 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 (e.g 22mm copper) and should not
have any other connections to it.
Note: If a warning/overow pipe is NOT provided the top up cistern should be
lled from a temporary hose connection supplied from any cold water tap or
from a permanent cold branch provided adjacent to the top up cistern. The
temporary hose must be tted with a double check valve and removed once
the appliance is lled.
The store may ll more slowly than the feed tank. It is important to check the
water level again in the cistern after commissioning.
Page 17
INSTALLATION
INSTALLATION
1
2
3
4
5
6
7
8
9
10
11
12
13
14
1
2
3
4
1
2
3
4
1
2
3
4
5 6 7 8
1
2
1
2
3
4
5
6
7
8
9
1
10
2 3
4 5 6
J18
J20
J19
J3 J7
J8
J1 TS sensor
GND GND
IN OUT
T1 T2
1
2
CW sensor
1
2
Combined flow
and
HW temperature
sensor
L - Brown
PR61
E – G/Y
N - Blue
PWM -
PWM +
SPARE
Fuse
Dip
Switch
1 2 3 4
To
DHW
pipe
All the these sensor inputs carry a
Voltage of 5V.
The max cable length is 1 meter.
The sensors connected to the control
Should be free from the appliance earth
Connector 2x3-poles with temperature output
from ow sensor perspective
Page 18
INSTALLATION
INSTALLATION
Programmer
Fuse
Spur
L
N
ELN
On On
Off Off
HW CH
Store
thermostat
EC12
2port
zonevalve
ML MN E PL SL
Room
thermostat
EC12
3port
divertvalve
ML MN E PL SL
Wiringdiagram– nopumprequired
Programmer
Fuse
Spur
L
N
ELN
On On
Off Off
HW CH
Store
thermostat
EC12
2port
zonevalve
ML MN E PL SL
Room
thermostat
EC12
3port
divertvalve
ML MN E PL SL
Wiringdiagram– CHpumprequired
CH
Pump
L
N
E
The following control wiring diagrams ensure
that the district heating system is isolated from
the dwelling when charging is not required.
Please note, it is part of the commissioning
process to ensure the controls are functioning
correctly.
Page 19
INSTALLATION
INSTALLATION
Programmer
Fuse
Spur L
N
E
LN
On On
Off Off
HW CH
Store
thermostat
EC12
2port
zonevalve
ML MN E PL SL
Room
thermostat
EC12
3port
divertvalve
ML MN E PL SL
Wiringdiagram– HW&CHpumprequired
CH
Pump
L
N
E
Page 20
Open the incoming stop valve and ll the domestic mains cold and hot water systems
including the BoilerMate CP appliance.
Check the water level in the top up cistern and if a ballvalve is tted adjust if necessary.
Check the whole of the domestic hot and cold distribution systems for leaks. Fully
ush and if necessary chlorinate the hot and cold water system in accordance with
the recommendations in the Water Regulations and BS EN 806:1-5: BS EN 8558:2011.
Please note that the whole of the domestic hot and cold water systems including
the appliance must be adequately ushed after chlorination. Failure to do this can
cause damage to the plate heat exchanger/immersion heaters etc. If there are any
doubts regarding this or the quality of the water being used to ll the BoilerMate CP
appliance an inhibitor such as Fernox MBI or Sentinel X100 should be added to the
appliance when lling in line with the manufacturers instruction for these products.
Check that the top up tank is lled up to the water level shown on the label. If it is a
manual ll model, this is most important.
If a ballvalve is provided, turn down the servicing valve once the system is nally
lled to the point where the warning/overow pipe will cope with the discharge
arising from a ballvalve failure.
If an overow is not provided ensure the temporary lling hose is isolated and
removed from its connection to the cold water supply.
It is essential that all systems function properly for optimum performance.
To achieve this the ow rate from each tap should be checked and a suitable number of
taps run simultaneously to check the impact of this on the ow rate at individual taps.
We recommend that ow regulators are provided for each tap/terminal tting
to ensure that the available ow is shared evenly - See Appendix A for further
details.
Commissioning the BoilerMate CP Control System
It can be checked that the boost immersion heater is drawing current by use of a
clamp meter on the live supply when boost is active.
If the appliance has been connected with the polarity incorrect it will not operate at all.
See the fault nding section of the manual for further details.
Run a tap and using a digital thermometer check that the temperature of the hot
water is about 52°C. This temperature is factory set and is independent of the store
temperature assuming the store is above 55°C and typical hot water ow rates of
6-15l/min are being drawn.
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 oered by Gledhill.
Basic pump operation testing
In order to conrm that the pump is operational,
and that all air has been cleared from the pump
circuit pipe work, including the PHE. Perform the
following actions.
1. Ensure that the unit is full of water
2. Ensure that the primary pipework to the PHE
and the PHE itself are bled of air
3. Open hot water tap
4. The pump should then run and hot water
will be delivered through the tap
INSTALLATION
COMMISSIONING
Page 21
INSTALLATION
INSTALLATION REVIEW
Circulating uid in thermal store pipework
• The BoilerMate CP and the thermal store pipework must have completed lling
prior to switching the electricity supply to the PWM controller PCB. If there is no
water in these pipes then there may be signicant wear on the PWM pump.
• This can be conrmed by
- Checking the thermal store pipework servicing valves are open
- Loosening the connection points on the thermal store pipework in a systematic
manner and checking for water presence.
- Conrming that the feed and expansion tank has completed lling and the
servicing valve is open.
Cold mains water supply to plate heat exchanger and hot water taps
• Conrm that the CW mains stop valve is open
• Open all HW taps and conrm that the water runs freely and that any air is bled
from the DHW system
• Determine the maximum ow rate obtained and record
• 15l/min for all BoilerMate CP products currently limited with a ow restrictor
• If ow rate not as expected determine the cause and rectify
- clean inline strainer
- check the ow restrictor is present and not blocked. It is located in the top of
the inline strainer
Power on
• Switch on the Local fuse spur and observe the PWM pump
• The green LED will ash showing the pump has a power supply and is in standby
mode.
• Open a HW tap and observe the PWM pump
• The green LED will be constantly lit showing the pump has a power supply and is
running to generate HW
NOTE: -The thermal store will only produce hot water when it is hot enough. A mid
40°C thermal store temperature will provide some hot water, higher thermal store
temperatures will provide more.
Inline scale inhibitor (if tted)
• Check power supply
• PWM Controller PCB supplies a maximum of 12vDC/300mA to the Scale inhibition
board. (From J3)
• Check dip switches set correctly
• The correct settings for tube diameter 22mm is switch no. 3 on.
• Switch no. 4 can be either on or o.
• If the switch no. 4 is turned on the output electromagnetic eld is generated
harmoniously otherwise the eld is generated inharmoniously.
Page 22
INSTALLATION
SERVICE / CHANGE COMPONENTS
Important Do’s and Don’ts
1. DO check the incoming mains water pressure. The preferred range of mains
pressure is 2 -3 bar.
2. DO check the ow rate of the incoming cold water main is adequate to meet the
maximum hot and cold water simultaneous demands.
3. DO check that all connections are in accordance with the labelling on the thermal
store.
4. DO check the water level is correctly set in the top up cistern when cold and if
tted that there is no overow when the appliance is up to temperature.
5. DO check that the control thermostats switch the immersion heaters o at the
correct set point i.e. approx 75°C.
6. DO insulate any exposed hot water pipework in the BoilerMate CP cupboard.
7. If the ballvalve in the F & E cistern is permanently connected to the mains cold
water supply DO plumb the overow/warning pipe in a 20mm internal diameter
pipe and ensure it discharges in a conspicuous external position. Use a material
which is suitable for use with heating F & E cisterns in accordance with BS 5449
(such as copper).
8. Once the appliance is lled and commissioned DO leave the electricity switched
on to the appliance to ensure the automatic pump run facility can operate to
prevent the pump sticking.
9. DO ensure that the functioning and control of the system is explained to the
occupant.
10. DON’T place any clothing or other combustible materials against or on top of this
appliance.
The front panel should then be retted.
Annual Servicing
No annual servicing of the BoilerMate CP is
necessary.
However, if required, the operation of the
controls and a hot water performance test can
be carried out to prove the appliance is working
satisfactorily and within its specication.
If it is decided to carry out the above tests the
water level in the top cistern should also be
checked and if necessary topped up.
Changing Components
Free of charge replacements for any faulty
components are available from Gledhill during
the in-warranty period on return of the faulty
part (normally 12 months).
After this, spares can be obtained direct from
Gledhill Spares or through any of the larger
plumbers merchants/specialist heating spares
suppliers.
Help and advice is also available from the
Technical Helpline on 01253 474584.
However, all components are readily accessible
and can be changed quickly and easily by the
installer using common plumbing/electrical
practice.
Note: All maintenance work on the
BoilerMate CP appliance must be carried
out by a competent trades person.
Note:
The pump is a Grundfos UPR 15-50 4 wire
pattern and any replacement must be the
same model.
Page 23
Description Stock Code
1PHE pump UPR 15-50 GT089
2Plate heat exchanger (24 Plate) GT017
3Pump isolating valve - outlet (90° valve) GT135
4Pump isolating valve - inlet GT133
5Immersion heater 3kW SH003
6Stat XB081
7Main PCB controller XB103
8Sensors GT198
9Y strainer XB314
10 Flow sensor XB091
11 Scale Inhibitor XB153
SERVICING
SHORT PARTS LIST
Page 24
SERVICING AND MAINTENANCE
FAULT FINDING
Test Equipment
The initial assumption in this procedure is that the plumbing and water supply is
working eectively. If in doubt please conrm and refer to the end of this section for
advice on specic components.
A multi meter, a weir gauge and a thermometer will be required to conrm that all
the components are working eectively.
The PWM controller PCB manufacturer suggests “Fluke 87 TRUE RMS Multi meter” as
a suitable product. This will be able to measure;
- the frequency output form the Board to the pump
- the Duty cycle % output from the Board to the pump
Connection numbering
For reference the connections to the PCB are numbered below for
Logical sequence;
- check electrical connections fault nding section on page 23 rst to ensure your
own safety. This section will potentially identify any short circuited components
and/or wiring faults that need to be rectied before continuing to work on the
appliance.
- check that the correct information is being supplied to the board. This section will
identify if any sensors are faulty or out of tolerance. These will need to be replaced
before continuing
- check that the overheat link is present
- check that the outputs to the board are being generated. If at this stage the board
does not provide the correct outputs then potentially the board should be replaced
- check the pump electrical circuit
1
2
3
4
5
6
7
8
9
10
11
12
13
14
1
2
3
4
1
2
3
4
1
2
3
4
5 6 7 8
1
2
1
2
3
4
5
6
7
8
9
1
10
2 3
4 5 6
J18
J20
J19
J3 J7
J8
J1
Page 25
SERVICING AND MAINTENANCE
FAULT FINDING
Electrical power connections
Check inputs to the PWM Controller PCB
Reference schematic
opposite
Check procedure
Power supply to PWM
Controller PCB
Electrically isolate power supply at fused spur switch and remove fuse.
Earth continuity test (dead test) – to ensure that the appliance is earthed
Mains voltage test (dead test) - to ensure that the appliance is isolated
Resistance to earth (dead test) – to ensure that the wiring insulation to the product is intact
Short circuit test (dead test) – to ensure that no components in the products circuit have a short circuit
Visually inspect wiring is correct as per g 4.3
Connect supply
Polarity test (live test) - to ensure that the live is connecter to the live etc
• Check 230V ac across L1 to Earth
• Check 230V ac across L1 to N
• Check for 0 to 15V ac N to earth
Reference to “Boilerfault nder.com” gives clear instructions to on how to perform these tests. (Menu
options 1st. Boiler Fault nder 2nd. Electrical safety checks).
Reference schematic
opposite
Check procedure
CW temperature sensor Power o
Disconnect J18
Measure and record the resistance across terminals 6 and 13
Measure the cold water inlet temperature
Compare the resistance measured with chart “Tasseron NTC 12k thermistor”
The reading should make sense taking measurement conditions into consideration
TS temperature sensor Power o
Disconnect J18
Measure and record the resistance across terminals 3 and 10
Measure the thermal store temperature
Compare the resistance measured with chart “Tasseron NTC 12k thermistor”
The reading should make sense taking measurement conditions into consideration
HW temperature sensor Power o
Disconnect J18
Measure and record the resistance across terminals 7 and 14
Measure the Hot water temperature
Compare the resistance measured with chart “HUBA combined ow sensor and NTC 10k thermistor”
The reading should make sense taking measurement conditions into consideration
Flow sensor Power on Sensor required a power supply 5 VDC
Open a HW tap and set to a ow rate.
Measure and record the frequency across terminals 1 and 12
Compare the frequency measured with chart “ow rate determination”
The reading should make sense taking measurement conditions into consideration
Page 26
SERVICING AND MAINTENANCE
FAULT FINDING
1
2
3
4
5
6
7
8
9
10
11
12
13
14
1
2
3
4
1
2
3
4
1
2
3
4
5 6 7 8
1
2
1
2
3
4
5
6
7
8
9
1
10
2 3
4 5 6
J18
J20
J19
J3 J7
J8
J1 TS sensor
GND GND
IN OUT
T1 T2
1
2
CW sensor
1
2
Combined flow
and
HW temperature
sensor
L - Brown
PR61
E – G/Y
N - Blue
PWM -
PWM +
SPARE
Fuse
Dip
Switch
1 2 3 4
To
DHW
pipe
All the these sensor inputs carry a
Voltage of 5V.
The max cable length is 1 meter.
The sensors connected to the control
Should be free from the appliance earth
Resistance Resistance
Ohm °C ±°C Ohm °C ±°C
309396 -40 1.7 334275 -36 0.9
171840 -30 1.7 47369 -6 0.1
98932 -20 1.6 26023 50.1
58879 -10 1.5 11000 23 0.6
36129 01.4 10500 24 0.6
22804 10 1.4 10000 25 0.6
14773 20 1.3 9500 26 0.7
12000 25 1.2 9000 27 0.7
9804 30 1.2 8500 29 1.4
6652 40 1.1 8000 30 1.5
4607 50 17500 31 1.6
3252 60 0.9 7000 33 1.7
2337 70 1.1 6500 35 1.7
1707 80 1.3 6000 37 1.8
1266 90 1.5 5500 39 1.9
952 100 1.8 5000 41 2.1
4500 44 2.2
4000 47 2.3
3500 50 2.5
3000 54 2.7
2500 59 2.9
2000 65 3.3
1500 73 3.7
1000 86 4.3
R-nominal R-nominal
B-value B-value
R-Tolerance R-Tolerance
Tmin
Tmin
Tmax Tmax
125°C
under 25°C±0.025*T °C over 25°C±0.05*T °C
Huba combined flow sensor and NTC 10k thermistor
Tasseron NTC 12k thermistor
12Kohm @25°C
B3740K
3%@60°C
150°C
Temperature
Temperature
-40°C
-40°C
Used on the store temperature sensors and the
cold water inlet temperature sensors
12Kohm @25°C
B4050K
HZ l/min HZ l/min
20 3.4 95 17.1
25 4.4 100 18.0
30 5.3 105 19.0
35 6.2 110 19.9
40 7.1 115 20.8
45 8.0 120 21.7
50 8.9 125 22.6
55 9.8 130 23.5
60 10.7 135 24.4
65 11.7 140 25.3
70 12.6 145 26.2
75 13.5 150 27.2
80 14.4 155 28.1
85 15.3 160 29.0
90 16.2 165 29.9
flow rate determination
Page 27
SERVICING AND MAINTENANCE
FAULT FINDING
Check for presence of overheat link
An overheat link connection should be present in connection Junction 7. If you are
tting a new board the overheat link that is on the board just removed must be retained
as the newly supplied board will not have one tted.
Check outputs from the PWM controller PCB to the pump
PWM pump power Check 230V ac across Junction 8, L(10) to E(6) and L(10) to N(8) (live test)
Check for 0-15V ac across Junction 8, N(8) to E(6) (live test)
PWM frequency Power on the unit
Set the multi meter to measure the frequency
Measure the PWM frequency produced by the board between pins 3 on J8 and pin 9 on J8
This can be between 100Hz – 5000 Hz (1000Hz nominal)
(Lab tested gure of 562Hz recorded in steady state conditions).
Duty cycle Switch your Multimeter to ‘duty cycle or %’ then it will show a percentage from 0 to 100%.
This percentage is the command for the pump how fast it should run.
When you perform a small DHW tapping, the percentage will be low
When you perform a large DHW tapping, the percentage will be higher
PWM input signal [%] indications
• 0-7 Pump stops (Standby)
• 7-15 Pump runs at minimum speed (operation)
• 12-15 Pump runs at minimum speed (start-up)
• 15-95 Pump speed increases linearly from minimum to maximum
• > 95 Pump runs at maximum speed
Page 28
SERVICING AND MAINTENANCE
FAULT FINDING
Check pump electrical circuits
LED Meaning Diagnosis Cause Remedy
Lights green Normal running Pump runs according
PWM input
Normal operation n/a
Blinks quick green Normal stopped Pump in standby n/a
Blinks red/ green Abnormal running mode
-pump stopped but still
functional
The pump has stopped
due to external failure
Pump restarts by itself
after the fault has
disappeared
Under voltage U<160 V
or
Over voltage U>253 V
Check voltage supply
195 V <U< 253 V
Pump overheating:
temperature inside motor
too high
Check water and
ambient temperature
Over speed:
the pump rotor is driven
by an external ow above
the maximum allowed
value
Ensure that there is no
other external ow (other
pump running) on
system
Over current:
the stator winding is in
short circuit due to water
Check for leakage
application on
application
Overload of motor:
friction due to particles
and/or impeller blocked
with debris
Check installation water
quality, clean system if
debris
Blinks red Pump out of function Pump stopped (blocked) Blockage:
the pumps is fully
blocked due to debris in
system
Check for blockage.
Turn ON/OFF to reset
the pump by unplugging
the power supply
If the pumps still blinking
red after a power reset
then replace the pump
Faulty electronic module
and/or faulty motor
LED o No power supply No voltage on electronics Pump is not connected to
power supply
Check cable connection
LED is damaged Check if pump is running
Electronics are damaged Replace pump
Check plumbing components
CW In line lter Isolate the CW mains supply at the servicing valve
Open HW taps to relieve the pressure
Undo securing nut ensuring that any remaining water is collected
Remove lter and clean it
The ow regulator can be checked at the same time by removing the upper pipe section.
Thermal store return
check valve + return
servicing valve
Isolate both servicing valves
Drain water from the section between the servicing valves
Remove the bottom pipe section
Check for free movement of the check valve incorporated in the body. Remove and replace if the check
valve sticks.
Page 29
SERVICING AND MAINTENANCE
FAULT FINDING
Check
plumbing
TS full
of water?
Water
mains on?
PHE pipework
air locked?
Check
sensors
Overheat link
present in J7
Sensors plugged
in securely?
Sensors providing
correct signal to PCB?
Check Electrical
supply
Electrically
safe?
Components
short circuited?
Wiring as per
circuit diagram?
Pump LED
on?
N
Check cable connection secure and
resistance in cable Pump running? LED is damaged pump replacement optional
OK? Y
Resolve
N
Electronics damaged replace pump
LED Blinks red?
Y
Y Check for blockage in pipework
or pump housing
N
LED
continues to Blink red after power
reset
Y
Motor or Electronics damaged replace pump
OK?
OK? OK? OK?
OK? OK? OK?
Wiring as per circuit diagram
& polarity correct?
OK?
OK? Sensors in
correct location?
OK? OK? OK?
N
OK?
OK?
LED Blinks red &
green?
Resolve
OK?
Under voltage U<160 V or
Over voltage U>253 V
Resolve
OK? Pump overheating: Check water
and ambient temperatures
Resolve
Pump Over speed Ensure that there
is no other external flow (other
pump running) on system
OK?
Resolve
Over current the stator winding
is in short circuit due to water. Check
for leak
OK?
Resolve
Over load of motor: friction due to
particles or impellor blocked. Clean
debris from system
Note pump will restart by itself when
the fault disappears OK?
Resolve
LED Blinks green? Normal stopped: pump in standby
Normal
running: pump runs according to PWM signal and the LED will be constantly on
Y
N
Check board output to
pump
Check
power output to pump J8 L(10),
N(8), E(6)
Check
PWM frequency
Check
Duty Cycle
Y
Board
electronics
damaged
N
Sophisticated
multi meter
available
Y
N
OK?
OK?
N
N
Page 30
APPENDIX
APPENDIX A
Vast quantities of water are needlessly run off to waste due to Taps, Mixers and Showers
discharging flow rates far in excess of the rates required for them to perform their
duties.
The contrasting flow rates shown on this leaflet clearly illustrate the savings that can
be made whilst still providing a good performance.
British made Aquaflow Regulators provide constant flow rates by automatically
compensating for supply pressure changes between 1 bar & 10 bars.
To facilitate installation into the wide range of plumbing equipment which is
encountered in the U.K, Four Fixing Options are available:-
Options For Showers
1.
MXF “DW” Range - For fitting behind Fixed Shower Heads or onto Flexible Hoses for
Handshowers (preferably onto the inlet end when lightweight hoses are used).
2.
Compression Fitting Range. “In Line” regulators as in Option 4 for Taps & Mixers.
Information by courtesy of
AQUAFLOW REGULATORS LTD
Haywood House, 40 New Road, Stourbridge, West Midlands DY8 1PA
TELEPHONE (01384) 442611 FAX: (01384) 442612
W
ater Savings
W
ater Related Costs Can Be Reduced By Good Plumbing Practice
TAPS & MIXERS
SHOWERS
Unregulated
25 - 30 l/m
Regulated
10 - 12 l/m
Over
20 l/m
5, 6 or
8 l/m
2 tap
half open
Fitted with regulator
Unregulated
4 Fixing Options For Taps & Mixers
1. MK Range - Combined Regulators & Aerator
for screwing onto Taps & Mixers with internal
or external threads on their noses. Anti Vandal
models also available.
2. MR05-T Range - Internal Regulators. Push-
fit into Tap or Mixer seats. Produced in
three sizes - 12.5mm (BS1010), 12mm &
10mm, Flangeless models also available for
Taps with Low Lift washers.
3. MXF Standard Range - Screw on tail
models for Taps & Mixers. Fix onto the tails
before fitting the tap connectors. Available
in 3/8", 1/2", 3/4" and 1" BSP.
4. Compression Fitting Range - “In Line”
regulators housed in 15mm & 22mm CXC
Couplers & Isolating Valves. “ ”UK WFBS listed
by the Water Research Centre. Isolation valves
available for slotted screwdriver operation or
with coloured plastic handles. Now available
also in plastic bodied push-fit couplers &
valves.
2
1
1
2
1
2
3
3
1
4
Page 31
APPENDIX
APPENDIX B
Page 32
APPENDIX
APPENDIX C
Description
Manual handling means any transporting or supporting of a load (including lifting,
putting down, pushing, pulling, carrying or moving) by hand or bodily force.
Scope
This assessment will cover the largest unit within each product range manufactured
by Gledhill.
For specific weights and dimensions please refer to technical data section.
Main Hazards
Vision may not be clear due to the size of the products.
Adopting an incorrect method of lifting may cause injury, attempting to lift these
products will require help from others. (Team lifts)
Control Measures
Manual lifting procedure
The lift, key factors in safe lifting are:
a. Balance
b. Position of back
c. Positioning of the arms and body
d. The hold
e. Taking the lead for team lifts
a. Balance - Since balance depends essentially upon the position of the feet,
they should be apart about hip breadth with one foot advanced giving full
balance sideways and forward without tension. In taking up this position,
lifting is done by bending at the knees instead of the hips and the muscles
that are brought into use are those of the thigh and not the back.
b. Position of back - Straight - not necessary vertical. The spine must be
kept rigid, this coupled with a bent knee position, allows the centre line of
gravity of the body to be over the weight so reducing strain.
c. Positioning of arms and body - The further arms are away from the side,
the greater the strain on the shoulders, chest and back. Keep elbows close
to the body arms should be straight.
d. The hold - Before lifting ensure you have a good hold. Two handles are
provided on Appliance products at the top rear side, these allow one or
two persons to have a purposely-designed hold at the top of the appliance
to ensure easy lifting at the top of the product.
e. Taking the lead for team lifts- As
more than one person is required
for these products ensure that one
person is taking the lead. This may
be you so ensure that each person
that is helping is made aware of the
weight and of the items listed within
this assessment. Make sure you and
any others helping know the route
you intend to take that it is clear of
any obstructions. Never jerk the load
as this will add a little extra force and
can cause severe strain to the arms,
back and shoulders. If there are steps
involved decide on where you will
stop and take a rest period. Move
smoothly and in unison taking care
to look and listen to others helping
with the lift. Where possible use
a sack truck to move the product
over long flat distances, only lift the
products when necessary. If in doubt
stop and get more help.
Individual capability
Individual capability plays an important
part in handling these products. Persons
above average build and strength will
find it easier and should be in good
health. Persons below average build and
strength may require more rest periods
during the handling process.
Pregnant women should not carry out
this operation.
Persons who are not in good health
should seek medical advice prior to
commencing any lifting or manual
handling operation.
Residual risk
Following the guidelines given above will
reduce any risk to injury.
All persons carrying out this operation
must be fully trained and copies of the
specific risk assessment made available
for inspection and use in their training
process.
Further guidance on Manual Handling
can be obtained from the Health and
Safety Executive. Manual Handling
Operations Regulations 1992.
MANUAL HANDLING OF APPLIANCE PRODUCTS
Page 33
NOTES
NOTES
Page 34
NOTES
NOTES
Page 35
NOTES
NOTES
Page 36
TERMS AND CONDITIONS
Gledhill (Building Products) Ltd
AMD.DECEMBER 2013
CONDITIONS OF SALE & GUARANTEE TERMS
1. Gledhill (Building Products) Ltd (“We” or “Gledhills”) only do business upon the Conditions which appear below
and no other. Unless we so agree in writing these Conditions shall apply in full to any supply of goods by us to the
exclusion of any Conditions or terms sought to be imposed by any purchaser. These Conditions of Sale and Warranty
Terms override those which are contained on the Invoice Forms and all Sales are now subject to these Conditions of
Sale and Warranty terms only.
2. PRICE
Once an order or call off has been accepted the price will be held for three months but if delivery is extended
beyond that period at the customer’s request, then we reserve the right to amend the price when necessary.
The company reviews its pricing annually to adjust for changes in our cost base. We reserve the right to alter prices
at any time for severe movements in raw materials (mainly copper and steel). If there is to be a change we will give
customers at least four weeks notice but anything delivered after that date will be at the revised price. An order
may not be cancelled or varied after acceptance without the written consent of the company. Such cancellation or
variation shall be subject to such reasonable charges as may be appropriate.
3. SPECIFICATION
The goods are supplied in accordance with the Specifications (if any) submitted to the Purchaser and any additions
and alterations shall be the subject of an extra charge. Any goods not so specified shall be in accordance with
our printed literature or the literature of any of our component suppliers (subject to any modifications made since
publication). If we adopt any changes in construction or design of the goods, or in the specification printed in our
literature, the Purchaser shall accept the goods so changed in fulfilment of the order.
4. PAYMENT
The buyer shall make payment in full within thirty days from the end of the month in which the invoice is dated. If
we receive payment in full on or before the due date we will allow an appropriate settlement discount except where
we have quoted a special net price. If payment is not received in full on or before the due date we shall be entitled
in addition to the invoice price to:
(i) payment of a sum equal to any increase in the copper price supplement applicable to the particular goods sold
between the date of receipt of order and the date of receipt of payment in full; and
(ii) interest on any part of the invoice price unpaid after the due date at the rate of 3% per annum over the base
rate for the time being of HSBC Bank plc.
5. TIME
We give estimates of delivery dates in good faith and time of delivery is not nor shall be made of the essence of any
contract nor shall we be liable for any loss or damage occasioned by delay in delivery.
6. DELIVERY
We deliver free normally by our own vehicles within 25 miles of any of our manufacturing depots. Delivery to any
place more than 25 miles from one of our manufacturing depots may be subject to our quoted delivery charges. We
reserve the right to make delivery of goods contained in one order by more than one consignment and at different
times. Where a period is agreed for delivery and such period is not extended by our Agreement, the Purchaser shall
take delivery within that period. If the Purchaser fails to take delivery, we shall be entitled at the Purchaser’s risk
and expense to store the goods at the Purchaser’s premises or elsewhere and to demand payment as if they had
been despatched. Off loading at point of delivery shall be the responsibility of and be undertaken by the Purchaser.
7. SHORTAGES OR DAMAGE
Goods must be inspected before signature of delivery note and any damage, shortage or discrepancy noted on the
delivery note and the goods returned on the same vehicle. The buyer must also give us immediate written notice of
the damage, shortage or discrepancy so that we may prompt investigation.
8. RETURN OF GOODS
Goods may not be returned to the Company except by prior written permission of an authorised officer of the
Company and such return shall be subject to payment by the Purchaser of handling and re-stocking charges,
transport and all other costs incurred by the Company.
9. COMPANY LIABILITY AND GUARANTEE
9.1. Subject to the terms of these Conditions of Sale and Guarantee Terms Gledhills provide Guarantees in respect
of specific products as set out in this clause.
9.2. Each Guarantee is strictly conditional upon the following:-
9.2.1. Complaints must be given to us immediately, before any action is taken, as responsibility cannot be accepted
if repairs or renewals are attempted on site without our written approval.
9.2.2. The unit has been installed in accordance with our installation and service instructions and all relevant codes
of practice and regulations in force at the time of installation.
9.2.3. All necessary inlet controls and safety valves have been fitted correctly.
9.2.4. The unit has only been used for the storage of potable water supplied from the public mains. The water quality
shall be in accordance with European Council Directive 98/83 EC, or revised version at the date of installation,
and is not fed with water from a private supply. Particular:
Chloride content: Max. 200 mg/l
Sulphate content: Max. 200 mg/l
Combination chloride/sulphate: Max. 300 mg/l (in total)
9.2.5 Where appropriate the unit has been regularly maintained as detailed in the installation and service instructions
9.2.6. Defects caused by corrosion or scale deposits are not covered by any Guarantee.
9.2.7. Where we agree to rectify any defect we reserve the right to undertake the work on our own premises.
9.2.8. We will not accept any labour charges associated with replacing the unit or parts for any of the following
products listed.
9.2.9. If the newly fitted water heater is not in regular use then it must be flushed through with fresh water for at least
15 minutes. Open at least one hot water tap once per week, during a period of at least 4 weeks.
9.3. Guarantees are provided in respect of specified goods supplied by Gledhills as follows:-
(a) Domestic and Commercial Open Vented Cylinders and Tanks.
The storage vessel is guaranteed for ten years and if it proves to be defective either in materials or workmanship,
we will either repair or supply replacement at our option with the closest substitute in the case of any obsolete
product to any address in Great Britain.
(i) free of all charge during the first year after delivery by us.
(ii) thereafter at a charge of one-tenth of the then current list price and any copper price supplement and
delivery charge during the second year after delivery by us and increasing by a further one-tenth on the
second and subsequent anniversary of delivery by us.
(b) Domestic Mains Fed Products [Primary Stores]
The storage vessel is guaranteed for five years and if it or any integral pipework as part of the storage vessel
assembly proves to be defective either in materials or workmanship, we reserve the right to either repair or
supply replacements or the closest possible substitute in the case of any obsolete product and will collect and
deliver to any address in England, Wales and Scotland (excluding all Scottish Islands).
(i) free of all charge during the first year after delivery
by us.
(ii) thereafter at a charge of one-fifth of the then current
list price or any copper price supplement and
delivery charge during the second year after delivery
by us increasing by a further one-fifth on the second
and subsequent anniversary of delivery by us.
(c) StainlessLite Unvented Cylinders
Gledhill guarantee the components including controls,
valves and electrical parts for two years from the date
of purchase. IT SHOULD BE NOTED THAT THE FACTORY
FITTED TEMPERATURE AND PRESSURE RELIEF VALVE
MUST NOT BE REMOVED OR ALTERED IN ANY WAY OR
THE GUARANTEE WILL NOT BE VALID. GLEDHILL WILL
NOT BE RESPONSIBLE FOR ANY CONSEQUENTIAL LOSS
OR DAMAGE HOWEVER IT IS CAUSED.
The guarantee for the stainless steel vessel is
for twenty five years against material defect or
manufacturing faults if the original unit is returned to
us AND PROVIDED THAT:
(i) It has not been modified, other than by Gledhill.
(ii) It has not been subjected to wrong or improper
use or left uncared for.
(iii) It has only been used for the storage of potable
water supplied from the public mains, max
200mg/litre chloride.
(iv) It has not been subjected to frost damage.
(v) The benchmark service record is completed after
each annual service.
(vi) The unit has been serviced annually.
(vii) Any disinfection has been carried out strictly in
accordance with BS6700.
If the stainless steel vessel proves to be defective
either in materials or workmanship we reserve the
right to either repair or supply replacements or the
closest possible substitute in the case of any obsolete
product and will collect and deliver to any address in
England, Scotland and Wales (excluding all islands):
(i) free of charge during the first year after delivery by
us.
(ii) thereafter at a charge of one twenty fifth of the
then current list price during the second year
after delivery by us and increasing by a further
one twenty fifth on the second and subsequent
anniversary of delivery by us.
ACTION IN THE EVENT OF FAILURE
We will require the return of a cylinder which develops
a leak for inspection. If our examination confirms a
failure then an appropriate level of credit against the
cost of the original cylinder will be issued in line with
the terms of our warranty.
Please note:
- Installation must have been carried out by a
licensed specialized company (heating contractor
or plumber) following the version of installation
instructions in force.
- Gledhill or its representative was given the
opportunity to check complaints on site
immediately after any defect occurred.
- Confirmation exists that the system was
commissioned properly and that the system
was checked and maintenance was performed
annually by a specialised company licensed for
this purpose.
(d) Components of our products other than
Storage Vessels and Integral Pipework.
We will either extend to the purchaser the same terms
of warranty as we are given by the manufacturer of the
component or if the manufacturer does not give any
warranty, replace free of charge any component which
becomes defective within two years after the date of the
delivery by us and is returned to us at the purchaser’s
expense but we shall not meet the cost of removal or
shipping or return of the component or any other cost
charges or damages incurred by the purchaser.
9.4.
9.4.1. In respect of goods supplied by us and in respect of
any installation work carried out by or on our behalf,
our entire liability and the purchaser’s sole remedies
(subject to the Guarantees) shall be as follows:-
(a) We accept liability for death or personal injury to
the extent that it results from our negligence or
that of our employees
Page 37 TERMS AND CONDITIONS
(b) Subject to the other provisions of this clause 9 we accept liability for direct physical damage to tangible
property to the extent that such damage is caused by our negligence or that of our employees, agents or
subcontractors.
(c) Our total liability to the purchaser over and above any liability to replace under the Guarantees (whether
in contract or in tort including negligence) in respect of any one cause of loss or damage claimed to result
from any breach of our obligations hereunder, shall be limited to actual money damages which shall not
exceed £20,000 provided that such monetary limit shall not apply to any liability on the part of ourselves
referred to in paragraph (a) above
(d) Except as provided in paragraph (a) above but otherwise not withstanding any provision herein contained
in no event shall we be liable for the following loss or damage howsoever caused and even if foreseeable
by us or in our contemplation:-
(i) economic loss which shall include loss of profits, business revenue, goodwill or anticipated savings
(ii) damages in respect of special indirect or consequential loss or damage (other than death, personal
injury and damage to tangible property)
(iii) any claim made against the purchaser by any other party (save as expressly provided in paragraph (b)
above)
(e) Except in respect of our liability referred to in paragraph (a) above no claim may be made or action brought
(whether in contract or in tort including negligence) by the purchaser in respect of any goods supplied by
us more than one year after the date of the invoice for the relevant goods.
(f) Without prejudice to any other term we shall not be liable for any water damage caused directly or
indirectly as a result of any leak or other defect in the goods. We cannot control the conditions of use of
the goods or the time or manner or location in which they will be installed and the purchaser agrees to be
fully responsible for testing and checking all works which include the goods at all relevant times (up to,
including and after commissioning) and for taking all necessary steps to identify any leaks and prevent any
damage being caused thereby.
(g) Nothing in these Conditions shall confer on the purchaser any rights or remedies to which the purchaser
would not otherwise be legally entitled
10. LOSS OR INJURY
Notwithstanding any other provision contained herein the purchaser’s hereby agree to fully indemnify us against
any damages losses costs claims or expenses incurred by us in respect of any claim brought against us by any third
party for:-
(a) any loss injury or damage wholly or partly caused by any goods supplied by us or their use.
(b) any loss injury or damage wholly or partly caused by the defective installation or substandard workmanship or
materials used in the installation of any goods supplied by us.
(c) any loss injury or damage in any way connected with the performance of this contract.
(d) any loss resulting from any failure by the purchaser to comply with its obligations under these terms as to
install and/or check works correctly.
PROVIDED that this paragraph will not require the purchaser to indemnify us against any liability for our own acts of
negligence or those of our employees agents or sub-contractors
FURTHER in the case of goods supplied by us which are re-sold and installed by a third party by the purchaser it will
be the sole responsibility of the purchaser to test the goods immediately after their installation to ensure that inter
alia they are correctly installed and in proper working order free from leaks and are not likely to cause any loss injury
or damage to any person or property.
11. VARIATION OF WARRANTY AND EXCLUSION
Should our warranty and exclusion be unacceptable we are prepared to negotiate for variation in their terms but
only on the basis of an increase in the price to allow for any additional liability or risk which may result from the
variation. Purchasers are advised to insure against any risk or liability which they may incur and which is not covered
by our warranty.
12. ADVICE
Any advice or assistance given by the Company is provided without charge and is in good faith without undertaking,
representation or warranty, and we will not accept any liability, whether consequential or compensatory, for advice
or assistance given.
13. RISK AND RETENTION OF TITLE
(a) goods supplied by us shall be at the Purchaser’s risk immediately upon delivery to the Purchaser or into
custody on the Purchaser’s behalf or to the Purchaser’s Order. The Purchaser shall effect adequate insurance
of the goods against all risks to the full invoice value of the goods, such insurance to be effective from the time
of delivery until property in the goods shall pass to the Purchaser as hereinafter provided.
(b) property in the goods supplied hereunder will pass to the Purchaser when full payment has been made by the
Purchaser to us for :-
(i) the goods of the subject of this contract.
(ii) all other goods the subject to of any other contract between the Purchaser and us which, at the time of
payment of the full price of the goods sold under this contract, have been delivered to the Purchaser but
not paid for in full.
(c) until property in the goods supplied hereunder passes to the Purchaser in accordance with paragraph (2)
above.
(i) the Purchaser shall hold the goods in a fiduciary capacity for us and shall store the same separately from
any other goods in the Purchaser’s possession and in a manner which enables them to be identified as our
goods.
(ii) the Purchaser shall immediately return the goods to us should our authorised representative so request.
All the necessary incidents associated with a fiduciary relationship shall apply.
(d) the Purchaser’s right to possess the goods shall cease forthwith upon the happening of any of the following
events, namely :-
(i) if the Purchaser fails to make payment in full for the goods within the time stipulated in clause 4 hereof.
(ii) if the Purchaser, not being a company, commits any act of bankruptcy, makes a proposal to his or her
creditors for a compromise or does anything which would entitle a petition for a Bankruptcy Order to be
presented.
(iii) if the Purchaser, being a company, does anything or fails to do anything which would entitle an
administrator or an administrative receiver or a receiver to take possession of any assets or which would
entitle any person to present a petition for winding up or to apply for an administration order.
(e) the Purchaser hereby grants to us an irrevocable licence to enter at any time any vehicle or premises owned
or occupied by the Purchaser or in the possession of the Purchaser for the purposes of repossessing and
recovering any such goods the property in which has remained in us under paragraph (2) above. We shall
not be responsible for and the Purchaser will indemnify us against liability in respect of damage caused to
any vehicle or premises in such repossession and
removal being damaged which it was not reasonably
practicable to avoid.
(f) notwithstanding paragraph (3) hereof and subject to
paragraph (7) hereof, the Purchaser shall be permitted
to sell the goods to third parties in the normal course
of business. In this respect the Purchaser shall act
in the capacity of our commission agent and the
proceeds of such sale :-
(i) shall be held in trust for us in a manner which
enables such proceeds to be identified as such, and:
(ii) shall not be mixed with other monies nor paid into
an overdrawn bank account.
We, as principal, shall remunerate the Purchaser as
commission agent a commission depending upon
the surplus which the Purchaser can obtain over and
above the sum, stipulated in this contract of supply
which will satisfy us.
(g) in the event that the Purchaser shall sell any of the
goods pursuant to clause (6) hereof, the Purchaser
shall forthwith inform us in writing of such sale and of
the identity and address of the third party to whom the
goods have been sold.
(h) if, before property in the goods passes to the
Purchaser under paragraph (2) above the goods are or
become affixed to any land or building owned by the
Purchaser it is hereby agreed and declared that such
affixation shall not have the effect of passing property
in the goods to the Purchaser. Furthermore if, before
property in the goods shall pass to the Purchaser
under paragraph (2) hereof, the goods are or become
affixed to any land or building (whether or not owned
by the Purchaser), the Purchaser shall:-
(i) ensure that the goods are capable of being removed
without material injury to such land or building.
(ii) take all necessary steps to prevent title to the
goods from passing to the landlord of such land or
building.
(iii) forthwith inform us in writing of such affixation and
of the address of the land or building concerned.
The Purchaser warrants to repair and make good
any damage caused by the affixation of the goods
to or their removal from any land or building and to
indemnify us against all loss damage or liability we
may incur or sustain as a result of affixation or removal.
(i) in the event that, before property in the goods
has passed to the Purchaser under paragraph (2)
hereof, the goods or any of them are lost, stolen,
damaged or destroyed :-
(ii) the Purchaser shall forthwith inform us in writing
of the fact and circumstances of such loss, theft,
damage or destruction.
(iii) the Purchaser shall assign to us the benefit of any
insurance claim in respect of the goods so lost,
stolen, damaged or destroyed.
14. NON-PAYMENT
If the Purchaser shall fail to make full payment for the goods
supplied hereunder within the time stipulated in clause 4
hereof or be in default of payment for any other reason then,
without prejudice to any of our other rights hereunder, we
shall be entitled to stop all deliveries of goods and materials
to the Purchaser, including deliveries or further deliveries of
goods under this contract. In addition we shall be entitled to
terminate all outstanding orders.
15. VALUE ADDED TAX
All prices quoted are exclusive of Value Added Tax which
will be charged at the rate ruling at the date of despatch of
invoice.
16. TRADE SALES ONLY
We are only prepared to deal with those who are not
consumers within the terms of the Unfair Contract Terms
Act 1977, the Sale of Goods Act 1979 and the Supply of
Goods and Services Act 1982. Accordingly any person who
purchases from us shall be deemed to have represented that
he is not a consumer by so purchasing.
17. JURISDICTION
The agreement is subject to English law for products
delivered in England and Scottish law for products delivered
in Scotland and any dispute hereunder shall be settled in
accordance therewith dependent upon the location.
18. PRODUCT DEVELOPMENT
Gledhill have a policy of continuous product development
and may introduce product modifications from time to time.
Page 38
BENCHMARK
This Commissioning Checklist is to be completed in full by the competent person who commissioned the storage system as a means of
demonstrating compliance with the appropriate Building Regulations and then handed to the customer to keep for future reference.
Failure to install and commission this equipment to the manufacturer’s instructions may invalidate the warranty but does not affect statutory rights.
MAINS PRESSURE HOT WATER STORAGE SYSTEM COMMISSIONING CHECKLIST
Customer name: Telephone number:
Address:
Cylinder Make and Model
Cylinder Serial Number
Commissioned by (PRINT NAME): Registered Operative ID Number
Company name: Telephone number:
Company address:
Commissioning date:
To be completed by the customer on receipt of a Building Regulations Compliance Certicate*:
Building Regulations Notication Number (if applicable)
ALL SYSTEMS PRIMARY SETTINGS (indirect heating only)
Is the primary circuit a sealed or open vented system? Sealed Open
What is the maximum primary ow temperature? °C
ALL SYSTEMS
What is the incoming static cold water pressure at the inlet to the system? bar
Has a strainer been cleaned of installation debris (if tted)? Yes No
Is the installation in a hard water area (above 200ppm)? Yes No
If yes, has a water scale reducer been tted? Yes No
What type of scale reducer has been tted?
What is the hot water thermostat set temperature? °C
What is the maximum hot water ow rate at set thermostat temperature (measured at high ow outlet)? I/min
Time and temperature controls have been tted in compliance with Part L of the Building Regulations? Yes
Type of control system (if applicable) Y Plan S Plan Other
Is the cylinder solar (or other renewable) compatible? Yes No
What is the hot water temperature at the nearest outlet? °C
All appropriate pipes have been insulated up to 1 metre or the point where they become concealed Yes
UNVENTED SYSTEMS ONLY
Where is the pressure reducing valve situated (if tted)?
What is the pressure reducing valve setting? bar
Has a combined temperature and pressure relief valve and expansion valve been tted and discharge tested? Yes No
The tundish and discharge pipework have been connected and terminated to Part G of the Building Regulations Yes
Are all energy sources tted with a cut out device? Yes No
Has the expansion vessel or internal air space been checked? Yes No
THERMAL STORES ONLY
What store temperature is achievable? °C
What is the maximum hot water temperature? °C
ALL INSTALLATIONS
The hot water system complies with the appropriate Building Regulations Yes
The system has been installed and commissioned in accordance with the manufacturer’s instructions Yes
The system controls have been demonstrated to and understood by the customer Yes
The manufacturer’s literature, including Benchmark Checklist and Service Record, has been explained and left with the customer Yes
Commissioning Engineer’s Signature
Customer’s Signature
(To conrm satisfactory demonstration and receipt of manufacturer’s literature)
* All installations in England and Wales must be notied to Local Authority Building Control (LABC) either directly or through a
Competent Persons Scheme. A Building Regulations Compliance Certicate will then be issued to the customer.
© Heating and Hotwater Industry Council (HHIC) www.centralheating.co.uk
This Commissioning Checklist is to be completed in full by the competent person who commissioned the storage system as a means of
demonstrating compliance with the appropriate Building Regulations and then handed to the customer to keep for future reference.
Failure to install and commission this equipment to the manufacturer’s instructions may invalidate the warranty but does not affect statutory rights.
MAINS PRESSURE HOT WATER STORAGE SYSTEM COMMISSIONING CHECKLIST
Customer name: Telephone number:
Address:
Cylinder Make and Model
Cylinder Serial Number
Commissioned by (PRINT NAME): Registered Operative ID Number
Company name: Telephone number:
Company address:
Commissioning date:
To be completed by the customer on receipt of a Building Regulations Compliance Certicate*:
Building Regulations Notication Number (if applicable)
ALL SYSTEMS PRIMARY SETTINGS (indirect heating only)
Is the primary circuit a sealed or open vented system? Sealed Open
What is the maximum primary ow temperature? °C
ALL SYSTEMS
What is the incoming static cold water pressure at the inlet to the system? bar
Has a strainer been cleaned of installation debris (if tted)? Yes No
Is the installation in a hard water area (above 200ppm)? Yes No
If yes, has a water scale reducer been tted? Yes No
What type of scale reducer has been tted?
What is the hot water thermostat set temperature? °C
What is the maximum hot water ow rate at set thermostat temperature (measured at high ow outlet)? I/min
Time and temperature controls have been tted in compliance with Part L of the Building Regulations? Yes
Type of control system (if applicable) Y Plan S Plan Other
Is the cylinder solar (or other renewable) compatible? Yes No
What is the hot water temperature at the nearest outlet? °C
All appropriate pipes have been insulated up to 1 metre or the point where they become concealed Yes
UNVENTED SYSTEMS ONLY
Where is the pressure reducing valve situated (if tted)?
What is the pressure reducing valve setting? bar
Has a combined temperature and pressure relief valve and expansion valve been tted and discharge tested? Yes No
The tundish and discharge pipework have been connected and terminated to Part G of the Building Regulations Yes
Are all energy sources tted with a cut out device? Yes No
Has the expansion vessel or internal air space been checked? Yes No
THERMAL STORES ONLY
What store temperature is achievable? °C
What is the maximum hot water temperature? °C
ALL INSTALLATIONS
The hot water system complies with the appropriate Building Regulations Yes
The system has been installed and commissioned in accordance with the manufacturer’s instructions Yes
The system controls have been demonstrated to and understood by the customer Yes
The manufacturer’s literature, including Benchmark Checklist and Service Record, has been explained and left with the customer Yes
Commissioning Engineer’s Signature
Customer’s Signature
(To conrm satisfactory demonstration and receipt of manufacturer’s literature)
* All installations in England and Wales must be notied to Local Authority Building Control (LABC) either directly or through a
Competent Persons Scheme. A Building Regulations Compliance Certicate will then be issued to the customer.
© Heating and Hotwater Industry Council (HHIC) www.centralheating.co.uk
While this Checklist can be used for any installation covered by its description, only appliances manufactured by Scheme Members will
be covered by the rules and requirements of the Benchmark Scheme.
Page 39 BENCHMARK
It is recommended that your hot water system is serviced regularly and that the appropriate Service Record is completed.
Service Provider
Before completing the appropriate Service Record below, please ensure you have carried out the service as described in the manufacturer’s instructions.
SERVICE RECORD
SERVICE 01 Date:
Engineer name:
Company name:
Telephone No:
Comments:
Signature
SERVICE 03 Date:
Engineer name:
Company name:
Telephone No:
Comments:
Signature
SERVICE 05 Date:
Engineer name:
Company name:
Telephone No:
Comments:
Signature
SERVICE 07 Date:
Engineer name:
Company name:
Telephone No:
Comments:
Signature
SERVICE 09 Date:
Engineer name:
Company name:
Telephone No:
Comments:
Signature
SERVICE 02 Date:
Engineer name:
Company name:
Telephone No:
Comments:
Signature
SERVICE 04 Date:
Engineer name:
Company name:
Telephone No:
Comments:
Signature
SERVICE 06 Date:
Engineer name:
Company name:
Telephone No:
Comments:
Signature
SERVICE 08 Date:
Engineer name:
Company name:
Telephone No:
Comments:
Signature
SERVICE 10 Date:
Engineer name:
Company name:
Telephone No:
Comments:
Signature
Due to a programme of continuous improvement Gledhill Building Products reserve the right to modify products without prior notice.
It is advisable to check the product technical detail by using the latest design and installation manuals available from our technical support team or on our website.
It is an offence to copy or adapt this document without consent of the owner.
Protect your Gledhill
product after your
initial warranty period
For any spare part requirements on
this product simply
go to www.gledhill-spares.net
On expiry of your initial warranty period, Gledhill Response Limited would be
pleased to provide further customer support with a range of services including:
Low cost annual repair and maintenance contracts direct from Gledhill
Annual servicing and safety checks
Expert response to ‘out of warranty’ breakdowns at fixed charges
Please call 08445 679898 or visit www.gledhill.net for further details
“Only the best
is acceptable”
FM 02057
Gledhill Building Products Limited
Sycamore Estate, Squires Gate, Blackpool FY4 3RL Tel: 01253 474550 Fax: 01253 474551 sales@gledhill.net
After Sales Technical Support Tel: 01253 474584
Gledhill Building Products produce cylinders for use with a wide range of heat sources including;
Gas and oil boilers Electricity Air source heat pumps
Ground source heat pumps Solar energy Wood burning stoves
Further information on Gledhill products can be found at www.gledhill.net
