Benchmark SYSTEMATE 2000 Series User guide

DESIGN,INSTALLATION AND
SERVICING INSTRUCTIONS
A SEALED CENTRAL HEATING
AND MAINS PRESSURE HOTWATER SUPPLY
SYSTEM INCORPORATING
ATHERMAL STORE
ALL MODELS COMPLYWITHTHE
WATER HEATER MANUFACTURERS
SPECIFICATION FOR HOTWATER
ONLYTHERMAL STORES
SYSTEMATE 2000
SYSTEMATE 2000
TM
benchmark
The code of practice for the installation,
commissioning & servicing of central heating systems
Gas Council Approved Reference Numbers
SysteMate 125 97-317-26
SysteMate 145 97-317-27
SysteMate 185 97-317-28
SysteMate 210 97-317-29
SysteMate 225 97-317-30

Page 2
CONTENTS
Section Page
1.0 DESIGN
1.1 Introduction 3
1.2 TechnicalData 5
1.3 System Details 10
2.0 INSTALLATION
2.1 SiteRequirements 16
2.2 Installation 17
2.3 Commissioning 25
3.0 SERVICING
3.1 Annual Servicing 29
3.2 Changing Components 29
3.3 Short Parts List 30
3.4 FaultFinding 32
Appendix A 34
Appendix B 35
Appendix C 38
Appendix D 39
Appendix E 40
Terms & Conditions 38
ISSUE 10 :06-08
The Gledhill SysteMate 2000 range is a
WBS listed product and complies with
the WMA Specification for hot water only
thermal storage products. The principle
was developed in conjunction with British
Gas. This product is manufactured under
an ISO 9001:2000 Quality System audited
by BSI.
Patents Pending
TheGledhillGroup’sfirstpriorityistogivea
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.
As part of the industry wide “Benchmark” Initiative all Gledhill SysteMates now
include a Benchmark Installation, Commissioning and Service Record Log Book.
Pleaseread carefullyand completeall sections relevantto the appliance installation.
The details of the Log Book will be required in the event of any warranty work being
required. There is also a section to be completed after each regular service visit.
The completed Log Book and these instructions should be left in the pocket
provided on the back of the front panel.
TM
benchmark
The code of practice for the installation,
commissioning & servicing of central heating systems

Page 3
SYSTEMATE 2000
1.0 DESIGN
1.1 INTRODUCTION
These instructions should be read in
conjunctionwiththeInstallationandServicing
Instructions issued by the manufacturers of
the heat source e.g.the boiler used.
Any water distribution and central heating
installation must comply with the relevant
recommendations of the current version of
the Regulations and British Standards listed
below:-
Gas Safety Regulations
Building Regulations
I.E.E.Requirements for Electrical Installations
Water Regulations
British Standards
BS6798, BS5449, BS5546, BS5440:1, BS5440:2,
CP331:3,BS6700,BS5258,BS7593 and BS7671.
AcompetentpersonasstatedintheGasSafety
Regulations must install the SysteMate 2000
heating system. The manufacturer’s notes
must not be taken as overriding statutory
obligations.
The SysteMate 2000 is only suitable for use
with a sealed primary, i.e. central heating,
system.
The SysteMate 2000 is not covered 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
remainthatofthecustomerandanyDesigners
orConsultantsconcernedwiththedesignand
installation.
Please Note: We do not therefore accept any
responsibility for matters of design,selection
or specification or for the effectiveness of an
installation containing one of our products
unless we have been specifically 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 SysteMate range, Gledhill Water Storage
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.

Page 4
TheSysteMate2000shownschematicallyaboveisdesignedtoprovidesealedsystem
spaceheatingandmainspressurehotwaterathighflowrateswhencoupledtoany
remotely sited, condensing or non condensing, boiler suitable for sealed heating
systems,as long as they comply with the recommendations contained in the rest
of this manual.
The SysteMate 2000 is an indirectly heated hot water only thermal store and is
supplied with the factory fitted controls and equipment shown in Section 1.2
Technical Data.
The indirect heat exchanger is highly efficient and designed to provide extremely
quick hot water recovery as well as back-up space heating when using‘Switch’.
For details of how to produce SAP ratings calculations contact Gledhill Technical
Department.
Because the F & E cistern is only used to fill the thermal store the standard
applianceissuppliedasamanualfillmodel,i,e,withoutaballvalveandoverflow,
whichmakesitparticularlysuitableforuseinflats/apartments. Aballvalveand
overflow fitting can be supplied as an optional extra if required.
1.0 DESIGN
Description
1.1 INTRODUCTION
An important feature of this product is that
hot water can be supplied directly from the
mains at conventional flow rates without the
needfortemperatureandpressurereliefsafety
valves or expansion vessels. This is achieved
by passing the mains water through a plate
heatexchanger. Theoutlettemperatureofthe
domestichot water ismaintained byaprinted
circuit board,which controls the speed of the
pump circulating the primary water from the
store through the plate heat exchanger.
TocomplywiththeBenchmarkGuidanceNote
for WaterTreatment in heating and hot water
systemstheinstallershouldcheckthehardness
levels of the water supply and if necessary fit
an in-line scale inhibitor/reducer to provide
protectiontothewhole ofthedomesticwater
system.
Ifscaleshouldeverbecomeaproblemtheplate
heat exchanger is easily isolated and quickly
replaced with a service exchange unit which
canbeobtainedatanominalcostfromGledhill.
ForfurtherdetailsseeSection1.3Hotandcold
Water Systems.
The whole system is controlled by a special
electronic control p.c.b. complete with
programmer to which an external room
thermostat can be easily connected.
Thepcbalsoincorporatesthefacilitytooperate
theheatingpumpfora fewsecondseveryfew
days when the heating is not being used, to
reduce the likelihood of the pumps sticking
as well as providing a boiler pump overrun
facility.
Any sealed system automatic boiler designed
to operate on an 820C flow and a 710C return
up to a maximum of 35kW can be linked to
anysuitablemodel of SysteMate2000and the
deciding factor is the space heating and the
hot water requirements of a dwelling. See
Section 1.2 Technical Data for further details.
TheSysteMate2000isavailablewiththeoption
of‘Switch’which will provide a 9kW electrical
emergency backup in case of failure of the
main heat source. See section 1.3 System
Details for further information.
There is no facility available to incorporate a
standard 3kW immersion heater for back up
hot water only.
Gledhill are part of the ‘Benchmark’ scheme
and a separate commissioning/service log
book is included with the product.
Remote
F&E cistern
Cold feed
Hot
Cold
OpenVent
Boiler
Expansion
Vessel
Pressure relief (safety) valve
Componentsfitted within
the appliance case
Automatic
bypassvalve
Fillingloop
Pressure gauge

Page 5
SYSTEMATE 2000
ledoM 521MS 541MS 581MS 012MS 522MS
)ytpme(thgieWgk56gk86gk27gk98gk101
)lluf(thgieWgk081gk391gk222gk952gk192
pmuPWHD05/51sofdnurG05/51sofdnurG05/51sofdnurG05/51sofdnurG05/51sofdnurG
pmuPgnitaeH05/51sofdnurG05/51sofdnurG05/51sofdnurG06/51sofdnurG06/51sofdnurG
pmuPrelioB05/51sofdnurG05/51sofdnurG05/51sofdnurG06/51sofdnurG06/51sofdnurG
epipgnitaeh/yramirP snoitcennoc mm22mm22mm22mm82mm82
epipWHD&WCM snoitcennoc mm22mm22mm22mm22mm22
noisnapxe/deefdloC noitcennoc mm51mm51mm51mm51mm51
tnevnepoytefaS noitcennoc mm22mm22mm22mm22mm22
snoitcennocyramirP esuremmusrof( )liarlewotmoorhtab mm51mm51mm51mm51mm51
noitcennoCniarD''½R''½R''½R''½R''½R
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erusserpmumixaM retawcitsemod rab5rab5rab5rab5rab5
liocyramirpfoemuloV )sertil( 0.20.20.20.40.4
etarwolfretawtoHnim/stl53otpunim/stl53otpunim/stl53otpunim/stl53otpunim/stl53otpu
ezisreliobxaMk51W k02W k52W k03W k53W
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sepytgnillewDlacipyT
smoordeB3-13-24-25-36-4
smoorhtaB11212234
rewohsetius-nE12142420
1.2TECHNICAL DATA
Notes:-
1. The SysteMate 225 appliance is suitable for use in large properties because it produces the same ‘peak hour output’
as a typical 250 - 320 litre unvented cylinder. For properties requiring the SM 225 the incoming main should be a
minimum of 32mm MDPE with a pressure of not less than 2 bar dynamic and an adequate flow in line with the pipe sizing
calculations. In many cases, properties of this size will benefit from having 2 smaller sized appliances located adjacent
to the areas of peak hot water use which will increase the available flow rate and may remove the need to provide trace
heating on the hot water distribution.
2. The plastic F & E cistern complete with fittings and the expansion vessel are supplied separately.
3. Theflowratesarebasedona35°Ctemperatureriseandassumenormalpressureandadequateflowtotheappliance. Theactual
flow rate from the appliance is automatically regulated to a maximum of 28 litres/min.
4. Models are available in Hard and Soft water versions (suffixed‘H’or‘S’).
5. Unit is supplied on a 100mm high installation base.
6. Thedomestichotwateroutlettemperatureisautomaticallyregulatedtoapproximately55°Catthebathflowrateof18litres/min
recommended by BS 6700. The temperature is not user adjustable.
7. The maximum boiler size shown above is for the standard pump fitted and for a typical system. The designer/installer must
calculate the suitability of the standard pump as part of normal design procedures.
8. The expansion vessel sizes shown above have been calculated to be adequate for typical systems. The designer/installer must
calculate their suitability for the actual system and provide an extra vessel if required.
1.0 DESIGN

Page 6
2
6
8
7
9
3
10
11
1
4
5
12
1.2TECHNICAL DATA
Standard Equipment
The standard configuration of the SysteMate
2000isshownopposite.TheApplianceControl
Board (A.C.B.),mounted inside the appliance,
controlstheoperationofthecompletesystem.
The A.C.B. is pre-wired to a terminal strip
where all electrical connections terminate. It
is supplied with the following factory fitted
equipment:-
1. Space heating pump
2. Domestic hot water primary
(plate heat exchanger) pump
3. Boiler pump
4. Hardwaterappliancecontrolboard (A.C.B.)
5. Electro-mechanical clock to control the
space heating (in conjunction with room
thermostat - if fitted)
6. Expansionvesselfortheprimary/heating
system (supplied separately)
7. Plate heat exchanger
8. DHW temperature sensor
9. PHE return sensor
10. Store temperature sensor
11. Y type strainer/flow regulator
12. A feed and expansion cistern for filling
theprimarythermalstore(completewith
coldfeed/openventpipeworkassembly)
is supplied separately.
Optional Extra Equipment
* A soft water model is available for areas
where the hardness level is below 200
p.p.m.(mg/ltr)
* Flexible connection kit for use in
connection with suitable push fit
connectors for quick connection to first
fix pipe installation.
* ‘Switch’ emergency electrical back-up
for hot water and/or heating in the event
of a boiler fault.
* A seven day digital clock/programmer
to control the space heating (in
conjunction with a room thermostat if
fitted).
* A kit to site the clock/programmer
remotely.
* A no clock option - because of the
design of the appliance it should not be
necessary to fit anything other than a
single channel clock to control the
heating system.
* 15mm 3 bar pressure relief (safety) valve
for fitting near the boiler (see boiler
manufacturers recommendations.
* Pressure gauge and filling loop for fitting
near the boiler.
* Hot and cold water manifolds for use
with plastic pipework.
* Ballvalve/overflow connector for F & E
cistern.
1.0 DESIGN
Appliance Control Board
A.C.B.
Electro-mechanical clock
programmer
Digital clock programmer Switch

Page 7
SYSTEMATE 2000
1.0 DESIGN
1.2TECHNICAL DATA
Note: The dimensions below do not allow for the100mm
high installation base.
The following table of minimum cupboard dimensions only
allowtheminimumspacerequiredfortheappliance(including
the F & E cistern and expansion vessel) and any extra space
required for shelving etc in the case of airing cupboards etc
must be added.
D
600mm min clear opening- if
located directly in front of the
appliance. Maintenance
access
Min maintenance
access - to comply
withtheWater
Regulations if a
ballvalve is being fited
APPLIANCE
E
C
300mm
420mm
450mm*
600mm
100mm
F
A
F&ECistern
F & E Cistern
plan
290mm*
Expansion
Vessel
25litre
* Note : 12 litre vessel
(supplied with SM 125 - 185)
Size 280mm diam x 300mm long
Note : 225mm is considered adequate
access if the ballvalve is not being
fitted i.e.manual fill is being used
280mm
25 litre
Expansion
Vessel
(Supplied
with
SM 210-225)
plan
B
350mm
SNOISNEMIDECNAILPPA
ledoM thgieH htdiW htpeD
ABC
521MSmm0411mm595mm595
541MSmm0411mm595mm595
581MSmm0531mm595mm595
012MSmm5941mm595mm595
522MSmm0761mm595mm595
SNOISNEMIDDRAOBPUCMUMINIM
ledoM thgieH htdiW htpeD
FDE
521MSmm0981mm007mm006
541MSmm0981mm007mm006
581MSmm0012mm007mm006
012MSmm5422mm007mm006
522MSmm0242mm007mm006
Note: The above dimensions are based on the Appliance and
the F & E cistern (fitted with a ballvalve) being in the same
cupboard. Ifthemanual fillmethod is chosen the heightscan
be reduced by 125mm.

Page 8
1.0 DESIGN
1.2 TECHNICAL DATA
Cut out area through
base of unit - showing
recommendedpipework
riserpositions.
120
408
595
595
555
REAR
PLAN
478
508
453
22mm OpenVent (for thermal store)
15mm Cold feed (for thermal store)
REMOVABLE FRONT ACCESS PANEL
325
45
TOP
HeatingFlow
HeatingReturn
BoilerFlow
Primary Return
Towel Rail Circuit
BoilerReturn
HotSupply
Cold Mains Supply
The SysteMate 2000 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
fit connections can be used and we do offer a set of flexible connectors as
an option,(for use with suitable push fit connectors only). All pipe
positions are approximate and subject to a tolerance of +/- 10mm in any
direction. Space for a 15mm cold water supply and a 22mm
warning/overflow pipe for the separate feed and expansion cistern (if
fitted) will also be required.
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 any
cold water tap or from a permanent cold branch provided adjacent to the
F & E cistern. The temporary connection must be removed once the
applianceis filled.
15mm ExpansionVessel
Primary Flow
Towel Rail Circuit
70
405
450 450
360
330
297
225
195
157
55
*Drawingnottoscale.

Page 9
SYSTEMATE 2000
1.2 TECHNICAL DATA
PERFORMANCE GRAPHS OF GRUNDFOS PUMPS
1.0 DESIGN
GRUNDFOS 15/50 GRUNDFOS 15/60
litres/sec
6
litres/sec
Note:1mW.G.= 10kPa

Page 10
1.3 SYSTEM DETAILS
Hot and ColdWater System
General
A schematic layout of the hot and cold water services in a typical small dwelling is
shownbelow. SysteMate2000will operate atmains pressures as lowas 1bar and as
highas5baralthoughtherecommendedrangeis2-3bar. Ifthemanifolds(availableas
anoptionalextra)arebeingusedtheinletpressuretothemanifoldmustbeaminimum
of 2 bar. It is also important to check that all other equipment and components in
thehotandcoldwatersystemarecapableofacceptingthe mains pressureavailable
tothe property. If themains pressurecanrise above5bar orthe maximumworking
pressureofanyitemofequipmentorcomponenttobefittedinthesystem,asuitable
pressure limiting (reducing) valve will be required.
If you encounter a situation where the water pressure is adequate but flow rates are
poor please contact our technical helpline for details of an effective solution.
Note: Each SysteMate 2000 is fitted with a strainer and flow regulator on the cold
mainssupply connection. If thesupply pressureis lessthan 2bar or if the manifolds
(available as an optional extra) are being used or if all taps are provided with flow
regulators the flow regulator on the cold inlet should be removed.
Nocheck valveorsimilar deviceshould befitted onthe coldwater supply branch to
the SysteMate 2000.
TocomplywiththeBenchmarkGuidanceNoteforWaterTreatmentinHeatingandHot
Water Sytems the installer should check the hardness level of the water supply and
if necessary fit an in-line scale inhibitor/reducer to provide protection to the whole
of the domestic water system. See Appendix C for a copy of the relevant part of the
Benchmark Guidance Note.
1.0 DESIGN
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Note: ThediagramaboveshowstheF&Ecisternwithaballvalveandwarning/overflow
pipe which can be fitted if required. However,the standard preferred arrangement
is for the cistern to be manually filled from a temporary hose connection fitted with
a double check valve.
When specifying this appliance we would
recommend that for hardness levels above
200ppm (mg/l) a hard water appliance is used.
For hardness levels above 280ppm (mg/l) we
would recommend that some form of in-line
scaleinhibitor/reducerisrecommendedbyone
ofthewatertreatmentcompanieslistedin the
Benchmark Guidance Note (See Appendix C).
The hot water flow rate from the SysteMate
2000 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
shouldbecalculatedusingproceduresdefined
in BS 6700.
If a water meter is fitted in the service pipe,
it should have a nominal rating to match the
maximum hot and cold water peak demands
calculated in accordance with BS 6700. This
could be up to 80ltr/min in some properties.

Page 11
SYSTEMATE 2000
1.3 SYSTEM DETAILS
Hot and ColdWater System
Pipe Sizing / Materials
To achieve even distribution of the available supply of hot and cold water, it is
important in any mains pressure system, that the piping in a dwelling should be
sized in accordance with BS 6700. This is particularly important in a large property
with more than one bathroom.
However, the following rule of thumb guide lines should be adequate for most
smaller property types as long as water pressures are within the recommended
range of 2-3 bar.
1. A 15mm copper or equivalent external service may be sufficient for a
small 1bathroom dwelling (depending upon the flow 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 SysteMate
should be run in 22mm pipe. The cold main and hot draw-off should also
be run in 22mm as far as the branch to the bath tap.
3. The final branches to the hand basins and sinks should be in 10mm and to
the baths and showers in 15mm.(1 metre recommended)
4. We would recommend that best results for a balanced system are achieved
by fitting appropriate flow regulators to each hot and cold outlet. This is
particularly relevant where the water pressures are above the recommended
water pressure range of 2-3 bar. See Appendix A for further details.
Note: If manifolds (available as an optional extra) are being used suitable flow
regulators are automatically provided in the manifold and do not need to be
provided at each outlet - See Appendix B for further details.
Note: If a warning/overflow pipe is NOT provided the F & E cistern should be
filled from a temporary hose connection supplied from any cold water tap
or from a permanent cold branch provided adjacent to the F & E cistern. The
temporary hose must be fitted with a double check valve and removed once
the appliance is filled.
Alltherecommendationswithregardtopipeworksystemsinthismanualaregenerally
based on the use of BS/EN Standard copper pipework and fittings.
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.
Thisisparticularlyimportantinrelationtouseofpushfitconnectionswhenusingthe
optional flexible hose kits - see 2.2 Installation,Pipework connections.
It is also essential that if an alternative pipework material/system is chosen the
manufacturerconfirmsthatthedesigncriteriaofthenewsystemisatleastequivalent
to the use of BS/EN Standard copper pipework and fittings.
Taps/Shower Fittings
Aeratedtapsarerecommendedtopreventsplashing.
Anytypeofshowermixingvalvecanbeusedaslongasboththehotandcoldsupplies
aremainsfed. However,allmainspressuresystemsaresubjecttodynamicchanges
particularlywhenotherhotandcoldtaps/showersareopenedandclosed,whichwill
causechangesinthewatertemperatureatmixedwateroutletssuchasshowers. For
thisreasonandbecausethesearenownomoreexpensivethanamanualshowerwe
stronglyrecommendtheuseofthermostaticshowerswiththisappliance.
Theshowerheadprovidedmustalsobesuitableformains pressuresupplies.
However,if it is proposed to use a‘whole body’or similar shower with a number of high
flow/pressureoutletspleasediscusswiththe Gledhill technical department.
1.0 DESIGN
If the length of the hot water draw off
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.
Theappliancehasnotbeendesignedtosuita
re-circulating domestic hot water circuit.
PleaseconsultGledhillTechnicalDepartment
for further details.
It is important that the cold water pipework
is adequately separated/protected from any
heating/hot water pipework to ensure that
thewaterremains coldandofdrinkingwater
quality.
Hot and ColdWater System.
The hot water supply to a shower-mixing
valveshouldbefedwhereverpracticaldirectly
fromthe SysteMate2000or be the first draw-
off point on the hot circuit. The cold supply
to a shower-mixing valve should wherever
practicalbe feddirectlyfromthe risingmains
viaanindependentbranch. Theshowermust
incorporate or be fitted with the necessary
check valves to provide back-syphonage
protection in accordance with the Water
Regulations.
Thesupplyofhotandcoldmainswaterdirectly
toabidetispermittedprovidedthatitisofthe
over-rim flushing type and that a type ‘A’air
gap is incorporated.

Page 12
1.0 DESIGN
Heating System
General
A schematic layout of the heating system in a typical small dwelling is shown
above.
The flow and return from the boiler must always run directly to the SysteMate 2000
andtheflowshouldrisecontinuouslytofacilitateventing.Theheatingcircuitistaken
from the SysteMate 2000 and is piped in the conventional manner.
The SysteMate 2000 is only suitable for a sealed heating system and therefore
boiler/heating pipework can run at a higher level than the store.
It is recommended that the F & E cistern for the appliance is fitted at high level in
the same cupboard as the SysteMate 2000. However, it can be fitted remotely up
to 10m above the base of the SysteMate 2000 i.e. the maximum static pressure in
the store must not exceed 1 bar.
It is recommended that the expansion vessel is fitted at high level in the appliance
cupboard alongside the F & E cistern.
TheperformanceofthesystempumpandthepressurelossesthroughtheSysteMate
2000primarycoilcircuitareshownin1.2TechnicalData. Thenettpumpheadavailable
fortheheatingcircuitcanbedeterminedfromthesefiguresandthisnettpumphead
should be used for sizing the heating circuit pipework.
If any radiatorsare located abovethe levelof the SysteMate 2000 the systemshould
be designed so that gravity circulation does not occur when the heating pump is
not running. To be certain of preventing this it is recommended that a check valve,
or valves,are fitted on the vertical flow pipes.
1.3 SYSTEM DETAILS
Forexample: At24litres/minprimaryflowrate,
the pressure loss through the SysteMate 2000
model SM210 (coil and fittings) is 2.1m W.G.
(21kPa).Themaximumpumpheadavailableat
24litres/minandsetting3is 3.2mH2O(32kPa),
therefore1.1mW.G.(11kPa)isavailableforthe
boiler circuit.
With sealed heating systems air is released
during the first few weeks of operation.
This will need to be vented and the system
re-pressurised.
Theoverflow/warningpipeshouldbeinstalled
in a material suitable for a heating system
feedandexpansioncisterninaccordancewith
BS 5449.
Anautomaticbypassisfittedon theSysteMate
2000tocompensateforpressure(i.e.flow)rate
changes in the heating circuit e.g. when the
thermostaticradiatorvalvesclose. Thesystem
does not require any other bypass valves but
a bypass radiator used in conjunction with a
room thermostat is suitable.
There shall be no permanent connection to
the mains water supply for filling the system,
even through a non-return valve without the
approval of the Local Water Authority. An
approved filling loop is required with the
SysteMate 2000 (available as an optional
extra)whichthisshouldbedisconnectedafter
commissioning the system. This should be
located adjacent to the boiler along with
a suitable gauge and pressure relief valve
(also available as optional extras) as shown
opposite.
Remote
F&E cistern
Cold feed
Hot
Cold
OpenVent
Boiler
Expansion
Vessel
Pressure relief (safety) valve
Components fitted within
the appliance case
Automatic
bypass valve
Fillingloop
Pressure gauge

Page 13
SYSTEMATE 2000
1.0 DESIGN
1.3 SYSTEM DETAILS
Heating System
Pipe Sizing/Materials
The SysteMate 2000 is designed to be installed with any condensing or non
condensing boiler which is suitable for a sealed heating system (i.e. fitted with an
overheat thermostat) and is capable of delivering hot water at a minimum of 80oC.
The primary pipework connecting the boiler and the thermal store should be sized
to achieve a maximum of 11°C rise across the boiler or the maximum temperature
rise specified by the boiler manufacturer,whichever is smaller,but in any instance it
should not be less than 22mm copper tube.
If the boiler is a condensing type the boiler must be set to operate at a normal 82oC
flow 71oC return system.
Note: There should be no valves in the pipework connecting the boiler to the
SysteMate 2000.
The heating circuit operates on the normal primary boiler temperatures i.e. 82°C
flow and 71°C return. Therefore any traditional hot water radiators or convectors
can be used with this system and no special over-sizing of the heat emitters is
necessary.
All the recommendations with regard to
pipeworksystemsin thismanualaregenerally
based on the use of BS/EN Standard copper
pipework and fittings.
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 heating
systems by the manufacturer and is installed
fully in accordance with their recommendations.
We always recommendthe use of barrier pipe
for these systems.
Itisalsoessentialthatifanalternativepipework
material/system is chosen the manufacturer
confirms that the design criteria of the new
systemisatleastequivalenttotheuseofBS/EN
Standard copper pipework and fittings.
Boiler Size
It is only necessary to calculate the heating
requirementsinaccordancewithBS5449. The
allowances shown below should be added
for domestic hot water. The control system
automaticallygivesprioritytohotwaterwhen
necessary.
Boiler Sited Below SysteMate 2000
TheflowpipefromtheboilertotheSysteMate
2000mustrisecontinuously. No valveshall be
fittedintheprimaryflowpipeasthisformsthe
expansion pipe to the expansion vessel.
The size of the primary pipework connecting
the boiler to the SysteMate 2000 must not be
lessthan22mm(orthatspecifiedbytheboiler
manufacturer).
Boiler
SM 2000
Expansion
Vessel
Remote F & E
Cistern
Boiler Return
Boiler Flow
Pressure relief (safety) valve
Fillingloop
Pressure gauge
Allowance for Domestic
HotWater
Model (kW)
SM125 2
SM145 3
SM185 3
SM210 3.5
SM225 4

Page 14
If a pumped circuit is required for a bathroom
radiator/towel rail, the flow and return
pipework can be connected into the 15mm
copper blanked connections provided. We
recommend any radiators/towel rails on this
circuit are provided with T.R.V.’s and that the
total heat output of the radiators/towel rails is
not more than 5% of the boiler output.
The radiators will only get hot when the
boiler is firing and the store is being
heated.
Itisimportantthattheflowratesthroughthese
radiatorsisadjusted tothe minimum required
atthelockshield valvesonthe radiators. Ifthis
is not done the performance of the SysteMate
will be adversely affected.
Heating System
Connection of Bathroom Radiator/Towel -
Rail for Summer use
1.0 DESIGN
1.3 SYSTEM DETAILS
Boiler sited above the SysteMate or with
dipped flow and return pipes
A gravity check valve should be fitted in the
boiler return pipework to prevent gravity
circulation between the SysteMate 2000 and
the boiler during dormant periods.
An automatic air vent will be required on the
flow adjacent to the boiler and depending
upon the pipe layout an automatic or manual
air vent will also be required on the return
adjacent to the boiler.
The pressure relief (safety valve) must be
located on the flow immediately adjacent to
the boiler.
Heating System
Remote
F & E cistern
Boiler
Expansion
Vessel
AAV
AAV
GCV
SM 2000
Boiler
Flow
Boiler
Return
AAV - Automaticair vent
GCV-Gravity checkvalve
Pressure relief (safety) valve
Fillingloop
Pressure gauge
Remote
F & E cistern
Expansion
Vessel
Boiler
SM 2000
Boiler Return
Boiler Flow
Bathroom/Towel
Radiator
Pressure relief (safety) valve
Filling loop
Pressure gauge

Page 15
SYSTEMATE 2000
1.3 SYSTEM DETAILS
Heating System
ExpansionVessel Requirements
The SysteMate expansion vessel is pre-charged to 1.0 bar. The maximum water
content of the heating system (boiler + radiators + connecting pipework + primary
coil but NOT store volume) must not be greater than those shown in the table
below.
A figure of 4.5 litres/kW of installed radiator capacity can be used for a preliminary
assessment of the water content of the heating system.
The values presented in the table are based on a maximum boiler flow temperature
of 93oC. The expansion vessel must be suitable to accommodate the change in
volume of the water in the system when heated from 10oC to 110oC as specified
in BS 5449:1990 clause 16.2.
The primary heating coil and pipework volumes are shown in the table in 1.2
Technical Data.
In normal circumstances an initial vessel and system charge pressure of 1 bar is
suitable for most domestic purposes.
The minimum system pressure should not be 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 margin of 0.5 bar.
Ifthesystemvolumeisgreaterthanthatshowninthetableattheselectedoperating
conditions then an additional expansion vessel must be fitted.
1.0 DESIGN
‘Switch’
The SysteMate 2000 can be ordered with
theoptionof‘Switch’whichprovidesa9kW
electrical emergency back up in the case
of failure of the main heat source i.e. gas
boiler.
This must NOT be used to provide hot
water only in summer if the main system is
working correctly.
If Switch is ordered the electrical supply will
need to take account of the increased load.
Full details of the requirements are provided
in Section 2.1 Site Requirements and 2.2
Installation.
Otherwise the design requirements are the
same as the standard appliance.
Switchcanoperateon‘hotwater’or‘hotwater
and heating’ modes. In the former only hot
water pump and electric heating element are
energized. In the latter the heating system
pump is also energized. This means that
the heating will be on permanently unless
manuallyswitchedbacktothe‘hotwater’only
position.
It also means that wherever Switch is
being used the normal domestic hot water
temperaturecontrolsareover-ridden. Initially
dependent on the flowrate/store temperature
hot water can be delivered at the tap at
temperatures as high as 75°C. A warning
notice to this effect is provided in the front
of the appliance.
However,oncetheinitialstoretemperaturehas
been reduced the Switch element thermostat
will reduce the temperature at the tap to no
morethan65°C. Fulldetailsofhowtooperate
thesystemareprovidedonalabelfixedtothe
front of the appliance.
12 LitreVessel i.e.SM 125/145/185
Maximum Recommended Heating SystemVolumes
Safety valve setting (bar) 3.0
Vessel charge pressure (bar) 0.5 1.0 1.5
Initial system pressure (bar) 0.5 1.0 1.5 1.0 1.5 2.0 1.5 2.0
Maximum permitted system
volume (litres) 140 80 40 110 60 27 70 35
25 LitreVessel i.e.SM 210/225
Maximum Recommended Heating SystemVolumes
Safety valve setting (bar) 3.0
Vessel charge pressure (bar) 0.5 1.0 1.5
Initial system pressure (bar) 0.5 1.0 1.5 1.0 1.5 2.0 1.5 2.0
Maximum permitted system
volume (litres) 270 160 85 200 115 50 140 65

Page 16
2.0 INSTALLATION
2.1 SITE REQUIREMENTS
The appliance is designed to be installed in an airing/cylinder cupboard and the
relevant minimum dimensions are provided in section 1.2 Technical Data.
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 fitted after installation.
Ifthe unit needstobestoredprior to installationitshould be storeduprightina dry
environment and on a level base/floor.
Installationandmaintenanceaccessisneeded to the front of the appliance and
abovethe F & E cistern. SeeTechnical Data section for further details.
The minimum dimensions contained in section 1.2 Technical Data 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 floor 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 section 1.2 Technical Data.
Theapplianceisdesignedtooperateasquietly as practicable. However,somenoise
(from pumps etc) is inevitable in any heating system. This will be most noticeable
in cupboards formed on bulkheads, or at the mid span of a suspended floor. In these
cases the situation can be improved by placing the appliance on a suitable sound
deadening material (i.e.carpet underlay or similar).
Cupboard temperatures will normally be higher than in a conventional system and
thedesignofthecupboardanddoorwillneedtotakethisintoaccount.Noventilation
isnormallyrequiredtothecupboard.
A suitable location will be needed for the separate feed and expansion cistern
and expansion vessel. This will often be at high level in the cupboard housing the
SysteMate2000. Thedimensionsandclearancesareprovidedinsection1.2Technical
Data. The location will need to provide a suitable route for the cold feed/expansion
pipe and the open safety vent pipe for the appliance as well as the connecting pipe
to the system expansion vessel. The location will also need to provide a suitable
route and discharge position for the warning/overflow pipe and the ballvalve supply
fromthe mainscold watersystem if these are being fitted.
Note: The standard appliance is supplied with a cistern without a ballvalve/
overflow for filling 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
BS7671.
The electrical mains supply needs to be 230V/50Hz/1Ph
Connection must be made using a double-pole linked isolator with a contact
separation of 3mm in both poles which is located within 1m of the appliance. The
supply must only serve the appliance.
Thesupplytothestandardapplianceshallbefusedat3amp-nominalmaximumfull
load current for all SM models = 1.4 amps (this does not include the boiler).
Electrical Supply requirements for
SysteMate2000 with Switch
If the ‘Switch’ electrical emergency backup
is being provided, the minimum breaking
capacity of the main isolation switch and
cable sizes/lengths at 230V shall follow the
recommendations in the table below.
Nominal
full load
current
Min
rating of
isolating
switch
Cable
size Max.recommended cable run-based
on 9.2V drop
and 0.4 second
disconnection
time using a type
1 or B breaker
41.0
Amps 45 Amps 10mm249 metres
Recommended
circuit protection
device - based
on 0.4 second
disconnection time
45A type 1 - M.C.B.to BS 3871
45A type B circuit breaker to
BS EN 60898

Page 17
SYSTEMATE 2000
2.2 INSTALLATION
2.0INSTALLATION
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 need team lift.
Preparation/placing the appliance in
position.
Details of the recommended positions for
terminationofthefirstfixpipeworkareprovided
insection1.2TechnicalData.Thepipeworkcanbe
locatedoritspositioncheckedusingthetemplate
providedwitheachappliance. Ifthesehavebeen
followed installation is very simple and much
quicker than any other system.The appliance is
suppliedshrinkwrappedonatimberinstallation
base. Carrying handles are also provided in the
back of the casing.
The feed and expansion cistern complete with
ballvalve, cold feed/expansion and overflow/
warning fittings are provided in a separate box
alongwiththesystemexpansionvessel. Ifflexible
connectionshavebeenorderedthesewillalsobe
inside the feed and expansion cistern.
The appliance should be handled carefully to
avoid damage and the recommended method
is shown opposite. Before installation the site
requirementsshouldbechecked andconfirmed
as acceptable.The plastic cover and protective
wrappingshouldberemovedfromtheappliance
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 (see opposite) ready
for connection of the pipework and electrical
supplies.Thefeedandexpansioncisternsupport
shall be installed ensuring that the base is fully
supportedandtheworkingheadoftheappliance
is not exceeded. The recommended access for
maintenancemustalsobeprovided-seesection
1.2Technical Data.
Note:Although the above guidance is provided
anymanualhandling/liftingoperationswillneed
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
storeyswewouldrecommendthattheappliances
are moved vertically in a mechanical lift.
If it is proposed to use a crane expert advice
shouldbeobtainedregardingtheneedforslings,
lifting beams etc.
A specific manual handling assessment is shown in
Appendix D at the rear of this manual.

Page 18
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.
The connections can be hard piped but we
recommend the use of flexible connections
(available as an optional extra).
When using push fit connectors with the
flexible hose kits it is important to check that
they are compatible. Written approval has
already been obtained for:-
Hepworth - Hep2O BiTite
John Guest - Speedfit
Yorkshire -Tectite
However, as similar assurances cannot be
obtained for Polypipe fittings we cannot
recommend their use.
Connections A,B,D,E,F,G,H,I, and L are plain
ended copper pipe.
Connections C & J are compression fittings.
Connection K is a RC½ (½”BSPT internal)
A - Safety open vent
B - Cold feed/expansion
C - Expansion vessel pipe
D - Central heating flow
E - Central heating return
F - Primary flow (from boiler)
G - Primaryreturn(forsummerusebathroom
towel rail circuit)
H - Primary return (to boiler)
I - Domestic hot water
J - Incoming mains water
K - Drain (valve is not provided with the
appliance)
L - Primary flow (for summer use bathroom
towel rail circuit)
Note: The safety open vent and cold feed/
expansion should be connected to the
F & E cistern using the pipework assembly
provided.
2.0INSTALLATION
2.2 INSTALLATION
Pipework connections
DEFGHI JKL
ABC

Page 19
SYSTEMATE 2000
2.2 INSTALLATION
2.0INSTALLATION
It is normally envisaged that the feed and
expansion cistern will be located in the same
cupboard as the SysteMate appliance itself to
maintain a dry roof space.
The cold feed/open vent pipework assembly
(as supplied) should be used if it is intended
to install the F & E cistern directly on top of
the appliance.
However,if it is necessary to locate the cistern
in the roof space (or on a higher floor) the
cold feed/open vent pipework assembly (as
supplied)shouldbeusedtoconnecttotheF&
Ecisternandpipeworksiterunbytheinstaller
to connect this to the appliance,
Obviously,anypipeworkinthe roofspaceand
the feed and expansion cistern will need to
be adequately insulated to protect against
frost damage.
All factory made joints should be checked after installation in case they have
been loosened during transit.
The fittings for the feed and expansion cistern should be installed following the
instructionsprovidedbythemanufacturerinapositiontosuittheparticularlocation
and the cistern fitted on its supports/base.
The cold feed/expansion and safety open vent should be installed between the
appliance and the feed and expansion cistern.
Combined feed and open vent pipe arrangements must not be used.
No valves should be fitted in the safety open vent which must be a minimum of
22mm copper pipe or equivalent.
The expansion vessel should be positioned on the supports provided and the
connecting pipe from the SysteMate 2000 connected to the air vent assembly
provided.
If an overflow/warning pipe is fitted it shall have a continuous fall, be fitted to
discharge clear of the building and be sited so that any overflow can be easily
observed. It shall alsobe installedin a sizeand materialsuitableforuse withheating
feed and expansion cisterns in accordance with BS 5449 and should not have any
other connections to it.
Cold feed / open vent
pipework assembly
(as supplied)
Interconnecting
Pipework
(ByInstaller)

Page 20
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2.0 INSTALLATION
2.2 INSTALLATION
KEY
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