Heatmate

5.1

How It Works
The Heatmate is a closed circuit water heater circulator that can be connected to a variety of
storage tanks depending on the application. The configuration drawings in Part 2.0 of this manual
(Full manual supplied with storage tank) set out these applications.

It heats the water from these tanks by heating the circulating water as it passes through the heat
exchanger inside the cabinet. Located underneath this heat exchanger is a gas burner
arrangement that is controlled by a gas supply valve. The gas supply valve will open and the burner
will ignite when the control box (attached to the Heatmate and storage tank) energises.

Once the control box senses that the storage tank water temperature is OK it de-energises and the
Heatmate shuts down until next required.

Installation Details
Location of Heatmate Connections – fig. 1
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5.1
Positioning

The Heatmate should be installed in a convenient position up to a maximum of 10m from the
storage tank (otherwise the flow of water will become too restricted).
The Heatmate is supplied with mounting brackets. These brackets are designed for the unit to
be mounted to a wall near the storage tank or on the tank itself. Refer to fig. 2 below for bracket
mounting diagram.
More than one Heatmate can be connected to a storage tank – details of this are provided
further on.

Mounting Bracket Arrangement – fig. 2

Stand

The Heatmate may be mounted on ground-mounted special stands. These are available on request
from Edwards Hot Water.
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5.1
External Positioning

The Heatmate must be located in accordance with the requirements of AS5601. The diagram
opposite shows suitable locations.

Minimum Clearances for Balanced Flue Terminals – fig. 3

!
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Incoming Flow Line

The Heatmate 250 model has a 20 BSP female coupling (see fig. 1). It is used to connect the
incoming water supply pipe from the storage tank. An isolating valve must be fitted between the
Heatmate and the storage tank for easier servicing.

A check valve and 2 x pressure & temperature relief valve must be installed in this line after each
Heatmate when connecting to a direct tank. The lines should be insulated.

This main line should be sized to suit the number of Heatmates that are being connected together
as follows:

No. of Pipe Size

Heatmates
1 25mm
2 40mm
3 50mm
4 65mm

Outgoing Return Line

The Heatmate 250 model has a 25mm copper starter pipe (see fig. 1). It is used to connect the
outgoing water supply pipe back to the storage tank. An isolating valve must also be installed for
easier serving and the line sized the same way as shown above for the Incoming Line.

The main return line should be sized as shown above for the flow line.

Gas Supply

Refer to fig. 1 for the location of the 20mm BSP socket gas connection for each Heatmate. The gas
pipe should be sized in accordance with AS5601. The table below provides a guide for the main
incoming gas supply:

No. of Heatmate 250

Heatmates Natural Gas LPG

1.25kPa 2.75kPa
1 20mm 20mm
2 25mm 20mm
3 40mm 25mm
4 50mm 25mm

If you are installing natural gas and you have an inlet gas pressure that exceeds 1.7 kPa, you must
fit a second stage regulator into the incoming gas line. Also, a second stage regulator is required to
all LPG connections. These regulators are not supplied with the unit.
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5.1

Heatmate Gas Conversion for use with LPG:

- The Heatmate is manufactured for use with Natural Gas as a standard.

- To convert the unit to LPG, a conversion kit and two new gas jets will be required.
- The gas jets supplied for NG use have an orifice diameter of 5mm.
- LPG jets have an orifice diameter of 3mm.
- NG jets will need to be removed from burner manifold and replaced with LPG jets.
- Conversion Kit modifications as per instructions supplied with Kit.
- Kit contains a replacement jet with an orifice diameter of 0.01mm for pilot conversion. Jet is
located in the pilot assembly. Remove ¼” compression fitting to replace pilot jet.

Connecting A Control Box

The unit comes with a 4-pin lead and plug which is simply plugged into the 4-pin socket on the
bottom of the control box.

If you are installing one control box for a multiple number of Heatmates, simply plug one of the
Heatmates into the control box. Plug the next Heatmate directly into the socket at the bottom of the
Heatmate with the control box. Then plug any other Heatmates (the 3rd, 4th etc.) into the socket of
the Heatmate next to it. Figure 5 shows how they are linked together.

For further details on the control box if needed, refer to Part 4.0 of the manual.

Heatmate Wiring Diagram – fig. 4

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5.1

Manifolding Heatmates together – fig. 5

Filling the Heatmate with Water

The Heatmate is filled up as part of the procedure for filling the storage tank. Follow the instructions
provided for the storage tank.

Make sure that air has been bled from the heat exchanger by opening the air bleed valve shown
below:
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5.1
Commissioning
Commissioning may only be done by a qualified tradesperson.

Before trying to fire up the Heatmate ensure that the checklist below is completed.

Completion Checklist

All gas components are secure and wiring in place.

Unit is filled with water. Isolating valves are open.

Gendex water treatment has been added if applicable.

Heat exchanger has been purged of air.

Circulating pump primed with water to prevent burning

out. Unscrew seal screw at end of motor and tighten
once water flows.

Control Box thermostats are set to the desired

temperature.

Pump set to MAXIMUM speed.

‘Firing Up’ the Heatmate

Each Heatmate comes with a gas control valve. This valve (shown in fig. 7) has the necessary
controls for starting the Heatmate.

Fig. 7
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5.1
Firing Up Sequence Of Steps

1. Remove the front cover of the Heatmate.

2. Remember to ensure that the Commissioning Checklist has been done. That is mainly that
power, water and gas have all been completed and are available.
3. Turn on the power supply to the control box– this will automatically activate the pump, and
the Gas Control valve should allow gas to the burner and fire up.

To shut down the burner, turn off the power supply to the control box.

Maintenance
Owner

No specific maintenance is required by the owner as the unit is fully automatic. It is your
responsibility to ensure that the unit is serviced regularly by a qualified person (every 12 months) –
contact Edwards for your nearest service provider.

Full Maintenance

Servicing may only be done by a qualified tradesperson.

Visual Open the front cover and inspect the air

ways and flue ways for debris and clear if
required.
Check the heat exchanger for signs of
corrosion, debris or obstructions and clear
if required.
Check the burner blades for any foreign
matter or build-ups and clear if required.
Check that the pump is set on the
maximum position.
In high TDS areas clean pump impeller &
deposits from inside pump housing
Check for any gas leaks using a soap rich
solution and rectify if necessary.
Clean flow switch paddle and check
operation.
Performance Check the performance of the safety relief
valves by opening the lever and closing it
again. If connected to treated water, be
careful not to discharge very much water.
Check the burner rating by checking the
burner gas operating pressure. Connect
the manometer to the test nipple on the
gas valve and check with the data plate on
the unit. Adjust the gas pressure if
required.

Check the water treatment level is good –

this is usually done as part of the tank
maintenance (see section 3.0)
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5.1
Spare Parts

Description Heatmate 250 Model Stock Code

Isolating Valves 25mm BSP Ball type 2020309

Support Brackets Edwards 2020160
Combination Gas Honeywell SV9605 2020381
Control Valve (NOV 00 - )
Honeywell 2020365
VR8305P(94-00)
Over-temperature Derwent 24V, 97°C 6060300
Thermostat manual reset
Water Flow Switch Caleffi 24V 6060299
Circulating Pump Grundfos UPS 20 –
60B (10/00-) 56860242
Burner Polidoro ribbon type 2030188
P & T Valve RMC HTE 575 – 2020331
1000kPa (2 off)

Problem Solving

Heater Fails to Light

Possible Cause Remedy
Gas supply turned off or too Open isolating valve or readjust regulator if necessary.
low.
Power supply turned off. Check lead from control box is plugged in. If OK there
will be a temperature reading on the panel. Turn off the
power supply for 30 seconds to reset the system.

Flow switch activated. Check heat exchanger is full of water and there are no
air locks. Bleed air from heat exchanger using bleed
valve. Flow switch contacts should be closed when
pump is running.

Over-temperature thermostat Press reset button on thermostat located on the

activated. Heatmate (not control box). If it is a controlled
temperature control box check the reset button on the
over temperature thermostat.

Manifolded Heatmates Check that each Heatmate is plugged into the one next
burners are not connected to it.
together.

Control box is faulty. Make sure operating thermostat is calling for heat.
Replace control box.
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Noisy operation
Possible Cause Remedy
Air in heat exchanger. Bleed air from the heat exchanger by opening the bleed
valve.

Pump speed set too low. Set pump speed to MAXIMUM setting.

Pump run on timer incorrect. Check that timer is wired so that the timer runs for 4
minutes after the pump shuts down.

Temperature setting too high Reset the operating temperature to a maximum of 82°C
on control box thermostat for SV tanks & 65°C for LEX tanks.

Safety Valve Drips – for SV tank only

The valve on the Heatmate is a safety valve and should only release water in the event
of a problem.

Possible Cause Remedy

Cold water expansion is not Fit a 700kPa cold water expansion valve into cold water
fitted to tank or is faulty. line or remove the valve, flush the valve with water,
check the closing operation and re-fit.

Unstable Burner Performance

Possible Cause Remedy
Gas pressure is incorrect. Check gas pressure is within the required pressure
specified on the data plate.

Insufficient air is available to Check flueways and airways for debris and blockages.
burn.

Warranty
Specific To Heatmate

Item Coverage

Heat Exchanger 3 years full cover

4th year 75% cover
5th year 50% cover
Associated parts- valves 1 year
Labour, Travel & Freight 1 year

Refer to General Warranty terms & Conditions (Part 1.3) for greater details.