Benchmark ELECTRAMATE 2000-270/12KW User guide

DESIGN,INSTALLATION AND
SERVICING INSTRUCTIONS
A COMBINED PRIMARY STORAGE UNIT (CPSU) FOR
DOMESTIC HOTWATER SUPPLY AND CENTRAL
HEATING UTILISING OFF-PEAK ELECTRICITY
ALL MODELS COMPLYWITHTHE
WATER HEATER MANUFACTURERS SPECIFICATION
FOR INTEGRATEDTHERMAL STORES
ELECTRAMATE2000 -
270/12KW MODEL
TM
benchmark
The code of practice for the installation,
commissioning & servicing of central heating systems
ELECTRAMATE2000 -
270/12KWMODEL

Page 2
CONTENTS
Section Page
1.0 DESIGN
1.1 Introduction 3
1.2 Technical Data 6
1.3 System Details 10
2.0 INSTALLATION
2.1 Site Requirements 17
2.2 Installation 18
2.3 Commissioning 23
3.0 SERVICING
3.1 Annual Servicing 27
3.2 Changing Components 27
3.3 Short Parts List 28
3.4 Fault Finding 30
Appendix A 33
Appendix B 34
Appendix C 37
Terms & Conditions 38
The Gledhill ElectraMate range is a WBS
listed product and complies with theWMA
Specificationforintegratedthermal 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.
ISSUE 3 : 06-06
As part of the industry wide “Benchmark” Initiative all Gledhill ElectraMates now
include a Benchmark Installation, Commissioning and Service Record Log Book.
Pleaseread carefullyand complete all sectionsrelevantto theappliance installation.
The details from the Log Book will be required in the event of any warranty work
being required and when completed it will meet the requirements of Building
Regulations ADLI for a commissioning certificate. 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.
WARNING : There are no user serviceable parts inside the appliance cover. All
annual inspections and/or servicing must be carried out by suitably qualified
and competent persons.
TM
benchmark
The code of practice for the installation,
commissioning & servicing of central heating systems

Page 3
ELECTRAMATE 2000 - 270/12KW
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,
CP331:3,BS6700,BS5258,BS7593 and BS7671.
Although the domestic water supply to the
ElectraMate 2000 is at mains pressure,it is not
necessary to fit an expansion vessel,pressure
or temperature relief valve.
The ElectraMate 2000 is available for use with
sealed primary central heating systems.
Themanufacturersnotesmustnotbetakenas
overriding statutory obligations.
TheElectraMate2000isnotcoveredbysection
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
ElectraMate 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
1.0 DESIGN
1.1 INTRODUCTION
Key to Schematic
1. Automatic air vent
2. Anti-vacum valve
3. Blending valve
4. Heating pump
5. PHE pump
6. Plate heat exchanger
7. DHW sensor
8. PHE return sensor
9. Hot water 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. Pressure gauge
15. Heating flow
16. Heating return
17. 12kW electric flow boiler
18. Boiler pump
19. Pressure relief valve - discharging into CA tundish pipe
20. Expansion vessel
21. Drain valve
22. Store temperature sensor
23. Store overheat thermostat
24. Electric boiler overheat thermostat
12 11
14
15
17
18
19
20 21
21
23
22
16
13
24

Page 5
ELECTRAMATE 2000 - 270/12KW
1.0 DESIGN
1.1 INTRODUCTION
TheElectraMate2000 has been designed to utilize the latest technologyto provide
mains pressure hot water and traditional wet central heating from conventional
radiators utilising off-peak electricity.
For optimumefficiencyit isimportantthat thebest off-peak tariff is available,anda
minimum of Economy 10 is recommended (see Model Selection Table below).
The ElectraMate 2000 is controlled by a microprocessor based PCB and operates
as follows.
Charging of the thermal stores
Theelectronicsensormonitorsthestoretemperatureandwhenthestoreisdepleted
the controller starts the recharge cycle giving priority to times when off-peak
electricity is available. When the controls are enabled to recharge the store,pump
and heaters are switched on and these continue to run until the store sensor is
satisfied i.e.fully charged.
The control system automatically selects the store charge temperature and control
thermostatdifferentialtomatchelectricitytariffs. Inthesummermonthsthereisno
requirementforspaceheatingthereforethebuiltin controlslowerthe storecharge
temperature to reduce the runnings costs.
Space Heating Operation
The operation of the space heating is
controlled by user 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
storetotheradiators.Thespaceheatingpump
continues to run as long as the heat demand
signal is present from the user controls,other
than when hot water is being drawn.
Theself-acting3-portmixingvalvecontrolsthe
space heating flow temperature to increase
the utilisation of stored energy.
Domestic HotWater Operation
An important feature of this concept is that
hot water can be supplied directly from the
mains at conventional flow rates without the
need for temperature and pressure relief
safety valves or expansion vessels. This
is achieved by passing the mains water
throughaplateheatexchanger(PHE),whichis
heated instantaneously by the primary water
circulated by the dedicated pump through
the PHE.
The outlet temperature of the domestic
hot water is maintained at a pre-set level
(normally about 50 - 55°C at 18 litres/min) by
an electronic controller, which regulates the
speed of the pump circulating the primary
water from the store through the plate heat
exchanger.
TocomplywiththeBenchmarkGuidanceNote
forWaterTreatment in heating and hot water
systemstheinstallershouldcheckthehardness
levels of the water supply and if necessary fit
an in-line scale inhibitor/reducer to provide
protectiontothe whole of the domestic water
system.
Ifscaleshouldeverbecomeaproblemtheplate
heat exchanger is easily isolated and quickly
replaced with a service exchange unit which
canbeobtainedatanominalcostfromGledhill.
For further details see Section 1.3 Use in Hard
Water Areas.
The self-acting 3 port mixing valve controls
the flow temperature to the PHE at a pre-set
value. This not only limits the maximum flow
temperaturetothePHEbutitalsoincreasesthe
utilisation efficiency of the stored energy.
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Page 6
1.0 DESIGN
1.2TECHNICAL DATA
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1. The flow rates quoted are based on a 35°C temperature rise and assumes the minimum recommended dynamic working pressure
and adequate flow are available at the connection to the appliance.
2. The expansion vessel is separate from the appliance complete with a manual air vent/connector. This must be connected
on site by the installer.
3. The domestic hot water outlet temperature is automatically regulated to approximately 55ºC at the bath flow rate of 18 litres/min
recommended by BS6700. The temperature is not user adjustable.
* Minimum water supply pressure at the connection to the appliance under simultaneous demand conditions. (2.0 bar
recommended)

Page 7
ELECTRAMATE 2000 - 270/12KW
27
Pre-Wired Cable Entry 23,24 & 25
1
2
21
3
20
5
7
22
6
12
18
17
91410 15 26
4
13
16
8
11
28
29
1.2TECHNICAL DATA
Standard Equipment
ThestandardconfigurationoftheElectraMate
2000isshownopposite.TheApplianceControl
Board (A.C.B.),mounted inside the appliance,
controlstheoperationofthecompletesystem.
It is supplied with the following factory fitted
equipment:-
1. Automatic air vent
2. Anti-vacuum valve
3. Primary mixing valve
4. Heating pump
5. PHE pump
6. PHE
7. DHW sensor
8. PHE return sensor
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. 12kW electric flow boiler (2 x 4.5kw +
1 x 3kw elements)
17. Boiler pump
18. Pressure relief valve - connecting to
discharge below C A valve tundish
19. Expansion vessel (supplied separately)
20. Store temperature sensor
21. Store overheat thermostat
22. System pressure gauge
23. 3mx16mm2restrictedOffPeakelectricity
supply cable
24. 3m x 16mm2on peak electricity supply
cable
25. 3m x 0.75mm2 x 4 core for the room
thermostat
26. Connection to expansion vessel
27. DanfossTP5E Programmable Room Stat.
28. Boiler overheat thermostat
29. 100mm high installation pallet
Optional Equipment
* Flexible connectors for quick/easy
connection to first fix pipe installation
* 2 x 20 litre expansion vessels
* 4 pole isolator box for fitting adjacent to
theappliancetoprovideasinglecomplete
electricalisolationpointfortheincoming
mains supplies and outgoing room
thermostat control supply.
1.0 DESIGN

Page 8
1.0 DESIGN
1.2TECHNICAL DATA
The following table of minimum cupboard
dimensions only allow the minimum space
required for the appliance (including the
expansionvessel)andanyextraspacerequired
forshelvingetcinthecaseofairingcupboards
etc must be added.
If the expansion vessel is being fitted above
the appliance it will need to be fitted first and
access arrangements made for maintenance
etc if the minimum cupboard dimensions are
used.
SNOISNEMIDECNAILPPA
thgieH htdiW htpeD
ABC
mm0191mm595mm595
EM 2000
A
D
B
320 dia.*
550
mm
CF
150
mm
E
600mmminimum
maintenanceaccess
650mm minimum clear opening
if directly in front of appliance
40 ltr.expansion
vessel
100mm
Note : The above cupboard height assumes
the use of the installation pallet and the 40
litre expansion vessel.
SNOISNEMIDDRAOBPUCMUMINIM
thgieH htdiW htpeD
DEF
mm0042mm057mm006

Page 9
ELECTRAMATE 2000 - 270/12KW
1.0 DESIGN
1.2 TECHNICAL DATA
Itiseasierifallpipesterminateverticallyinthe
positions shown opposite. Compression or
push fit connections can be used and we do
offer a set of flexible connectors as an option.
Allpipepositionsareapproximateandsubject
to a tolerance of ± 10mm in any direction.
litres/sec
Performance Graph of Grundfos UPS
15/50 Pump
$OMESTIC(7
(EATING&LOW
#OLD-AINS
(EATING2ETURN
%XPANSION
MM
MM
0RE7IREDMM/FF0EAKSUPPLYCABLE
0RE7IREDMM/N0EAKSUPPLYCABLE
0E7IREDCOREMM0ROGROOMSTAT
!!6!66
$RAINVALVE
$ISCHARGEPIPEFROM#!VALVEPRV











NOTE: Pipework terminates at low level. Electric supply
and room stat cables rise through the cable entry provided
in the top of the front cover on the appliance - see photo
on page 7.

Page 10
Element _1
(4.5kW)
Element _2
(4.5kW)
Element _3
(3.0kW)
Store
stat
Store stat calling
10-180s 10-180s
10-180s
Element_3, boiler pump
and Green LED _2 ON
Element_2, and Green LED _4 ON Element_1, and Green LED _1 OFF
Element_2, and Green LED _4 OFF
Element_3, boiler pump
and Green LED _2 OFF
Element_1,
and Green LED _1 ON
Time
Note: The boiler pump will
continue to run for a short
period after Green LED 2 has
gone off to provide a boiler
overrun.
10-205
DHW
Pump
Boiler
Pump
Heating
Pump
Appliance Control Board (ACB)
PCB
Store Sensor
DHW Sensor
PHE Sensor
Programmable
Room Stat.
TIMED INTERLOCK
CONTACTOR LOGIC
RESTRICTED OFF-PEAK
63 Amp 230 VAC~50 Hz
Pre-Wired feed cable
PERMANENT ON-PEAK 24Hr
63 Amp 230 VAC~50 Hz
Pre-Wired feed cable
A2
A1
MCB
A2
A1
MCB
A2
A1
MCB
H1
4.5 KW
H3
3.0 KW
H2
4.5 KW
B-OHT
S-OHT
N
L
24 Hour
Supply
R1
A1
A1
A1
A2
24 Hour ON-PEAK MCB 6A
OFF-PEAK MCB 6A
OFF-PEAK C2
ON-PEAK C1
A2
A2
25A 20A
25A
LIVE BUS
NEUTRAL BUS
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
ensure that the best off peak supply/tariff is
utilized. However,the appliance can be easily
configured on site at any time to suit any type
of tariff which is/becomes available.
Whendesigningtheelectricalsystemreference
should be made to the latest issue of the IEE
Requirements for Electrical Installations and
the table on the next page to ensure that
the electrical supplies are adequate and that
the correct circuit protection/cable sizes are
chosen.
This is particularly important in existing
properties, especially if these are blocks of
flats/apartments.
However,theACBwill only allowthe supplyto
each of the three elements in the electric flow
boiler to be switched at random to keep the
maximum simultaneous switching current to
aminimum. Therandomswitchingwillvaryat
each cycle and for each appliance (see sketch
opposite)

Page 11
ELECTRAMATE 2000 - 270/12KW
C D
Double Pole
100 Amp
MCB
Regional
Electricity
Property
ON
OFF
ON
OFF
ON ON ON ON
ON ON
OFF OFF
OFF
OFF
OFF OFF
63A 63A
24 HOUR
ON-PEAK
RESTRICTED
OFF PEAK
SUPPLY
24 HOUR
DOMESTIC
SUPPLY
ON
OFF
ElectraMate
Wiring Guide
All Tariffs 12kW
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 British Standards
Min. Rating of Isolating
switch @ 230 V
(amps)
Max. Cable run based on a 9.2Volt
drop & earth fault loop impedance
for 0.4s disconnection time, when
using type B Protection device to
BS EN 60898.
16mm
2
Maximum 60 mtrs cable run
63 Amp
63 Amp
63A type 1 mcb to BS 3871
63A type B circuit breaker to BS EN 60898 *** Provides best protection
12.3 KW Thermal Storage Appliance
recommended C.P.D (circuit protection
device) to ensure a 0.4sec disconnection
time under fault conditions.
KW Rating @ 230V
+ 10% / -6%
24 Hour ON - PEAK
12.3 KW Heating + Controls
Restricted OFF - PEAK
12.0 KW Heating load only
.
Nominal current @ 230V
(amps)
53.5 Amp
52.2 Amps
APPLIANCE
FEED OFF-PEAK
Mains Tail 25mm +
Double Insulated
2
1
COM OFF ON
23
TP5E
PROGRAMMABLE
ROOM THERMOSAT
Metal
back box
earth
1.0 mm Flat Twin & Earth
2
16mm
2
Maximum 60 mtrs cable run
16 mm Flat Twin & Earth
2
2 x Pre-Wired16 mm Flat Twin & Earth
2
Pre-Wired 4 Core 0.75mm Flex
2
ELECTRAMATE
2000 12 KW
Gledhill optional extra:
Local isolator box, with a
4 pole linked disconnector,
room thermostat installer
terminals and din rail earth
connections pre-assembled.
Clearly labelled giving a
single point of isolation
for maintenance work.
1.This appliance needs two
63 amp supplies. The unit
will only ever draw 12kW
heater load on one supply
and never both. The control
system is electrically
inter-locked to prevent this
from happening.
2.The 24 hour ON-PEAK supply
feeds the control circuit at all
times and only the heater 12kW
load during non OFF-PEAK
availablility and when the
store demands.
3.The Restricted OFF-PEAK supply
only ever feeds the 12kW heater
load and its own control relays
at the times dictated by the supply
company and the tariff utilized.
4. We recommend you select from
the locally available tariffs the one
that gives you the greatest number
of true OFF-PEAK hours of operation,
spread evenly across any 24 hour
period particulary around peak
demand times of the day.
1.3 SYSTEM DETAILS
1.0 DESIGN
Note : Before carrying out any work on the appliance
ensure that BOTH independent electrical supplies
are isolated.

Page 12
1.3 SYSTEM DETAILS
Use in HardWater Areas
The patented control system offers a
sophisticatedlevelofpumpspeedcontroland
will help prevent the formation of scale. This
prevents domestic hot water from exceeding
55°C for most of the operational times of the
appliance.
Thepre-settemperatureofapproximately55°C
is not adjustable.
To comply with the Benchmark Guidance
Note for WaterTreatment in Heating and Hot
Water Systems 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.
When specifying this appliance we would
recommend that for hardness levels above
200ppm(mg/l)adviceis obtained onthetype
of in-line scale inhibitor/reducer to be used
from one of the Water Treatment companies
listed in the Benchmark Guidance Note (see
Appendix C).
Hot and ColdWater System
General
A schematic layout of the hot and cold water services in a typical 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
andcomponentsinthehotandcoldwatersystemarecapableofacceptingthemains
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 fitted in
the system,a pressure limiting (reducing) valve set to 3 bar will be required.
No check valve or similar device should be fitted on the cold water supply branch
to the ElectraMate 2000.
Thehotwater flow ratefromtheElectraMate2000 isdirectly relatedtothe adequacy
ofthe coldwater supplyto thedwelling. Thismust becapable ofproviding for those
services,which could be required to be supplied simultaneously,and this maximum
demand should be calculated using procedures defined in BS 6700.
If a water meter is fitted in the service pipe,it should have a nominal rating to match
themaximumhotandcoldwaterpeakdemandscalculatedaboveinaccordancewith
BS 6700. This could be up to 50ltr/min in some properties.
3UPPLY
PIPE
3ECOND
DWELLING
(
A
A
#
(
A
A
A
#(
A
A
#
3INK
(AND
BASIN
"ATH
3HOWER
$OUBLECHECKVALVE./42%15)2%$UNLESS
SUPPLYPIPESERVICESMORETHANONEDWELLING
#HECKVALVE./42%15)2%$UNLESS
CHEMICALWATERTREATMENTUNITISFITTED
3CALEINHIBITOR
)&2%15)2%$
gAgFLOWREGULATORRECOMMENDEDFORBETTER
BALANCEOFHOTANDCOLDWATERSUPPLY
0RESSURELIMITINGVALVE
./42%15)2%$ATPRESSURES
BELOWBARUNLESSANYSYSTEM
COMPONENTSHAVEALOWER
MAXIMUMWORKINGPRESSURE
%-
4YPICALHOTANDCOLDWATERDISTRIBUTION
1.0 DESIGN

Page 13
ELECTRAMATE 2000 - 270/12KW
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.
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 ElectraMate
should be run in 22mm pipe. The cold main and hot draw-off should alsobe 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 minimum)
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 pressuresareabovethe
recommendedwater pressure range of 2-3 bar.(See Appendix 1 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.
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,wearehappy thatplastic pipeworksystemscan beused inplace 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
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
dynamicchangesparticularlywhenotherhotandcoldtaps/showersareopened
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 only recommend the use of thermostatic
showers with this appliance, even if these are the over the bath/telephone
handset type.
The shower head provided must also be suitable for mains pressure supplies.
1.0 DESIGN
The hot water supply to a shower-mixing
valve should be fed wherever practical
directly from the ElectraMate 2000 or be the
first draw-off point on the hot circuit. The
coldsupply toa shower-mixingvalveshould
wherever practical be fed directly from the
risingmainsvia anindependent branch. The
shower must incorporate or be fitted with
the necessary check valves to provide back-
syphonageprotectioninaccordancewiththe
Water Regulations.
The supply of hot and cold mains water
directly toa bidet ispermitted providedthat
it is of the over-rim flushing type and that a
type‘A’air gap is incorporated.
Hot and ColdWater System
If the length of the hot water draw off
pipework is excessive and the delivery time
willbemorethan1minutebeforehotwateris
availableatthetap,youmaywishtoconsider
usingtraceheatingtothehotwaterpipework
such as the Raychem HWAT system. Please
consult Gledhill Technical Department for
further details.
PleasenotethattheElectraMate2000is NOT
suitable for use with a secondary domestic
hot water circulation system.
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.

Page 14
1.0 DESIGN
Heating System
General
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.
The ElectraMate 2000 is only suitable for a
sealed heating system. Therefore heating
circuitpipework canrun at ahigher levelthan
theapplianceifrequiredaslongassuitableair
vents are provided.
If any radiators are located above the level of
the ElectraMate 2000 the system should be
designed so that gravity circulation does
not occur when the heating pump is not
running. To be certain of preventing this it is
recommendedthatacheckvalve,orvalves,are
fitted on the vertical flowpipes.
The heating circuit operates on the normal
primary boiler temperatures i.e.82°C flow and
71°Creturn.Thereforeanytraditionalhotwater
radiators or convectors can be used with this
system and it is recommended that they are
sized in accordance with BS EN 442.
The Grundfos 15/50 pump characteristics are
shownin1.2TechnicalData.Approximatelyall
theheadcan beusedwhen sizing theheating
circuit pipework.
All the recommendations with regard to
pipeworksystemsinthismanualaregenerally
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.Wealwaysrecommendthe
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.
1.3 SYSTEM DETAILS
EM 2000
Expansion vessel
Air vent
Full bore auto bypass valve NOT REQUIRED
unless the heating system incorporates
mechanical thermostatic control valves e.g.
T.R.V's to all radiators or 2 port zone valves.
As an alternative one of the radiators can be
fitted with lockshield valves which are left
fully open, permanently.

Page 15
ELECTRAMATE 2000 - 270/12KW
1.0 DESIGN
1.3 SYSTEM DETAILS
h-thgieH
)M( eziSepiP mumixaM )M(eL
2.0
mm511
mm229
mm8203
3.0
mm512
mm2231
mm8254
4.0
mm513
mm2291
mm8236
6.0
mm514
mm2272
mm8249
8.0
mm225
mm2273
mm82721
1
mm5
17
mm2264
mm82751
hLe
h = Height of Tundish
Le = Total equivalent length of discharge pipe (M)
Note : 90° bend is equivalent to 1M of straight pipe
DISCHARGE PIPE DIAMETERS
The ElectraMate 2000 appliance comes
completewithaCA typebackflowprevention
valveandpressureregulatingvalvetoprovide
automatic filling of the appliance/sealed
heating system from the mains cold water
connection to the appliance.
This is now allowed by the Water Regulations
to stop any possible contamination of the
mains cold water supply by the water in the
heating system.
This replaces the temporary filling loop
arrangement historically required by the
Water Byelaws and means the connection
to the mains cold water supply can be
permanent. This will allow any loss of
water from the heating 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 the sliding
piston,which opens the main port also closes
the vent (i.e. tundish) port. The valve will
therefore only discharge if the check valve on
the appliance/system side is faulty and the
mainspressure is less thanthe pressurein the
appliance/system.
The valve requires a pressure differential to
operate correctly and a minimum dynamic
pressureof1.5barisrequiredattheconnection
to the appliance under maximum domestic
water simultaneous demand conditions, 2.0
bar is recommended.
The pressure regulating valve is set to 1.0
bar. This is usually sufficient for the heating
systemsinmost domesticproperties- seethe
next page for further details.
Note: Do not open the 90º angle isolating
ballvalve to fill the appliance/heating
systemuntiltheheatingsystemiscomplete
-seethelabelsontheappliancefor further
details.
Filling the Heating System
1 Bar
PRV
CA
Incoming
MCWS
Tundish
Pressure relief
valve discharge
90º angle
isolating ballvalve

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
vesselprovidedwitheachmodelisconsidered
adequate for a typical installation. However
it is the designers/installers responsibility to
checkthisandprovideanadditionalexpansion
vessel if necessary.
The values presented in the table opposite
are based on a maximum store charge
temperature of 85°C.The expansion vessel
mustbesuitable toaccommodatethechange
in volume of the water in the primary system
from 10°C to 110°C as specified in BS 5449 :
1990 clause 16.2.
In normal circumstances an initial system
charge pressure of 1.0 bar is suitable for most
domestic installations.
The minimum system pressure (when cold)
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
safety margin of 0.5 bar. If a different system
pressure is required than 1.0 bar the initial
system and vessel charge pressures 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 temperatures up
to 110°C.
The expansion vessel’s must be sized to
accommodate the expansion of the total
watercontentof thesystem i.e.heating circuit
plus ElectraMate 2000 unit. Total expansion
vesselvolumerequiredfordifferentoperating
pressuresandradiatorcircuitvolumesisshown
in the table opposite.The sizing procedure is
outlined in BS 5449 :1990.
Note : There must be no isolating valve
between the expansion vessel(s) and the
appliance or any other such device.
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535034.527.242.33
040138.524.347.33
545132.621.442.43
050236.
628.447.43
555230.725.542.53
060334.722.647.53
565338.729.642.63

Page 17
ELECTRAMATE 2000 - 270/12KW
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 British Standards
Min. Rating of Isolating
switch @ 230 V
(amps)
Max. Cable run based on a 9.2Volt
drop & earth fault loop impedance
for 0.4s disconnection time, when
using type B Protection device to
BS EN 60898.
16mm 2
Maximum 60 mtrs cable run
63 Amp
63 Amp
63A type 1 mcb to BS 3871
63A type B circuit breaker to BS EN 60898 *** Provides best protection
12.3 KW Thermal Storage Appliance
recommended C.P.D (circuit protection
device) to ensure a 0.4sec disconnection
time under fault conditions.
KW Rating @ 230V
+ 10% / -6%
24 Hour ON - PEAK
12.3 KW Heating + Controls
Restricted OFF - PEAK
12.0 KW Heating load only
.
Nominal current @ 230V
(amps)
53.5 Amp
52.2 Amps 16mm 2
Maximum 60 mtrs cable run
The electrical mains supply needs to be
230V/50Hz.
The appliance requires 2 electricity supplies,
a 24 hour on peak continuous supply and an
off peak restricted supply each rated at 63
amps.
Connections must be made using a suitable
four-pole linked isolator switch which is
located within 2m of the appliance. The
supplies must only serve the appliance.
The minimum breaking capacity of the main
isolation switch and cable sizes/lengths at
230V shall follow the recommendations in the
table below.
The location of the appliance will need to
provideasuitablerouteandterminationpoint
for the discharge pipe from the CAValve/PRV.
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.
If the unit needs to be stored prior to installation it should be stored upright in a
dry environment and on a level base/floor.
Installationandmaintenanceaccessisneeded to the front of the appliance and
the separate expansion vessel. 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 pallet. Extra space may be needed if the
installation pallet is not used.
Thefloorofthecupboardneedstobelevelandevenandcapableofsupportingthe
weight of the appliance when full.If the ElectraMate 2000 is located on a platform
abovethefloorthismustprovidecontinuoussupporttothewholebaseareaandbe
made of a material which will not deteriorate if exposed to moisture.Details of the
weight when full is provided in section 1.2Technical Data.
Theapplianceisdesignedtooperateasquietlyaspracticable. However,somenoise
(from pumps etc) is inevitable in any heating system. This will be most noticeable
in cupboards formed on bulkheads,orat themid spanof asuspended 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 the design of the cupboard and door will need to take this into account. No
ventilationisnormallyrequiredtothecupboard.
A suitable location will be needed for the separate expansion vessel. This will often
beathighlevelin thecupboardhousingtheElectraMate2000butcan beataremote
position if required. The dimensions and clearances are provided in section 1.2
Technical Data. Thelocation will need to providea suitable routefor theexpansion
pipe from the vessel to the appliance.
The electrical supplies must be correctly earthed, polarized and installed in
accordance with the latest edition of the IEE requirements for electrical Installations
BS7671:2001.

Page 18
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.
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. If these have been followed
installation is very simple and much quicker
than any other system.
Theapplianceis supplied shrinkwrapped and
carrying handles are provided in the back of
the casing.
Theexpansionvesselcompletewithinletpipe
and air vent are provided in a separate box.
If flexible connections have been ordered
these will be supplied in the same box as the
expansion vessel.
The appliance should be handled carefully to
avoiddamageandtherecommendedmethod
isshownopposite. Wheneveritispossibleitis
recommendedthatitismovedusingasuitable
sack type truck on the rear face.
Beforeinstallationthesiterequirementsshould
be checked and confirmed as acceptable.The
bottom part of the plastic cover /protective
wrapping should be removed and the
applianceplaced in position.
Remove the front panel by loosening the
retainingscrews3-4turnsandliftingthepanel
up and out using the keyholes provided. Pull
the pipe cover off (see opposite) ready for
connection of the pipework and electrical
supplies. Ensure both panels are replaced
on completion and the retaining screws are
tightened to secure the main panel back in
position.
The expansion vessel shall be installed using
the supports provided. Ensure access is
provided for maintenance.
Note: Although the above guidance is provided
anymanualhandling/liftingoperationswill need
to comply with the requirements of the Manual
Handling Operations Regulations issued by the
H.S.E.
Theappliancecanbemovedusingasacktruckon
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.
Ifitisproposedtouseacraneexpertadviceshould
be obtained regarding the need for slings,lifting
beams etc.
Pipe Cover
Main Access
panel (or cover)
A specific manual handling assessment is shown in
Appendix D at the rear of this manual.

Page 19
ELECTRAMATE 2000 - 270/12KW
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).
ConnectionsA,B,C,D,E and Fare plain ended
copper pipe.
Connection G is a compression fitting.
Connection H is RC½ (½ in BSPT internal).
A - Domestic HotWater
B - Central Heating Flow
C - Incoming Mains ColdWater
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 provided with the expansion vessel.
There must be no isolating valve between
the expansion vessel(s) and the appliance.
Run the discharge pipe from the CA Valve/
PRV to a position where the termination is
visibleandwillnotcausedangertopersonsor
damage to materials - see 1.3 System Details
for further information.
2.0INSTALLATION
2.2 INSTALLATION
Pipework connections
A B C D E
H
G
F
C A Valve
ERV

Page 20
Heater
pump DHW
pump
Heating
pump
A1
A2
C2
N E L
Off-Peak Supply
A1
A2
C1
N E L
On-Peak Supply
A1
A2
T1
Y1
Z2
A1
A2
T3 A1
A2
R1
A1
A2
T2
Y1
Z2
MCB1 – Off peak
MCB2 – on peak
A1
A2
R2
135135
246246
123 4 5 6 7 8 9 10
1112 1314 15 16 17 1819 20 21 22 23 24 25 26 27 28
35 34 33 32 31 30 29
A1
A2
C3
A1
A2
C4
A1
A2
C5
MCB3 – IH-1
MCB4 – IH-2
MCB5 – IH-3
On-peak switch
Off-peak switch
Filter
N E L
NL
Busbar
H1-4.5kW H2 – 4.5kW H3 – 3kW
12kW switch
1
2
331
24
4
S-OHT
H-OHT
15
16 2
15
16 442
16 18
1
1
10
th
Sept 2002
Issue: 01
Approved:________________
Store sensor
PHE sensor
DHW sensor
SL
N
L
E
Programmable
room thermostat
15
Combined Board
Earth
terminals
3
1
24
ElectraMate2000 – 12kW Model Wiring Diagram
b
aa
b
b
b
c
e
ff
2.2 INSTALLATION
2.0INSTALLATION