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Benchmark ELECTRAMATE 2000-270/12KW Design, Installation And Servicing Instructions

Combined primary storage unit cpsu for domestic hot water supply and central heating utilising off-peak electricity
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2000
2000
ELECTRAMATE
ELECTRAMATE
- 270/12KW MODEL
- 270/12KW MODEL
DESIGN, INSTALLATION AND
SERVICING INSTRUCTIONS
benchmark
TM
A COMBINED PRIMARY STORAGE UNIT (CPSU) FOR
DOMESTIC HOT WATER SUPPLY AND CENTRAL
HEATING UTILISING OFF-PEAK ELECTRICITY
The code of practice for the installation,
commissioning & servicing of central heating systems
ALL MODELS COMPLY WITH THE
WATER HEATER MANUFACTURERS SPECIFICATION
FOR INTEGRATED THERMAL STORES

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Summary of Contents for Benchmark ELECTRAMATE 2000-270/12KW

  • Page 1 ELECTRAMATE - 270/12KW MODEL - 270/12KW MODEL DESIGN, INSTALLATION AND SERVICING INSTRUCTIONS benchmark A COMBINED PRIMARY STORAGE UNIT (CPSU) FOR DOMESTIC HOT WATER SUPPLY AND CENTRAL HEATING UTILISING OFF-PEAK ELECTRICITY The code of practice for the installation, commissioning & servicing of central heating systems...

  • Page 2: Table Of Contents

    & servicing of central heating systems Patents Pending As part of the industry wide “Benchmark” Initiative all Gledhill ElectraMates now include a Benchmark Installation, Commissioning and Service Record Log Book. The Gledhill Group’s fi rst priority is to give a Please read carefully and complete all sections relevant to the appliance installation.

  • Page 3: Design

    1.0 DESIGN 1.1 INTRODUCTION Any water distribution and central heating installation must comply with the relevant recommendations of the current version of the Regulations and British Standards listed below:- Building Regulations I.E.E. Requirements for Electrical Installations - BS 7671 : 1992 Water Regulations British Standards BS6798, BS5449, BS5546, BS5440:1, BS5440:2,...
  • Page 4 1.0 DESIGN 1.1 INTRODUCTION Key to Schematic Automatic air vent Anti-vacum valve Blending valve Heating pump PHE pump Plate heat exchanger DHW sensor PHE return sensor Hot water outlet Mains cold water inlet 90º angle isolating ballvalve CA type backflow prevention valve - discharging into a tundish Filling pressure regulating valve Pressure gauge Heating flow...
  • Page 5 To comply with the Benchmark Guidance Note for Water Treatment in heating and hot water systems the installer should check the hardness levels of the water supply and if necessary fi t...

  • Page 6: Issue 3

    1.0 DESIGN 1.2 TECHNICAL DATA r t i l l u r i c c i t r i c c i t l l i ½ " r i c i n I a i t i n I a i t t i l °...
  • Page 7 1.0 DESIGN 1.2 TECHNICAL DATA Pre-Wired Cable Entry 23, 24 & 25 Standard Equipment The standard confi guration of the ElectraMate 2000 is shown opposite. The Appliance Control Board (A.C.B.), mounted inside the appliance, controls the operation of the complete system. It is supplied with the following factory fi...
  • Page 8 1.0 DESIGN 1.2 TECHNICAL DATA 40 ltr. expansion vessel 320 dia. The following table of minimum cupboard dimensions only allow the minimum space required for the appliance (including the expansion vessel) and any extra space required for shelving etc in the case of airing cupboards EM 2000 etc must be added.
  • Page 9 1.0 DESIGN 1.2 TECHNICAL DATA It is easier 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 ±...

  • Page 10: System Details

    1.0 DESIGN 1.3 SYSTEM DETAILS This appliance requires 2 electrical supplies, a 24 hour ON PEAK continuous supply and an OFF PEAK restricted supply each rated at 63 amps. A schematic arrangement of the ElectraMate system is shown below. To ensure efficient operation of the appliance it is important that discussions take place with the Electrical Supply Authority to Element_3, boiler pump...
  • Page 11 1.0 DESIGN 1.3 SYSTEM DETAILS 2000 ElectraMate Wiring Guide Pre-Wired 4 Core 0.75mm Flex All Tariffs 12kW 2 x Pre-Wired16 mm Flat Twin & Earth ELECTRAMATE 2000 12 KW 1. This appliance needs two Gledhill optional extra: 63 amp supplies. The unit Local isolator box, with a will only ever draw 12kW heater load on one supply...
  • Page 12 BS 6700. domestic water system. See Appendix C for a copy of the relevant part of the Benchmark If a water meter is fi tted in the service pipe, it should have a nominal rating to match Guidance Note.
  • Page 13 1.0 DESIGN 1.3 SYSTEM DETAILS Hot and Cold Water System Pipe Sizing / Materials To achieve even distribution of the available supply of hot and cold water, it is The hot water supply to a shower-mixing important in any mains pressure system, that the piping in a dwelling should be valve should be fed wherever practical sized in accordance with BS 6700.
  • Page 14 1.0 DESIGN 1.3 SYSTEM DETAILS Heating System Expansion vessel General Air vent A schematic layout of the heating system in a typical small dwelling is shown opposite. The heating circuit is taken from the ElectraMate 2000 and is piped in the conventional manner.
  • Page 15 1.0 DESIGN 1.3 SYSTEM DETAILS h = Height of Tundish Filling the Heating System Le = Total equivalent length of discharge pipe (M) The ElectraMate 2000 appliance comes Note : 90° bend is equivalent to 1M of straight pipe complete with a CA type backflow prevention valve and pressure regulating valve to provide automatic filling of the appliance/sealed heating system from the mains cold water...
  • Page 16 1.0 DESIGN 1.3 SYSTEM DETAILS Expanson vessel requirements The ElectraMate 2000 is supplied with a 40 litre expansion vessel pre-charged to 1.0 bar to accommodate the expansion of the total water content of the system including the thermal store. The size of the expansion vessel provided with each model is considered adequate for a typical installation.

  • Page 17: Installation

    2.0 INSTALLATION 2.1 SITE REQUIREMENTS The electrical mains supply needs to be The appliance is designed to be installed in an airing/cylinder cupboard and the 230V/50Hz. relevant minimum dimensions are provided in section 1.2 Technical Data. The appliance requires 2 electricity supplies, Because of the ease of installation we recommend that the cupboard construction a 24 hour on peak continuous supply and an is completed and painted before installation of the appliance.

  • Page 18: Installation

    2.0 INSTALLATION 2.2 INSTALLATION Preparation/placing the appliance in position. Details of the recommended positions for termination of the first fix pipework are provided in section 1.2 Technical Data. The pipework can be located or its position checked using the template provided with each appliance.
  • Page 19 2.0 INSTALLATION 2.2 INSTALLATION Pipework connections The position of the pipework connections is shown opposite. The connection sizes and dimensions are listed in Section 1.2 Technical Data. All the connections are also labelled on the appliance. It is essential that the pipework is connected to the correct connection.
  • Page 20 2.0 INSTALLATION 2.2 INSTALLATION Page 20...
  • Page 21 2.0 INSTALLATION 2.2 INSTALLATION Gledhill optional extra: Local isolator box, with a Wiring the System 4 pole linked disconnector, room thermostat installer A printed circuit board (ACB) controls 2 x Pre-Wired16 mm Flat Twin & Earth terminals and din rail earth the complete system and all the internal connections pre-assembled.
  • Page 22 2.0 INSTALLATION 2.2 INSTALLATION Off Peak Switch Wiring the system (contd.) On Peak Switch The appliance is suitable for functioning with all types of tariff by positioning the on and off peak disconnection switches (shown opposite) in accordance with the switch settings in the Fig.

  • Page 23: Commissioning

    2.0 INSTALLATION 2.3 COMMISSIONING It is essential that all systems function properly for optimum performance. To achieve Once all the air has been vented from the this, the primary system should be commissioned in accordance with good practice system the two 30 amp fuses should be and generally in accordance with the requirements of BS 6798, BS 5449 and BS 7593.
  • Page 24 2.0 INSTALLATION Mixing valve 2.3 COMMISSIONING Thermal store Heating pump Sensor T1 Heating circuit Heat Boiler pump exchanger pump Sensor T3 Elec. Flow Domestic BAR 1 - HT ON hot water Boiler BAR 2 - OFF PEAK ON BAR 3 - HW ON Sensor T2 LED DISPLAY Jumper...
  • Page 25 2.0 INSTALLATION 2.3 COMMISSIONING Powering the system/appliance The appliance will automatically commission when it is switched on. However it is essential that the following steps are carried out to check the correct functioning of all the controls. Before switching ON the mains supply to the appliance check that : 1.
  • Page 26 2.3 COMMISSIONING Switch off space heating from the programmer or room thermostat. This product is covered by the ‘Benchmark’ Horizontal bar on the LCD screen ‘HT’ will switch off and green LED-3 will switch off. scheme and a separate commissioning/ The heating pump will stop circulating water to the radiator circuit.

  • Page 27: Servicing

    3.0 SERVICING 3.1 ANNUAL SERVICING No annual servicing of the ElectraMate 2000 is necessary. However, we would recommend that checks on the appliance controls and a hot water performance test are carried out annually to prove the appliance is working satisfactorily and within its specification.

  • Page 28: Short Parts List

    3.0 SERVICING 3.3 SHORT PARTS LIST l i c " 2 f e i l i a c i t " 2 c i t r i a i r t l i o ' l l x i f t i l i l e i l p...
  • Page 29 3.0 SERVICING 3.3 SHORT PARTS LIST 13/15 25/26 28/29/30 Page 29...

  • Page 30: Fault Finding

    3.0 SERVICING FAULTS AND THEIR CAUSES 3.4 FAULT FINDING 9. If 1 to 8 are correct then it is likely that Any fault in the system design or malfunction of system components will generate the performance of the heat exchanger is customer complaints.
  • Page 31 3.0 SERVICING 3.4 FAULT FINDING The operation of the ACB itself can be checked as follows : • Switch off mains. • Check/insert correct jumpers i.e. across 2 and 4. • Insert jumper 5. • Switch on mains. • The PCB will carry out functional tests and then stop. LED’s 1-4 will be switched ON then OFF at 5 second intervals and the output number will be indicated on the LED display.
  • Page 32 W h e n r e q u e s t i n g a v i s i t f r o m t h e (current value) manufacturer the installer must have the completed ‘Benchmark’ commissioning/ Press SW1 to move across Press SW2 the diagram.
  • Page 33 APPENDIX A WATER SAVINGS WATER RELATED COSTS CAN BE REDUCED BY GOOD PLUMBING PRACTICE. TAPS & MIXERS 2 TAP 5, 6 OR HALF OPEN OVER 8 L/M 20 L/M Unregulated Fitted with regulator SHOWERS 4 FIXING OPTIONS FOR TAPS & MIXERS 1.
  • Page 34 APPENDIX B MANIFOLDS Two sets of manifolds are available as an optional Manifold type: 1 - Stock Code MIP 050 extra. Each set comprises a separate hot and cold (one bathroom, one en suite shower room, one cloakroom, one kitchen) water manifold.
  • Page 35 APPENDIX B The pressure loss through a fl ow regulator at the designated fl ow rate is about 1.8 bar. Therefore for the fl ow regulator to control the fl ow rate at pre-set level, the inlet pressure must be greater than 1.8 bar.
  • Page 36 APPENDIX B The size of the distribution pipes supplying the manifold should be calculated using the method set out in BS 6700. A typical diagrammatic arrangement of a system using M a n i f o l d Ty p e 1 i s s h o w n b e l o w . This is only meant to show the principles involved and the actual connection of fi...
  • Page 37 The levels of water hardness may be measured using a water hardness test kit. BUILDING REGULATIONS Completion of the BENCHMARK log book requires that the ‘competent person’ undertaking the installation and commissioning provide information relating to Cleaning, Inhibitor and Scale Protection.

  • Page 38: Terms & Conditions

    APPENDIX C Page 38...

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