gledhill ElectraMate 2000 Installation And Servicing Instructions Download Page 1

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Supplied By www.heating spares.co Tel. 0161 620 6677

DESIGN, INSTALLATION AND

SERVICING INSTRUCTIONS

PLEASE LEAVE THESE INSTRUCTIONS IN THE POCKET PROVIDED ON

THE BACK OF THE FRONT PANEL

A COMBINED PRIMARY STORAGE UNIT (CPSU) FOR

DOMESTIC HOT WATER SUPPLY AND CENTRAL

HEATING UTILISING OFF-PEAK ELECTRICITY

ALL MODELS COMPLY WITH THE

WATER HEATER MANUFACTURERS SPECIFICATION

FOR INTEGRATED THERMAL STORES

ELECTRAMATE

2000

ELECTRAMATE

2000

benchmark

The code of practice for the installation,

commissioning & servicing of central heating systems

Gas Council Approved Reference Numbers

ElectraMate 270 97-317-36
ElectraMate 170 97-317-37

Summary of Contents for ElectraMate 2000

Page 1: ...E UNIT CPSU FOR DOMESTIC HOT WATER SUPPLY AND CENTRAL HEATING UTILISING OFF PEAK ELECTRICITY ALL MODELS COMPLY WITH THE WATER HEATER MANUFACTURERS SPECIFICATION FOR INTEGRATED THERMAL STORES ELECTRAMATE 2000 ELECTRAMATE 2000 TM benchmark Thecodeofpracticefortheinstallation commissioning servicingofcentralheatingsystems Gas Council Approved Reference Numbers ElectraMate 270 97 317 36 ElectraMate 17...

Page 2: ...ity service to our customers Quality is built into every Gledhill product and we hope you get satisfactory service from Gledhill If not please let us know ISSUE 4 06 04 As part of the industry wide Benchmark Initiative all Gledhill ElectraMates now include a Benchmark Installation Commissioning and Service Record Log Book Please read carefully and complete all sections relevant to the appliance in...

Page 3: ...ed by section G3 of the current Building Regulations and is therefore not notiﬁable to Building Control The information in this manual is provided to assist generally in the selection of equipment The responsibility for the selection and speciﬁcation of the equipment must however remain that of the customer and any Designers or Consultants concerned with the design and installation Please Note We ...

Page 4: ...r outlet 10 Mains cold water inlet 11 90º angle isolating ballvalve 12 CA type backflow prevention valve discharging into a tundish 13 Filling pressure regulating valve 14 Heating flow 15 Heating return 16 9kW electric flow boiler 17 Boiler pump 18 Pressure relief valve discharging into CA tundish pipe 19 Expansion vessel 20 Store temperature sensor 21 Store overheat thermostat 22 Electric boiler ...

Page 5: ...er controls a programmable room thermostat is provided loose for this purpose When there is a demand for space heating from the programmable room thermostat the ElectraMate 2000 control system starts the space heating pump which circulates the preheated hot water from the stores to the radiators The space heating pump continues to run as long as the heat demand signal is present from the user cont...

Page 6: ...u f W k 5 7 0 5 l l A s p m u P e v l a v g n i d n e l b t r o p 3 g n i t c a f l e S t a t s o m r e h t t a e h r e v o e r o t S t a t s o m r e h t t a e h r e v o r e l i o b c i r t c e l E e c i v e d p u p o t o t u a f o t r a p e v l a v A C e c i v e d p u p o t o t u a f o t r a p r o t a l u g e r e r u s s e r P y r e t t a b r e t a e H B C P n i a M B C P k a e p f f O 0 5 5 1 S ...

Page 7: ...9 Hot water outlet 10 Mains cold water inlet 11 90º angle isolating ballvalve key screwdriver operated 12 C A type backflow prevention valve discharging into a tundish 13 Filling pressure regulating valve 14 Heating ﬂow 15 Heating return 16 9kW electric ﬂow boiler 17 Boiler pump 18 Pressure relief valve discharging into C A valve tundish 19 Expansion vessel 20 Store temperature sensor 21 Store ove...

Page 8: ...arrangements made for maintenance etc if the minimum cupboard dimensions are used EM 2000 A D B 320 dia 550 mm C F 150 mm E 600mm minimum maintenance access 650mm minimum clear opening if directly in front of appliance 40 ltr expansion vessel 25 ltr vessel for EM 170 model 290mm dia x 500mm 100mm Note The above cupboard height assumes the use of the installation pallet and the 40 litre expansion v...

Page 9: ...sier if all pipes terminate vertically in the positions shown opposite Compression or push fit connections can be used and we do offer a set of flexible connectors as an option All pipe positions are approximate and subject to a tolerance of 10mm in any direction litres sec Performance Graph of Grundfos 15 50 Pump ...

Page 10: ...ments for Electrical Installations and the table on the next page to ensure that the electrical supplies are adequate and that the correct fusing cable sizes are chosen This is particularly important in existing properties especially if these are blocks of flats apartments DHW Pump Boiler Pump Heating Pump Store overheat stat Boiler overheat stat Appliance Control PCB PR1 PR2 25A 25A 3A Fuse 1 Fus...

Page 11: ...lectricity Markets Ofgem available October 2000 The low rate will apply for a total of ten hours from 5 Hours 00 00 to 05 00 GMT 3 Hours 13 00 to 16 00 GMT 2 Hours 20 00 to 22 00 GMT 2000 All Electrical work must comply with the IEE Requirements for Electrical Installations BS 7671 It is the responsiblity of the competent Electrical Installer to use the details below in conjunction with the latest...

Page 12: ...l small dwelling is shown below ElectraMate 2000 will operate at mains pressures as low as 1 5 bar and as high as 5 bar although the recommended range is 2 3 bar All pressures must be achievable when the local demand is at its maximum and be measured at the connection to the appliance It is also important to check that all other equipment and components in the hot and cold water system are capable...

Page 13: ...he optional ﬂexible hose kits see 2 2 Installation Pipework connections It is also essential that if an alternative pipework material system is chosen the manufacturer conﬁrms that the design criteria of the new system is at least equivalent to the use of BS EN Standard copper pipework and ﬁttings Taps Shower Fittings Aerated taps are recommended to prevent splashing Any type of shower mixing valv...

Page 14: ...ed in accordance with BS EN 442 The Grundfos 15 50 pump characteristics are shown in 1 2Technical Data Approximately all the head can be used when sizing the heating circuit pipework All the recommendations with regard to pipework systems in this manual are generally based on the use of BS EN Standard copper pipework and ﬁttings However we are happy that plastic pipework systems can be used in pla...

Page 15: ...g system to be automatically replenished as with an open vented system fitted with a feed and expansion cistern Details of the valve and the discharge requirements are shown opposite A 22mm minimum diameter discharge pipe is required The construction of the valve is such that the mains cold water cannot discharge through the tundish even when the mains side check valve is faulty This is because th...

Page 16: ...e less than the static head plus 0 5 bar i e the height of the highest point in the system above the expansion vessel plus a safety margin of 0 5 bar If a different system pressure is required than 1 0 bar the initial vessel charge pressure must be adjusted to the same value If an additional expansion vessel is required this must comply with BS 4814 and must be suitable for heating circuit tempera...

Page 17: ...us support to the whole back area and be made of a material which will not deteriorate if exposed to moisture Details of the weight when full is provided in section 1 2 Technical Data The appliance is designed to operate as quietly as practicable However some noise from pumps etc is inevitable in any heating system This will be most noticeable in cupboards formed on bulkheads or at the mid span of...

Page 18: ...ble sack type truck on the rear face Before installation the site requirements should be checked and conﬁrmed as acceptable The bottom part of the plastic cover protective wrapping should be removed and the appliance placed in position Remove the front panel by loosening the retaining screws 3 4 turns and lifting the panel up and out using the keyholes provided Pull the pipe cover off see opposite...

Page 19: ...c Hot Water B Central Heating Flow C Incoming Mains Cold Water D Central Heating Return E Expansion Pipe F CA Valve PRV Discharge Pipe G AAV AVV Assembly H Drain Valve NOT provided with the appliance Allfactorymadejointsshouldbecheckedafter installation in case they have been loosened during transit The expansion pipe should be run from the appliance and connected to the inlet pipe air vent provid...

Page 20: ... BR BR GY BL BLK Store Sensor PHE Return Sensor DWH Sensor R R W B Wiring Key R BR BL GY BLK Red Brown Blue Green Yellow Black Cable Cleat Flat twin and earth PVC cable 10mm 2 Feed cable supplied with 3 metres available externally to connect to local isolator Programmable Room Stat Remove link when Room Stat installed Teleswitch PCB Winter 0 Summer 1 BR BL Note 30A fuse carriers F1 and F2 are fitt...

Page 21: ...equipment Remove the front panel The appliance is supplied with a 3 metre x 10mm mains supply cable and a 3 metre x 1 0mm low current off peak signal cable which should be connected via the slot grommets provided at low level on the appliance to the relevant local isolators provided as shown opposite To wire the Programmable room thermostat Remove the link between terminals 26 and 28 on the termin...

Page 22: ... Note The appliance is provided with a 4 0mm earth cable from an earthing strap on the primary return to boiler pipe to the earth stud on the wiring panel WARNING When the wiring is complete but before switching on the appliance electrically ensure the unit is full of water by checking the air vent on the side of the appliance and ensuring the pressure gauge reads between 0 5 1 0 bar Switch the un...

Page 23: ...nd cold distribution systems for leaks See Section 10 6 Once the system has been filled the electrical connection and system controls should be checked in line with page 25 Once this has been done the system should be operated for a few minutes without the heating elements being switched on which will allow any air trapped in the system to be vented The appliance should be switched on and the heat...

Page 24: ...TING PUMP ON 2 BOILER PUMP ON 1 ELEC BOILER ON Green LED S Fuse Jumper Settings SW1 SW2 8 LED DISPLAY BAR 1 HT ON BAR 2 ST ON BAR 3 HW ON BAR 5 OFF PEAK ON BAR 6 WINTER SWITCH ON Pump over run 3 minutes Heating Heating pump circuit Sensor T1 Domestic hot water Mixing valve Heat exchanger pump Sensor T3 Sensor T2 Thermal store Boiler pump Elec Flow Boiler ...

Page 25: ... system should be checked as follows on the ACB shown opposite Programmable Room Thermostat To test space heating first check the programmable room thermostat TP5E Slide the battery cover to the left to reveal the programming buttons PROG Press the and buttons together until the display shows the actual room temperature In the middle of the right hand side of the LCD display the current set point ...

Page 26: ...sed hot water heating pipework in the cupboard is insulated A link is fitted between terminals 21 22 on the appliance control board This allows the appliance to be charged automatically at any time under control of the store thermostat The internal controls automatically select the store charge temperature and control thermostatdifferentialtosuittheelectricitytariff Thetemperaturesettingsestablish...

Page 27: ...pares service or throughanyofthelargerplumbersmerchants specialist heating spares suppliers Help and advice is also available from the Technical Helpline on 01253 474401 However allcomponentsarereadilyaccessible and can be changed quickly and easily by the installer using common plumbing practice If it is necessary to replace any of the pumps fitted to the appliance the pump head motor pack only s...

Page 28: ... B X 7 5 1 9 3 E 2 1 l e s s e v n o i s n a p x E e r t i l 5 2 e c n a i l e R 5 6 1 G X 3 1 d r a o b l o r t n o c e c n a i l p p A k o l E 5 5 1 T G 8 5 1 9 3 E 4 1 r o s n e s n r u t e r E H P k o l E 7 4 1 T G 5 1 r o s n e s e r o t S k o l E 9 4 1 T G 2 2 0 6 2 E 6 1 r o s n e s W H D k o l E 3 5 1 T G 4 2 0 6 2 E 7 1 t a t S T m o o R e l b a m m a r g o r P E 5 P T s s o f n a D s s o...

Page 29: ...Supplied By www heating spares co Tel 0161 620 6677 Page 29 ELECTRAMATE 2000 3 0 SERVICING 3 3 SHORT PARTS LIST 9 10 2 4 6 8 1 13 11 14 15 16 18 19 23 22 21 5 3 12 17 24 25 26 27 20 7 ...

Page 30: ...arts when the hot water tap is opened and stops shortly after the tap is closed 6 Check that the plate heat exchanger pump is set at maximum speed 7 Check that the hot water outlet temperature does not change significantly when the hot water flow rate is increased from say 5 litres min to 15 litres min 8 Check that the space heating load is not greater than specified for the unit and that the occu...

Page 31: ...sel is correctly sized for the system volume Check the pressure relief valve seat replace if necessary The boiler overheat thermostat will trip pop out if TheBoiler pump is faulty The control thermostat on PCB is faulty The System is air locked i e poor circulation through electric boiler circuit Check and replace faulty parts and manually push the reset button on the boiler overheat thermostat If...

Page 32: ...pump LED 2 and Heating pump LED 3 LED 4 isnotusedonthis appliance For further details refer to Section 2 3 Commissioning Note If the ACB is replaced it will automatically initialize itself when the electricity supply is switched on The operation of the system controls operation should then be checked The same appliance control board is used on a number of appliances and the jumpers MUST be in the ...

Page 33: ...PENDIX A 3 4 3 1 2 2 2 1 1 1 Unregulated 25 30 l m Regulated 10 12 l m SHOWERS WATER SAVINGS OPTIONS FOR SHOWERS 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 AntiVandal models also available 2 MR05 T Range Internal Regulators Push ﬁt into Tap or Mixer seats Produced in three sizes 12 5mm BS101...

Page 34: ... F e t u n i m s e r t i l g n i t t i f l a n i m r e T s t e l t u o d l o f i n a m r e t a w t o H y t i t n a u Q s t e l t u o d l o f i n a m r e t a w d l o C y t i t n a u Q 8 1 p a t h t a B 1 1 8 n i s a b d n a H 3 3 0 1 k n i s n e h c t i K 1 1 8 n r e t s i c t e l i o T e n o N 3 8 r e w o h S 1 1 8 e n i h c a m g n i h s a W 1 1 8 r e h s a w h s i D e n o N 1 l a t o T 7 1 1 595...

Page 35: ...pe in table 1 and for plastic pipework in table 2 r e p p o c m m 5 1 n i h t g n e l e p i p t n e l a v i u q e m u m i x a M 1 e l b a T e r u s s e r p t e l n I r a b m e p i p f o h t n e l t n e l a v i u q e m u m i x a M m l 8 m l 0 1 m l 8 1 0 2 3 3 3 1 5 5 2 0 1 1 5 4 7 1 0 3 0 0 2 0 8 0 3 e p i p c i t s a l p n i s h t g n e l e p i p t n e l a v i u q e m u m i x a M 2 e l b a T e r ...

Page 36: ...anch in the sink should be branched off the cold water main prior to the treatment device instead of the cold water manifold Any other isolating control valves and backflow protection devices should be provided as necessary to comply with the Water Regulations Bath Toilet cistern Hand basin Toilet cistern Hand basin Hand basin Toilet cistern Mains supply Shower DW Kitchen sink Kitchen En Suite Bat...

Page 37: ...s added and a permanent label should be fixed to the system in a prominent location Where a combi boiler and or a hot water storage vessel is installed in areas where the mains water can exceed 200ppm Total Hardness as defined by BS 7593 1993 Table 2 a scale reduction device should be installed in accordance with the boiler manufacturer s instructions The levels of water hardness may be measured u...

Page 38: ...Supplied By www heating spares co Tel 0161 620 6677 Page 38 APPENDIX D ...

Page 39: ...Supplied By www heating spares co Tel 0161 620 6677 Page 39 ELECTRAMATE 2000 ...

Page 40: ...Supplied By www heating spares co Tel 0161 620 6677 Page 40 ...

Page 41: ...Supplied By www heating spares co Tel 0161 620 6677 ...

Page 42: ...Supplied By www heating spares co Tel 0161 620 6677 ...

Page 43: ...Supplied By www heating spares co Tel 0161 620 6677 ...

Page 44: ...Supplied By www heating spares co Tel 0161 620 6677 ...

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