ElectraStream BEL 130 User manual

1
User and Installation ManualUser and Installation Manual
User and Installation ManualUser and Installation Manual
User and Installation Manual
Single and Twin Coil Models
For owners, installers and service engineers
heating products
A complete cost effective solution for Hot and Cold water supply and Electric Central
Heating with water filled radiators, suitable for Self-contained Flats, Small Dwellings,
Offices, Home Offices and Granny Annexes.
9 kW (30,000 Btu) - for Heating and Hot Water
27/02/13
TT
TT
Twin Coil Cylinder option available for SOLAR enerwin Coil Cylinder option available for SOLAR ener
win Coil Cylinder option available for SOLAR enerwin Coil Cylinder option available for SOLAR ener
win Coil Cylinder option available for SOLAR energygy
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..
.

2
Important Health and Safety Information for Installers and Service Engineers
Health and Safety at Work Act 1974
Consumer Protection Act 1987
COSHH Regulations 1988
The following information is given as a requirement of the
above legislation.
Great care is taken by GAH (HEATING PRODUCTS) LIMITED
to ensure that Electrastream systems are designed and
manufactured to meet general safety requirements when
properly used and installed as recommended in this manual.
It is the responsibility of Users and Engineers to ensure that
adequate protective clothing and glasses are worn when
working with the Electrastream system.
SEALS AND INSULATIONSEALS AND INSULATION
SEALS AND INSULATIONSEALS AND INSULATION
SEALS AND INSULATION
Insulation and sealing materials are used in the construction
of the Electrastream cylinders. Units are sealed and when
used in the manner for which they are intended the insulating
and sealing materials do not present any known hazard.
However always observe the following recommendations:-
1. Avoid inhalation of fibres or dust, wear face mask.
2. Avoid eye contamination by fibres or dust - wear eye
protection.
3. As far as possible avoid any skin contact with Fibreglass
Insulation, Glass Rope, Mineral Wool, Insulation Pads and
Ceramic Fibre.
PP
PP
Patent application 01514800.2atent application 01514800.2
atent application 01514800.2atent application 01514800.2
atent application 01514800.2
©©
©©
©2010 GAH (HEATING PRODUCTS) L2010 GAH (HEATING PRODUCTS) L
2010 GAH (HEATING PRODUCTS) L2010 GAH (HEATING PRODUCTS) L
2010 GAH (HEATING PRODUCTS) LTD.TD.
TD.TD.
TD.
ElectrastrElectrastr
ElectrastrElectrastr
Electrastream is a Team is a T
eam is a Team is a T
eam is a Trademark of GAH (HEATING PRODUCTS) Lrademark of GAH (HEATING PRODUCTS) L
rademark of GAH (HEATING PRODUCTS) Lrademark of GAH (HEATING PRODUCTS) L
rademark of GAH (HEATING PRODUCTS) LTD.TD.
TD.TD.
TD.
Manual by Harber Technical Services Tel/Fax [phone]
E-mail:[email protected] www.harbertech.co.uk
GAH (Heating PrGAH (Heating Pr
GAH (Heating PrGAH (Heating Pr
GAH (Heating Products) Ltd.oducts) Ltd.
oducts) Ltd.oducts) Ltd.
oducts) Ltd.
Building 846
Bentwaters Parks
Rendlesham
Woodbridge
Suffolk IP12 2TW
TT
TT
Tel:el:
el:el:
el: 01394 42116001394 421160
01394 42116001394 421160
01394 421160
Fax:Fax:
Fax:Fax:
Fax: 01394 42117001394 421170
01394 42117001394 421170
01394 421170
email: [email protected]
www.gah.co.uk
In pursuance of a policy of constant development, GAH (HEATING PRODUCTS) LIMITED
reserve the right to change Electrastream parts or design without notice, therefore
certain details included in this manual may not be correct at the time of printing. Any
modification and improvements detailed in this manual does not commit GAH to update
any system previously supplied.
Manual Part No. ...................MAN1019
Manual Ref ..........................ES02
Issue ...................................13
Date ....................................25/02/13
GAH (HEATING PRODUCTS) LIMITED will not accept
responsibility for any damage or personal injury caused
by not giving due consideration to the above safety
recommendations.
OTHER MATERIALSOTHER MATERIALS
OTHER MATERIALSOTHER MATERIALS
OTHER MATERIALS
SEALANTS, ADHESIVES AND PAINTS
Sealants, Adhesives and Paints are used in the construction of
the Electrastream components. When used in the manner for
which they are intended they do not present any known hazard.
ELECTRICELECTRIC
ELECTRICELECTRIC
ELECTRIC
The Cylinder Tri-Core Heater, Pump, Thermostats and Contactor
Box all have electrical supply of 230V (enough to endanger
life).
Always isolate before connection, adjustment, servicing and
repair.
When the Tri-Core Heater cover is removed high power live
electrical terminals are exposed.
ISOLATE THE TRI-CORE HEATER BEFORE REMOVING ITS
COVER.
Earth protection - Earth Continuity Conductors must be fitted
and must comply with IEE Wiring Regulations.
HTS REF GAH ELECTRASTREAM 25/02/13
HEALHEAL
HEALHEAL
HEALTH & SAFETYTH & SAFETY
TH & SAFETYTH & SAFETY
TH & SAFETY

3
CONTENTSCONTENTS
CONTENTSCONTENTS
CONTENTS
1 INTRODUCTION1 INTRODUCTION
1 INTRODUCTION1 INTRODUCTION
1 INTRODUCTION
2 OPERA2 OPERA
2 OPERA2 OPERA
2 OPERATOR CONTROLSTOR CONTROLS
TOR CONTROLSTOR CONTROLS
TOR CONTROLS
3 TECHNICAL INFORMA3 TECHNICAL INFORMA
3 TECHNICAL INFORMA3 TECHNICAL INFORMA
3 TECHNICAL INFORMATIONTION
TIONTION
TION
5 COMMISSIONING5 COMMISSIONING
5 COMMISSIONING5 COMMISSIONING
5 COMMISSIONING
7 F7 F
7 F7 F
7 FAULAUL
AULAUL
AULT FINDINGT FINDING
T FINDINGT FINDING
T FINDING
CONTENTSCONTENTS
CONTENTSCONTENTS
CONTENTS
ImporImpor
ImporImpor
Important Informationtant Information
tant Informationtant Information
tant Information ----------------------------------------------------------------------------------
----------------------------------------------------------------------------------
----------------------------------------- 4
Section 1 IntrSection 1 Intr
Section 1 IntrSection 1 Intr
Section 1 Introductionoduction
oductionoduction
oduction
1-1 Introduction ---------------------------------------------- 5
1-2 System Layout ------------------------------------------- 8
1-3 Parts Supplied------------------------------------------- 11
1-4 The Electrastream System ------------------------------- 12
1-5 Tri Core Heater Operation -------------------------------- 13
Section 2 Operator ContrSection 2 Operator Contr
Section 2 Operator ContrSection 2 Operator Contr
Section 2 Operator Controlsols
olsols
ols
2-1 System Control ------------------------------------------ 14
2-2 Electrastream Control Unit ------------------------------- 16
2-3 Shut Off Valves ------------------------------------------ 20
2-4 Temperature & Pressure Relief Discharge ---------------- 22
2-5 Thermostatic Mixing Valve ------------------------------ 22
2-6 Servicing ------------------------------------------------ 22
Section 3 TSection 3 T
Section 3 TSection 3 T
Section 3 Technical Informationechnical Information
echnical Informationechnical Information
echnical Information
3-1 Specifications ------------------------------------------- 23
3-2 Dimensions --------------------------------------------- 25
3-3 Wiring --------------------------------------------------- 29
Section 4 InstallationSection 4 Installation
Section 4 InstallationSection 4 Installation
Section 4 Installation
4-1 Building Control ----------------------------------------- 31
4-2 Electrical ------------------------------------------------ 31
4-3 Hot Water System --------------------------------------- 33
4-4 Heating System ----------------------------------------- 37
4-5 Expansion Discharge ------------------------------------ 40
4-6 System Pressure ---------------------------------------- 43
4-7 Electrastream Connections - ---------------------------- 44
Section 5 CommissioningSection 5 Commissioning
Section 5 CommissioningSection 5 Commissioning
Section 5 Commissioning
5-1 Commissioning ----------------------------------------- 47
Section 6 ServicingSection 6 Servicing
Section 6 ServicingSection 6 Servicing
Section 6 Servicing
6-1 Routine Service ----------------------------------------- 50
Section 7 Fault FindingSection 7 Fault Finding
Section 7 Fault FindingSection 7 Fault Finding
Section 7 Fault Finding
7-1 Fault Finding -------------------------------------------- 52
Health & SafetyHealth & Safety
Health & SafetyHealth & Safety
Health & Safety ------------------------------------------------------------
------------------------------------------------------------
------------------------------ Inside Front Cover
6 SERVICING6 SERVICING
6 SERVICING6 SERVICING
6 SERVICING
4 INST4 INST
4 INST4 INST
4 INSTALLAALLA
ALLAALLA
ALLATIONTION
TIONTION
TION
IMPORTANT
BEFORE STARTING THE INSTALLATION OF THE ELECTRASTREAM CHECK ALL COMPONENTS HAVE
BEEN DELIVERED AND ARE IN SATISFACTORY CONDITION - Refer to 1-3 .
HEALHEAL
HEALHEAL
HEALTH & SAFETYTH & SAFETY
TH & SAFETYTH & SAFETY
TH & SAFETY

4
IMPORTANT INFORMATION
IMPORTIMPORT
IMPORTIMPORT
IMPORTANT INFORMAANT INFORMA
ANT INFORMAANT INFORMA
ANT INFORMATIONTION
TIONTION
TION
BEFORE STARBEFORE STAR
BEFORE STARBEFORE STAR
BEFORE STARTING THE INSTALLATION OF THE ELECTRASTREAM CHECK ALL COMPONENTS HAVE BEEN DELIVERED AND ARETING THE INSTALLATION OF THE ELECTRASTREAM CHECK ALL COMPONENTS HAVE BEEN DELIVERED AND ARE
TING THE INSTALLATION OF THE ELECTRASTREAM CHECK ALL COMPONENTS HAVE BEEN DELIVERED AND ARETING THE INSTALLATION OF THE ELECTRASTREAM CHECK ALL COMPONENTS HAVE BEEN DELIVERED AND ARE
TING THE INSTALLATION OF THE ELECTRASTREAM CHECK ALL COMPONENTS HAVE BEEN DELIVERED AND ARE
IN SATISFACTORY CONDITION - RIN SATISFACTORY CONDITION - R
IN SATISFACTORY CONDITION - RIN SATISFACTORY CONDITION - R
IN SATISFACTORY CONDITION - Refer to 1-3.efer to 1-3.
efer to 1-3.efer to 1-3.
efer to 1-3.
Delivery
Standard Electrastream systems will be delivered wrapped on single pallet with cylinder together with box containing control box
and loose components.
Pre-Plumbed Electrastream systems will be delivered wrapped on single pallet with cylinder, control box and all components fully
assembled.
Pack should be lifted using suitable sized pallet truck or fork lift truck.
WEIGHTS OF PACKED CYLINDERS and COMPONENTS
Storage
Prior to installation the cylinder and box should remain on its pallet with wrapping intact and stored upright. The cylinder and
components must be stored safely in a dry, frost free environment and protected from accidental damage.
WARNING TO THE USERWARNING TO THE USER
WARNING TO THE USERWARNING TO THE USER
WARNING TO THE USER
DO NOT rDO NOT r
DO NOT rDO NOT r
DO NOT remove or adjust any component paremove or adjust any component par
emove or adjust any component paremove or adjust any component par
emove or adjust any component part of the unvented water heater: contact thet of the unvented water heater: contact the
t of the unvented water heater: contact thet of the unvented water heater: contact the
t of the unvented water heater: contact the INSTALLERINSTALLER
INSTALLERINSTALLER
INSTALLER..
..
.
In the event of hot water/steam being emitted at the discharIn the event of hot water/steam being emitted at the dischar
In the event of hot water/steam being emitted at the discharIn the event of hot water/steam being emitted at the dischar
In the event of hot water/steam being emitted at the discharge pipe or tundish, switch the system Off and contact installer - rge pipe or tundish, switch the system Off and contact installer - r
ge pipe or tundish, switch the system Off and contact installer - rge pipe or tundish, switch the system Off and contact installer - r
ge pipe or tundish, switch the system Off and contact installer - refer toefer to
efer toefer to
efer to
Fault Finding section 7.Fault Finding section 7.
Fault Finding section 7.Fault Finding section 7.
Fault Finding section 7.
If the ElectrastrIf the Electrastr
If the ElectrastrIf the Electrastr
If the Electrastream system develops a fault or is not operating as expected: contact theeam system develops a fault or is not operating as expected: contact the
eam system develops a fault or is not operating as expected: contact theeam system develops a fault or is not operating as expected: contact the
eam system develops a fault or is not operating as expected: contact the INSTALLERINSTALLER
INSTALLERINSTALLER
INSTALLER..
..
.
IMPORIMPOR
IMPORIMPOR
IMPORTANT TO THE INSTALLERTANT TO THE INSTALLER
TANT TO THE INSTALLERTANT TO THE INSTALLER
TANT TO THE INSTALLER
This installation is subject to Building RThis installation is subject to Building R
This installation is subject to Building RThis installation is subject to Building R
This installation is subject to Building Regulation Appregulation Appr
egulation Appregulation Appr
egulation Approval, notifoval, notif
oval, notifoval, notif
oval, notify the Ly the L
y the Ly the L
y the Local Authority of intention to install.ocal Authority of intention to install.
ocal Authority of intention to install.ocal Authority of intention to install.
ocal Authority of intention to install.
Use only manufacturUse only manufactur
Use only manufacturUse only manufactur
Use only manufacturer’s rer’s r
er’s rer’s r
er’s recommended recommended r
ecommended recommended r
ecommended replacement pareplacement par
eplacement pareplacement par
eplacement parts.ts.
ts.ts.
ts.
The following Information must be prThe following Information must be pr
The following Information must be prThe following Information must be pr
The following Information must be provided:-ovided:-
ovided:-ovided:-
ovided:-
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INSTALLED BY:-
Name ............................................................................................................
Address .........................................................................................................
Tel. ................................................................................................................
Completion Date ...........................................................................................
ELECTRICS BY:-
Name ............................................................................................................
Address .........................................................................................................
Tel. ................................................................................................................
Completion Date ...........................................................................................

5
1-1 Introduction
INTRODUCTION 1INTRODUCTION 1
INTRODUCTION 1INTRODUCTION 1
INTRODUCTION 1
1-1.1 The Electrastream System
The Electrastream system by GAH (Heating Products) Ltd. has been developed as a cost
effective solution for domestic hot and cold water and electric central heating with water
filled radiators.
Electrastream is a 9kW - 30,000 Btu system suitable for flats, small dwellings, offices,
home offices and granny annexes.
1-1.2 Electrastream Options Available
Consult GAH (Heating Products) Ltd.
1-1.3 Basic Principles
ELECTRASTREAM
Water in the unvented cylinder is heated by the high powered titanium electric tri-core
heater. Hot water is drawn from the cylinder and mixed with cold water by a thermostatic
mixing valve; this ensures safer lower temperatures at the hot water outlets.
The hot water within the unvented indirect cylinder also heats the water for the heating
system via the indirect coil within the cylinder. The circulating pump for the heating
system is controlled by a thermostat and programmable timer with override so that heat
is available on demand, providing there is a supply of hot water.
ELECTRASTREAM PRE-PIPED
Operationally the same as the Electrastream but supplied pre-piped and assembled onto
a mounting frame.
GAH ElectrastrGAH Electrastr
GAH ElectrastrGAH Electrastr
GAH Electrastream Systems aream Systems ar
eam Systems aream Systems ar
eam Systems are pre pr
e pre pr
e protected pending patent applications.otected pending patent applications.
otected pending patent applications.otected pending patent applications.
otected pending patent applications.
ElectrastrElectrastr
ElectrastrElectrastr
Electrastream is a Team is a T
eam is a Team is a T
eam is a Trademark of GAH (HEATING PRODUCTS) Lrademark of GAH (HEATING PRODUCTS) L
rademark of GAH (HEATING PRODUCTS) Lrademark of GAH (HEATING PRODUCTS) L
rademark of GAH (HEATING PRODUCTS) LTD.TD.
TD.TD.
TD.
This Handbook has been compiled to assist in the Installation and Operation of GAH (HEATING PRODUCTS) LIMITEDThis Handbook has been compiled to assist in the Installation and Operation of GAH (HEATING PRODUCTS) LIMITED
This Handbook has been compiled to assist in the Installation and Operation of GAH (HEATING PRODUCTS) LIMITEDThis Handbook has been compiled to assist in the Installation and Operation of GAH (HEATING PRODUCTS) LIMITED
This Handbook has been compiled to assist in the Installation and Operation of GAH (HEATING PRODUCTS) LIMITED
ElectrastrElectrastr
ElectrastrElectrastr
Electrastream domestic hot water and heating system.eam domestic hot water and heating system.
eam domestic hot water and heating system.eam domestic hot water and heating system.
eam domestic hot water and heating system.
© 2009 GAH (HEATING PRODUCTS) LIMITED© 2009 GAH (HEATING PRODUCTS) LIMITED
© 2009 GAH (HEATING PRODUCTS) LIMITED© 2009 GAH (HEATING PRODUCTS) LIMITED
© 2009 GAH (HEATING PRODUCTS) LIMITED
Notified Body NB 0558Notified Body NB 0558
Notified Body NB 0558Notified Body NB 0558
Notified Body NB 0558
After installation the Installer of the system should give full operating instructions to the householder for the ElectrastrAfter installation the Installer of the system should give full operating instructions to the householder for the Electrastr
After installation the Installer of the system should give full operating instructions to the householder for the ElectrastrAfter installation the Installer of the system should give full operating instructions to the householder for the Electrastr
After installation the Installer of the system should give full operating instructions to the householder for the Electrastreameam
eameam
eam
System. This User and Installation Manual must be left for the end userSystem. This User and Installation Manual must be left for the end user
System. This User and Installation Manual must be left for the end userSystem. This User and Installation Manual must be left for the end user
System. This User and Installation Manual must be left for the end user..
..
.
11
11
1
Thermostatic
Mixing Valve
Unvented
Indirect
Cylinder
Incoming
Water Main
Tri-core Heater
Pump
lectrastream
Control
Unit
Fig. 1-1a Electrastream

6
11
11
1
Fig. 1-1b Electrastream Twin Coil - typical solar arrangement
Thermostatic
Mixing Valve
Unvented
Indirect
Cylinder
Incoming
Water Main
Tri-core
Heater
Pump
lectrastream
Control
Unit
Primary Coil
for alternative
energy
lectrastream
Coil
Solar
Control
Solar Collectors
ELECTRASTREAM TWIN COIL
Operationally the same as the Electrastream but supplied with a twin coil cylinder which
enables the Electrastream to be used in conjunction with alternative energy systems e.g.
Solar.
The Electrastream Plus system is supplied with a cold water storage accumulator.
The accumulator has an internally controlled butyl diaphragm, incoming cold water is
stored within this diaphragm at mains pressure. The air space between the diaphragm
and the accumulator case is pressurised, this balances the supply and maintains
pressure to the unvented hot water cylinder and cold outlets. When hot and cold water
outlets are turned on, the stored water from the accumulator supplements water from the
incoming main, this results in consistent pressure and flow to all taps, showers and baths
even when outlets are used simultaneously. Pressure will be sustained for as long as the
accumulator is holding sufficient volume of water.
ELECTRASTREAM PLUS PRE-PIPED
Operationally the same as the Electrastream Plus but supplied pre-piped and assembled
onto a mounting frame, the cold storage accumulator is supplied separately.
INTRODUCTION 1INTRODUCTION 1
INTRODUCTION 1INTRODUCTION 1
INTRODUCTION 1
Fig. 1-1c Electrastream Plus
Thermostatic
Mixing Valve
Tri-core
Heater
Incoming
Water Main
Unvented
Indirect
Cylinder
Pump
Accumulator
Cold water storage
lectrastream
Control
Unit
ELECTRASTREAM PLUS

7
INTRODUCTION 1INTRODUCTION 1
INTRODUCTION 1INTRODUCTION 1
INTRODUCTION 1
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Note
For components supplied with system refer
to page 9.
Note
Further options are available consult GAH
(Heating Products) Ltd.
1-1.4 Electrastream System Features
ELECTRASTREAM AND ELECTRASTREAM TWIN COIL
1. Only water and electric services required.
2. No gas or oil - no Boiler.
3. Central heating with conventional water filled radiators.
4. Heat on demand 24 hours a day.
5. Can be timed for economy tariff.
6. Far more flexible heating control than storage radiators.
7. Hot water to taps and shower from unvented cylinder.
8. Hot water to outlets temperature controlled by thermostatic mixing valve.
9. Mains pressure to hot and cold outlets.
10. All plumbing, water storage and controls are within the dwelling - no header tank.
11. Low maintenance cost, no CORGI Landlord Certificate required.
12. 9kW titanium tri-core heater (combined 3 x 3kW).
13. Tri-core heater will still work should one or two of its three elements fail.
14. Stainless Steel Unvented Cylinder with 25 years guarantee.
ELECTRASTREAM TWIN COIL
1. Cylinder with primary coil for alternative energy source typically solar and ground
source.
ELECTRASTREAM PLUS ONLY
1. Balanced hot and cold supply to taps.
2. All taps and showers at maximum system pressure.
3. Pressure maintained for both hot and cold taps even when other taps are open
(subject to volume used).
11
11
1

8
11
11
1
FLOW 22mm
R TURN 22mm
PRV
3Unvented
Cylinder
Bypass
3Pump & valves
3Tri-core Heater Combined 3 x 3kW
Room Thermostat
3lectrastream
Control Unit
2 Pole
Isolator
3TPRV
3PRV
Balanced cold supply to taps
Hot supply to taps
Thermostatic Shower
3Combination Valve
3Thermostatic Mixing Valve - limits temperature of hot water to taps
conomy Tariff
Kitchen
Kick Space Heater
Shower Room
Towel Rail
RCD
Consumer Unit with RCD
Drain 15mm
Discharge
3Hot Water
xpansion
Vessel
15mm
22mm
3
3
3
3Motorised Valve
28mm
28mm
22mm Incoming
mains supply
Single Check Valve 3Heating System Fill 15mm
3.5 Bar Pressure Reducing Valve
Water
Softener
(option)
3Isolating Valve
22mm
3Cylinder Temperature Sensor & Thermal Cut Out
3Tundish
3Heating xpansion Vessel 8l No valves to be fitted between PRV and xpansion Vessel
No valves to be fitted between Cylinder and PRV
15mm
3Isolating Valve
Fig. 1-2a Typical Schematic Installation - Electrastream
1-2 System Layout
INTRODUCTION 1INTRODUCTION 1
INTRODUCTION 1INTRODUCTION 1
INTRODUCTION 1
1-2.1 Electrastream

9
11
11
1
INTRODUCTION 1INTRODUCTION 1
INTRODUCTION 1INTRODUCTION 1
INTRODUCTION 1
✓
Accumulator
FLOW 22mm
RETURN 22mm
PRV
✓Unvented
Cylinder
22mm Incoming
mains supply
Bypass
✓Pump & valves
✓Tri-core Heater Combined 3 x 3kW
Room Thermostat
2 Pole
Isolator
✓TPRV
✓PRV
Balanced cold supply to taps
Hot supply to t
a
Thermostatic Shower
✓Combination Valve
✓Thermostatic Mixing Valve - limits temperature of hot water to taps
Single Check Valve
Economy Ta
r
✓Heating System Fill 15mm
Kitchen
Kick Space Heater
Shower Room
Towel Rail
RCD
Consumer Unit with RCD
Drain 15mm
✓Cylinder Temperature Sensor & Thermal Cut Out
Discharge
✓Hot Water
Expansion
Vessel
Cold water storage
✓Isolating Valve
✓Isolating Valve
15mm
22mm
22mm
Water
Softener
(option)
✓
✓
✓
✓
✓Motorised Valve
28mm
28mm
3.5 Bar Pressure Reducing Valve
✓Isolating Valve
✓Tundish
✓Heating Expansion Vessel 8l No valves to be fitted between PRV and Expansion Vessel
✓Electrastream
Control Unit
Fig. 1-2b Typical Schematic Installation - Electrastream Plus 130 & 150
1-2.2 Electrastream Plus

10
INTRODUCTION 1INTRODUCTION 1
INTRODUCTION 1INTRODUCTION 1
INTRODUCTION 1
FLOW 22mm
R TURN 22mm
22 mm
Incoming
mains supply
Bypass
3Pump & valves
2 Pole
Isolator
3TPRV
3PRV
Balanced cold supply to taps
Hot supply to taps
Thermostatic Shower
3Heating xpansion Vessel 8l
No valves to be fitted between PRV and xpansion Vessel
Water
Softener
(option)
3Thermostatic Mixing Valve - limits temperature of hot water to taps
Single Check Valve
conomy Tariff
3Heating System Fill 15mm
Kitchen
Kick Space Heater
Shower Room
Towel Rail
RCD
Consumer Unit with RCD
3HW xpansion
Vessel
3 Full Bore Isolating Valve
28mm
28mm
22mm
3Isolating Valve
Discharge
PRV
15mm
3
Drain 15mm
3Tri-core Heater Combined 3 x 3kw
3Motorised Valve
3
22mm
3.5 Bar Pressure Reducing Valve (option)
3
Alternative heat
source Return
Alternative heat
source Flow
3Combination Valve
22mm
Primary Coil
Lower Immersion Heater Tapping Blanked
No valves to be fitted between Cylinder and PRV
No valves to be fitted between PRV and xpansion Vessel
3lectrastream
Control Unit
Room Thermostat
3Cylinder Temperature Sensor & Thermal Cut Out
3Tundish
3Twin Coil Unvented
Cylinder
1-2.3 Twin Coil
Fig. 1-2c Typical Schematic Installation - Electrastream Twin Coil 215, 255 & 305
11
11
1

11
1-3 Parts Supplied
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Note
On Electrastream Pre-piped units,
components are supplied already
assembled.
INTRODUCTION 1INTRODUCTION 1
INTRODUCTION 1INTRODUCTION 1
INTRODUCTION 1
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1
Standard Electrastream systems will be delivered wrapped on single pallet with cylinder
together with box containing control box, expansion vessels and loose components.
Pre-Plumbed Electrastream systems will be delivered wrapped on single pallet with
cylinder, control box, expansion vessels and all components fully assembled.
Electrastream Plus only

12
INTRODUCTION 1INTRODUCTION 1
INTRODUCTION 1INTRODUCTION 1
INTRODUCTION 1
Note
All installations must comply with relevant
regulations - refer to section 4-1.
1-4.1 Hot & Cold Water Supply
Refer to fig. 1-2a for Electrastream.
Refer to fig. 1-2b for Electrastream Twin Coil
The incoming mains water supply is connected to the combination valve which is
assembled to the unvented indirect hot water cylinder. The combination valve has an
integral check valve. A single check valve is supplied, this is only required to be fitted if
back syphonage is possible from any item fitted prior to the combination valve.
Provision should also be provided in the cold supply for:-
1. Heating system fill.
2. Drinking water.
3. Water softener (when applicable).
4. Outside tap (when applicable).
The combination valve limits the incoming pressure to 3.5 Bar, it has an integral non-
return valve and pressure relief valve (PRV).
Supply to the hot outlets is taken from the cylinder and mixed with cold water by the
thermostatic mixing valve, this ensures that a safer lower temperature hot water is
available at outlets.
Cold supply to all outlets is taken direct from the main supply. If the mains pressure is
high (over 3.5 Bar) a 3.5 Bar pressure reducing valve is recommended.
1-4.2 Twin Coil - Alternative Heat Source
Twin Coil Cylinders have two coils, the upper coil is connected to the Electrastream
heating system. The Electrastream high powered titanium electric tri-core heater is
positioned about halfway up the cylinder so that it is only used to heat the water in the
upper part of the cylinder.
The lower coil is heated by the chosen alternative heat source (e.g. solar), this will heat
the water in the whole cylinder when ‘energy’ is available resulting in optimum efficiency.
1-4.3 System Control
The Electrastream system is controlled by a purpose designed Electrastream Control
Unit, this controls the hot water and heating ON/OFF times together with the heating
pump and valve. The control also has a dedicated programme that ensures efficient use
of electricity by selecting how many of the three immersion heater elements are required
to meet the current demand for heating or hot water.
1-4.4 Heating System
The heating system is for water filled radiators on a standard ‘sealed system’. The water
for the heating is heated by being pumped through the indirect coil of the cylinder. A
room thermostat and the Electrastream Control Unit’s programmable timers control the
circulating pump and motorised valve.
1-4.5 Electric System
The unvented cylinder is heated by a 240V, 9kW (combined 3 x 3kW) titanium tri-core
heater. This is controlled by the cylinder temperature sensor and the Electrastream
Control Unit.
Electrastream is designed to make full use of economy tariff electricity supplies and the
wiring must be arranged to make full use of this.
Note
The final fill of the heating system should
include the correct percentage of suitable
scale/corrosion inhibitor.
1-4 The Electrastream System
Note
The alternative heat source must be
configured correctly to be used with the
GAH Electrastream system.
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13
1-4.6 Output
The tri-core heater provides 9kW (30,000 Btu) for heating and hot water.
1-4.7 Scale Protection
IMPORTANT All installations should have a scale protection device fitted
and in areas known to have hard water, a water softening device is
strongly recommended. The cylinder is not guaranteed against damage
caused by scale. Higher water temperatures of 65°C and above can
cause excessive scale.
GAH recommend and promote the use of scale prevention devices and water softeners in
areas that are known to have hard water. Installed correctly they prolong the life of
equipment and help prevent limescale formation in the pipework. Water softeners
provide the advantages of soft water, as well as preventing scale build up on taps and
shower heads.
Water softeners and any mains fed system must be of adequate capacity and should be
installed with suitably sized hoses to prevent any possibility of flow reduction.
1-4.8 Frost Protection
When planning the installation location of both the accumulator and the unvented
cylinder, consideration must be given to the risk of frost and the use of frost protection.
The design of the accumulator gives it a degree of frost protection enabling it to be
located within the dwelling, loft space or garage without further protection.
The cylinder can also be installed within the dwelling or loft space without further
protection.
Cylinders or accumulators must have frost protection when they are installed where low
temperatures could be a potential problem. Cylinders can be protected by a frost
thermostat.
To comply with Building Regulations, all necessary pipework must be suitably lagged.
1-4.9 Handling and Storage
The Electrastream system will be delivered fully wrapped and palleted.
Lift the package carefully using a safe and suitable lifting method.
Keep the packaging intact and store in a secure dry and weatherproof area prior to
installation.
INTRODUCTION 1INTRODUCTION 1
INTRODUCTION 1INTRODUCTION 1
INTRODUCTION 1
1-5 Tri-core Heater Operation
The three elements of the tri-core heater are switched on and off by the Electrasteam
Control Unit. They have a staggered switch on sequence that prevents sudden high load
on the power supply.
The control unit also limits the use of the elements for efficiency.
When the hot water within the cylinder is within 2° of the set (8) Target 65°C, only one
element will be on.
When the hot water within the cylinder is between 2° and 4°C below the set (8) Target
65°C, then two elements will be on.
When the hot water within the cylinder is below 6°C of the set (8) Target 65°C, then all
three elements will be on.
Note
When a water softener is fitted, the take-
offs for heating system fill, drinking water
and outside tap (when applicable), must
be positioned before the water softener.
Note
Refer to 2-2.2 for display settings.
GAH offer a range of quality Water
Softeners, for information contact
GAH (HEATING PRODUCTS) LTD.
IMPORTANT
On twin coil cylinders the
Electrastream tri-core heater must
be fitted to the upper immersion
heater tapping.
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OPERAOPERA
OPERAOPERA
OPERATOR CONTROLS 2TOR CONTROLS 2
TOR CONTROLS 2TOR CONTROLS 2
TOR CONTROLS 2
2-1 System Control
Fig. 2-1a Schematic of Typical Controls
The heating and hot water system is all electric. The hot water for the taps (outlets) and
radiators is heated by the tri-core heater in the cylinder.
The system will have the following controls.
1
TH RMOSTAIC
MIXING VALV
HOT WAT R OUTL TS
ISOLATING SWITCH
RC
CONSUM R UNIT
ROOM TH RMOSTAT
MOTORIS D VALV
PUMP
L CTRASTR AM
CONTROL UNIT
CYLIND R
T MP RATUR S NSOR
& TH RMAL CUT-OUT
TRI-COR H AT R
UNV NT D CYLIND R
COLD WAT R OUTL TS
2-1.1 Isolating Switch
The system will have a double pole isolating switch with neon and mechanical indicators.
This could be a pull cord or wall mounted type.
When the switch is ON (neon on) the system is operational.
When the switch is OFF (neon off) no hot water or heating will be available.
It is advised to turn the switch off when hot water and heating are not required, i.e.
holidays etc.
2-1.2 Electrastream Tri-core Heater
WARNING Unlike immersion heaters, the Electrastream tri-core heater
does not have an internal thermostat, therefore the cover should not need
to be removed.
When the cover is removed live electrical terminals are exposed.
ISOLATE THE TRI-CORE HEATER BEFORE REMOVING ITS COVER.
2-1.3 Over Temperature Cut-Out Thermostat
In the Electrastream temperature sensor box on the cylinder is the over temperature cut-
out thermostat. This prevents the water within the cylinder from overheating.
The over temperature cut-out thermostat is a manual reset type, this means it has a small
button that pops up when the thermostat has been tripped by overheating.
To reset the system after overheating, switch heating and hot water OFF, allow time for
the water to cool, or run off some hot water, then remove the cap and press the button.
Fig. 2-1b Isolating Switch
MANUAL RESET
BUTTON
Fig. 2-1c Thermal Cut-Out Thermostat
Note
On twin coil systems the alternative heat
source supplements the electric.
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OPERAOPERA
OPERAOPERA
OPERATOR CONTROLS 2TOR CONTROLS 2
TOR CONTROLS 2TOR CONTROLS 2
TOR CONTROLS 2
If the over temperature cut-out trips more than once, switch off the Electrastream
isolating switch and contact your installer.
2-1.4 Heating Motorised Valve
When the room thermostat is calling for heat and the Electrastream control unit is set for
heat ON, the heating motorised valve will open allowing water to the radiators.
Display icon ‘Valve ’ indicates the valve is open.
2-1.5 Pump
The heating circulating pump is controlled by the Electrastream Control Unit in response
to the room thermostat.
The pump has 3 speeds, it is normally set to speed 2 (II). Consult the Electrastream
installer before changing this setting - see 4-4.3.
Display icon ‘Pump ’ indicates the pump is ON.
2-1.6 Room Thermostat
The room thermostat controls the heat within the property.
When the room thermostat is calling for heat and the Electrastream control unit is set for
heat ON, the heating circulating pump will run, pumping water through the radiators.
Display icon ‘Therm ’ indicates the room thermostat is calling for heat.
2-1.7 Tri-core Heater Elements
The three elements heat the water in the cylinder when the Electrastream control unit is
programmed for a heat cycle. The elements are switched On and Off by the
Electrastream control unit in response to the temperature within the cylinder as detected
by the temperature sensor.
The elements have a staggered On sequence to prevent sudden loads - see 1-5.
Display icons ‘Heat 1 , Heat 2 , and Heat 3 indicate that the elements are
heating.
If either of the Heat icons are displaying an exclamation mark ‘!’‘!’
‘!’‘!’
‘!’ this indicates a fault with
an element - see 2-2.3.
2-1.8 Residual Current Device (RCD)
The Electrastream system will be protected by a Residual Current Device, this will
automatically switch Off the electric supply if an earth fault develops.
The RCD must be tested at least every three months, this is done by pressing the RCD
‘Test’ or ‘T’ button, this should switch the supply Off. Reset RCD to On after test.
If the RCD appears not to be working correctly contact your installer or a qualified
electrician.
2-1.9 Alternative Heat Source Controls
For twin coil systems the alternative heat source will have its own controls - refer to
manufacturers instructions.
The alternative heat source would normally be a cost effective method of heating the
cylinder and should be used and controlled for optimum performance thus reducing
heating costs.
Note
Testing the RCD will not cause loss of the
Electrastream Control Unit settings.
Note
Refer to 2-2 for the Electrastream Control
Unit display and settings.
IMPORTANT
When a programmable room
thermostat is used it should only be
set to call for heat when ‘Economy
Tariff’ is available.
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16
WATER TEMP
HEAT 1
HEAT 2
HEAT 3
HOT WATER
MODE
HEATING
MODE
THERM
PUMP
VALVE
SET DOWN BOOST
24°c Boost
Day hh mm
Auto/On/Off
Auto/Off
UP
Auto Timed
On Hot Water permanently ON
Off Hot Water permanently OFF
Toggled by
Auto Timed
Not available when HOT WATER MODE is Off
Toggled by
Boost displayed - Heating
On until next set OFF time
Toggled by
Displays actual water
temperature in cylinder
Set by (8) Target °c
Off Heating Permanently OFF
Notes:- Select to turn heatin off.
For Heatin On use Boost.
Displays current Day
and Time (24 hr clock)
OPERAOPERA
OPERAOPERA
OPERATOR CONTROLS 2TOR CONTROLS 2
TOR CONTROLS 2TOR CONTROLS 2
TOR CONTROLS 2
2-2 Electrastream Control Unit
Fig. 2-2a Electrastream Control Unit - Normal Screen
2-2.1 Control Unit Display - Normal Screen
HEAT 1 Indicates Element 1 is ON HEAT 1 !!
!!
! Indicates heater element has failed - see 2-2.4
HEAT 2 Indicates Element 2 is ON HEAT 2 !!
!!
! Indicates heater element has failed - see 2-2.4
HEAT 3 Indicates Element 3 is ON HEAT 3 !!
!!
! Indicates heater element has failed - see 2-2.4
VALVE Indicates Heating Valve is OPEN
PUMP Indicates Heating Pump is ON
THERM Indicates Room Stat is calling for heat
TEST 1......5 Indicates heater test is being performed after midnight, this may take up to 30 minutes
>> >>
>
>> >>
>
>> >>
>
>>
>>
>
Heating on
WATER TEMP
HEAT 1
HEAT 2
HEAT 3
HOT WATER
MODE
HEATING
MODE
THERM
PUMP
VALVE
SET UP DOWN BOOST
ELECTRASTREAM
CONTROL
GAH HEATING PRODUCTS Ltd. 01394 4211 0
24°c Boost
Day hh mm
Auto/On/Off
Auto/Off
CAUTION
HIGH VOLTAGE!
DO NOT REMOVE ANY
COVERS (INCLUDING
ROOM THERMOSTAT)
BEFORE ISOLATING
THIS UNIT
For display settings see 2-2.2
For error displays see 2-2.3
>>
>>
>>>
>>
>
RESETTABLE THERMAL TRIPS
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33
33
3
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17
SET DOWN BOOST
24°c Boost
Day hh mm
Auto/On/Off
Auto/Off
UP
(1) Time
Day hh mm
(2) Start 1
hh mm
(3) Stop 1
hh mm
(4) Start 2
hh mm
(5) Stop 2
hh mm
(6) Start 3
hh mm
(7) Stop 3
hh mm
(8) Target
65 °C
Hrs Run = 0000.1
0000.0 0000.0
UP
DOWN
BOOST
HEATING & HOT WATER
WATER
TEMP.
TIME &
DATE
Use to increment time up
Use to increment time down
Use to select hours (hh:) or
minutes (:mm)
When SET is pressed, time settings are
displayed for 10 seconds, display then reverts
back to normal screen
Repeat pressing SET to index through
settings.
NORMAL SCREEN
2-2.2 Display Time Settings
Display only. Indicates the total hours that each tri-core
heater element has been in operation. (For service
engineers information only.)
Fig. 2-2b Electrastream Control Unit - Display Settings
Notes:-
All times are given in 24 hour clock.
Maximum cylinder temperature setting (Target °C) is 70°C.
For error displays see 2-2.3
OPERAOPERA
OPERAOPERA
OPERATOR CONTROLS 2TOR CONTROLS 2
TOR CONTROLS 2TOR CONTROLS 2
TOR CONTROLS 2
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2-2.3 Error Displays
When any of the following errors are displayed call service engineer.
ERROR 1
When ‘Error 1’ is displayed it indicates a faulty or disconnected temperature sensor.
Heating is disabled.
ERROR 2
When ‘Error 2’ is displayed it indicates:-
1. The auxiliary 5 amp fuse has blown, or
2. The pump, motorised valve or room thermostat is faulty, or
Heating is disabled.
ERROR 3
When ‘Error 3’ is displayed it indicates that all heater elements failed heater test.
Heating is disabled.
ERROR 5
One or more of the controller ‘set’, ‘up’, ‘down’ or ‘boost’ buttons is stuck or held down.
HEAT 1 !!
!!
!
When !!
!!
! is displayed under Heat 1, Heat 2 or Heat 3 it indicates a tri-core element has
failed. Check the resettable thermal trips in the Electrastream Control Unit - see 2-2.4.
2-2.4 Element Resettable Thermal Trips
Each of the three elements of the tri-core heater is protected by a 16amp Resettable
Thermal Trip, these have their reset buttons located on the front of the Electrastream
Control Unit.
In the event of electrical overload on an element the relevant thermal trip will trip out,
when this occurs the button will pop out. Also the control screen will display ‘!’ under
Heat 1, Heat 2, and/or Heat 3 see fig. 2-2a.
To reset the thermal trip:-
1. Turn OFF the Electrastream mains isolating switch - see 2-1.1.
2. Look at the three buttons; button/s that are protruding have tripped out.
3. Press the button in, if the button stays in when the power is turned on, then trip has
been reset. However if the button pops out again a possible fault exists - contact
the installer.
The Electrastream will still operate with one or two elements working, but this is not
satisfactory and the installer must be contacted to rectify the fault as soon as possible.
2-2.5 Economy Tariffs
Regional electricity suppliers have their own ‘Off-Peak’ tariffs that will provide an
economical supply of power for the Electrastream system.
It is vital that the time settings of the Electrastream control unit are set to make the most
use of the available ‘Off-Peak’ tariffs.
2-2.6 Normal Tariffs
Normal tariffs are at all times that are not designated for ‘Off-Peak’, the cost of electricity
during normal times will be more expensive. Therefore avoid setting heating and hot
water ON during these periods.
OPERAOPERA
OPERAOPERA
OPERATOR CONTROLS 2TOR CONTROLS 2
TOR CONTROLS 2TOR CONTROLS 2
TOR CONTROLS 2
AT
1
HEAT 2
HEAT 3
HOT WATER
MODE
HEATING
MODE
THERM
PUMP
ALV
E
DOWN BOOST
A
STREAM
T
ROL
CTS Ltd. 01394 4211 0
Auto/On/Off
Auto/Off
CAUTION
HIGH VOLTAGE!
DO NOT REMOVE ANY
COVERS (INCLUDING
ROOM THERMOSTAT)
BEFORE ISOLATING
THIS UNIT
Fig. 2-2c Resettable Thermal Trips
IMPORTANT
Operating the Electrastream during
normal tariffs will increase running
costs.
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24
23
22
21
20
19
18
17
16
15
14
13
12
11
10
9
8
7
6
5
4
3
2
1
N
I
G
H
T
D
A
Y
(6) Start 3
(7) Stop 3
(2) Start 1
(3) Stop 1
(5) Stop 2
Midday
Midnight
H
E
AT
I
N
G
&
W
AT
E
R
H
E
AT
I
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G
&
W
AT
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R
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T
N
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M
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M
A
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A
R
I
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A
L
T
A
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T
A
R
I
F
F
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C
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T
A
R
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F
F
SELF TEST
(4
) Start 2
H
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AT
I
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G
&
W
AT
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R
H
E
AT
I
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&
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AT
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Note:-
* The electricity supply company has to
make special arrangements to the
property’s electrical supply to enable
Electrastream to be used during both ‘off-
peak’ and ‘normal’ tariffs- consult the
installing electrician.
OPERAOPERA
OPERAOPERA
OPERATOR CONTROLS 2TOR CONTROLS 2
TOR CONTROLS 2TOR CONTROLS 2
TOR CONTROLS 2
‘Boost ’ can be used at any time during Economy or *Normal Tariff to provide heating
and hot water.
To turn hot water and heating OFF during ON periods (auto) press twice. It will
require switching to Auto again when required.
To turn heating only OFF during ON period (auto) and during ‘Boost’ press . It will
require switching to Auto again when required.
To turn hot water only ON during OFF periods (auto) press . It will require switching
to Auto again when required.
To turn hot water and heating ON during OFF periods (auto) press then . Both
will require switching to Auto again when required.
Note:-
Self Test
After 3am each day the unit carries out a
self test period for approx. 30 minutes.
This can be overridden if required.
2-2.7 Setting Heat and Hot Water Requirements
Figure below shows a 24 hour clock with typical use of the Electrastream during ‘Off-
Peak’ economy 10 settings.
IMPORTANT
Operating the Electrastream during
normal tariffs will increase running
costs. Start 1 - 03.00 (3am)
Stop 1 - 05.00 (5am)
Start 2 - 14.00 (2pm)
Stop 2 - 16.00 (4pm)
Start 3 - 20.00 (8pm)
Stop 3 - 21.30 (9.30pm)
All times fall within Economy Tariff
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20
OPERAOPERA
OPERAOPERA
OPERATOR CONTROLS 2TOR CONTROLS 2
TOR CONTROLS 2TOR CONTROLS 2
TOR CONTROLS 2
2-3 Shut Off Valves
The Electrastream installation will have a number of shut off valves, the location of these
will be dependent on the installation - fig. 2-3a shows typical layout.
Fig. 2-3a Typical Shut Off Valve Locations - single coil shown
INCOMING
MAINS WAT R
COLD SUPPLY TO TAPS
TH RMOSTATIC MIXING VALV
COLD WAT R SHUT OFF VALV
HOT WAT R SHUT OFF VALV
WAT R
SOFT N R
(OPTION)
STOP COCK
HOT SUPPLY TO TAPS
PRV - 6 Bar
SUPPLY WAT R SHUT OFF VALV
TH RMOSTATIC
SHOW R
BYPASS
IMPORTANT Before closing ANY valve, switch OFF the Electrastream
Isolating Switch.
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