gledhill SysteMate 125 User guide
Supplied By www.heating spares.co Tel. 0161 620 6677
DESIGN, INSTALLATION AND
SERVICING INSTRUCTIONS
PLEASE LEAVE THESE INSTRUCTIONS IN THE POCKET PROVIDED ON
THE BACK OF THE FRONT PANEL
A SEALED CENTRAL HEATING
AND MAINS PRESSURE HOT WATER SUPPLY
SYSTEM INCORPORATING
A THERMAL STORE
ALL MODELS COMPLY WITH THE
WATER HEATER MANUFACTURERS
SPECIFICATION FOR HOT WATER
ONLY THERMAL STORES
SYSTEMATE 2000
SYSTEMATE 2000
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
Supplied By www.heating spares.co Tel. 0161 620 6677
Page 2
Page 3
SYSTEMATE 2000
CONTENTS
Section Page
1.0 DESIGN
1.1 Introduction 3
1.2 Technical Data 5
1.3 System Details 10
2.0 INSTALLATION
2.1 Site Requirements 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 Fault Finding 32
Appendix ‘A’ 34
Appendix ‘B’ 35
Terms & Conditions 38
ISSUE 7 : 01-03
The Gledhill SysteMate 2000 range is a
WBS listed product and complies with
the WMA Specication for hot water only
thermal storage products. The principle
was developed in conjunction with British
Gas. This product is manufactured under
a BS EN ISO 9002 Quality System audited
by BSI.
Patents Pending
The Gledhill Group’s rst priority is to give a
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.
Please read carefully and complete all sections relevant to 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.
Supplied By www.heating spares.co Tel. 0161 620 6677
Page 2
Page 3
SYSTEMATE 2000
1.0 DESIGN
1.1 INTRODUCTION
These instructions should be read in
conjunction with the Installation and Servicing
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.
A competent person as stated in the Gas Safety
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 notiable to Building Control.
The information in this manual is provided to
assist generally in the selection of equipment.
The responsibility for the selection and
specication of the equipment must however
remain that of the customer and any Designers
or Consultants concerned with the design and
installation.
Please Note: We do not therefore accept any
responsibility for matters of design, selection
or specication or for the effectiveness of an
installation containing one of our products
unless we have been specically 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.
Supplied By www.heating spares.co Tel. 0161 620 6677
Page 4
Page 5
SYSTEMATE 2000
The SysteMate 2000 shown schematically above is designed to provide sealed system
space heating and mains pressure hot water at high flow rates when coupled
to any remotely sited, condensing or non condensing, boiler suitable for sealed
heating systems.
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 efcient 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 ll the thermal store the standard
appliance is supplied as a manual fill model, i,e, without a ballvalve and
overow, which makes it particularly suitable for use in ats/apartments. A
ballvalve and overow tting 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 ow rates without the
need for temperature and pressure relief safety
valves or expansion vessels. This is achieved
by passing the mains water through a plate
heat exchanger. The outlet temperature of the
domestic hot water is maintained by a printed
circuit board, which controls the speed of the
pump circulating the primary water from the
store through the plate heat exchanger.
Because of the innovative method of hot water
production no in-line scale reducer is normally
required on the cold supply to the appliance.
If scale should become a problem the plate
heat exchanger is easily isolated and replaced
with a service exchange unit.
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.
The pcb also incorporates the facility to operate
the heating pump for a few seconds every few
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 ow and a 710C return
up to a maximum of 35kW can be linked to
any suitable model of SysteMate 2000 and the
deciding factor is the space heating and the
hot water requirements of a dwelling. See
Section 1.2 Technical Data for further details.
The SysteMate 2000 is available with the option
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.
Supplied By www.heating spares.co Tel. 0161 620 6677
Page 4
Page 5
SYSTEMATE 2000
ledoM
521MS
541MS 581MS 012MS 522MS
)ytpme(thgieW gk56 gk86 gk27 gk98 gk101
)lluf(thgieW gk081 gk391 gk222 gk952 gk192
pmuPWHD 05/51sofdnurG 05/51sofdnurG 05/51sofdnurG 05/51sofdnurG 05/51sofdnurG
pmuPgnitaeH 05/51sofdnurG 05/51sofdnurG 05/51sofdnurG 06/51sofdnurG 06/51sofdnurG
pmuPrelioB 05/51sofdnurG 05/51sofdnurG 05/51sofdnurG 06/51sofdnurG 06/51sofdnurG
epipgnitaeh/yramirP
snoitcennoc mm22 mm22 mm22 mm82 mm82
epipWHD&WCM
snoitcennoc mm22 mm22 mm22 mm22 mm22
noisnapxe/deefdloC
noitcennoc mm51 mm51 mm51 mm51 mm51
tnevnepoytefaS
noitcennoc mm22 mm22 mm22 mm22 mm22
snoitcennocyramirP
esuremmusrof(
)liarlewotmoorhtab
mm51 mm51 mm51 mm51 mm51
noitcennoCniarD ''R ''R ''R ''R ''R
daeHmumixaM
erotSlamrehT sretem01 sretem01 sretem01 sretem01 sretem01
erusserpmumixaM
tiucricgnitaeh rab3 rab3 rab3 rab3 rab3
erusserpmumixaM
retawcitsemod rab5 rab5 rab5 rab5 rab5
liocyramirpfoemuloV
)sertil( 0.2 0.2 0.2 0.4 0.4
etarwolfretawtoH nim/stl53otpu nim/stl53otpu nim/stl53otpu nim/stl53otpu nim/stl53otpu
ezisreliobxaM k51 W k02 W k52 W k03 W k53 W
'hctiwS' Wk9 Wk9 Wk9 Wk9 Wk9
sepytgnillewDlacipyT
smoordeB 3-1 3-2 4-2 5-3 6-4
smoorhtaB 1 1 2 1 2 2 3 4
rewohsetius-nE 1 2 1 4 2 4 2 0
1.2 TECHNICAL 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 ow 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 ow rate and may remove the need to provide trace
heating on the hot water distribution.
2. The plastic F & E cistern complete with ttings and the expansion vessel are supplied separately.
3. The ow rates are based on a 35°C temperature rise and assume normal pressure and adequate ow to the appliance. The actual
ow rate from the appliance is automatically regulated to a maximum of 28 litres/min.
4. Models are available in Hard and Soft water versions (sufxed ‘H’ or ‘S’).
5. Unit is supplied on a 100mm high installation base.
6. The domestic hot water outlet temperature is automatically regulated to approximately 55°C at the bath ow rate of 18 litres/min
recommended by BS 6700. The temperature is not user adjustable.
7. The maximum boiler size shown above is for the standard pump tted 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
Supplied By www.heating spares.co Tel. 0161 620 6677
Page 6
Page 7
SYSTEMATE 2000
1.2 TECHNICAL DATA
Standard Equipment
The standard conguration of the SysteMate
2000 is shown opposite. The Appliance Control
Board (A.C.B.), mounted inside the appliance,
controls the operation of the complete system.
The A.C.B. is pre-wired to a terminal strip
where all electrical connections terminate. It
is supplied with the following factory tted
equipment:-
1. Space heating pump
2. Domestic hot water primary
(plate heat exchanger) pump
3. Boiler pump
4. Hard water appliance control board (A.C.B.)
5. Electro-mechanical clock to control the
space heating (in conjunction with room
thermostat - if tted)
6. Expansion vessel for the primary/heating
system (supplied separately)
7. Plate heat exchanger
8. DHW temperature sensor
9. PHE return sensor
10. Store temperature sensor
11. Y type strainer/ow regulator
12. A feed and expansion cistern for lling
the primary thermal store (complete with
cold feed/open vent pipework assembly)
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 t
connectors for quick connection to rst
x 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
tted).
* 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 lling loop for tting
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
Supplied By www.heating spares.co Tel. 0161 620 6677
Page 6
Page 7
SYSTEMATE 2000
1.0 DESIGN
1.2 TECHNICAL DATA
Note: The dimensions below do not allow for the100mm
high installation base.
The following table of minimum cupboard dimensions only
allow the minimum space required for the appliance (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.
SNOISNEMIDECNAILPPA
ledoM
thgieH htdiW htpeD
A B C
521MS mm0411 mm595 mm595
541MS mm0411 mm595 mm595
581MS mm0531 mm595 mm595
012MS mm5941 mm595 mm595
522MS mm0761 mm595 mm595
SNOISNEMIDDRAOBPUCMUMINIM
ledoM
thgieH htdiW htpeD
F D E
521MS mm0981 mm007 mm006
541MS mm0981 mm007 mm006
581MS mm0012 mm007 mm006
012MS mm5422 mm007 mm006
522MS mm0242 mm007 mm006
Note: The above dimensions are based on the Appliance and
the F & E cistern (tted with a ballvalve) being in the same
cupboard. If the manual ll method is chosen the heights can
be reduced by 125mm.
Supplied By www.heating spares.co Tel. 0161 620 6677
Page 8
Page 9
SYSTEMATE 2000
1.0 DESIGN
1.2 TECHNICAL DATA
Supplied By www.heating spares.co Tel. 0161 620 6677
Page 8
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
Supplied By www.heating spares.co Tel. 0161 620 6677
Page 10
Page 11
SYSTEMATE 2000
1.3 SYSTEM DETAILS
Hot and Cold Water System
General
A schematic layout of the hot and cold water
services in a typical small dwelling is shown
below. SysteMate 2000 will operate at mains
pressures as low as 1 bar and as high as 5
bar although the recommended range is 2-3
bar. If the manifolds (available as an optional
extra) are being used the inlet pressure to the
manifold must be a minimum of 2 bar. It is also
important to check that all other equipment
and components in the hot and cold water
system are capable of accepting the mains
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
suitable pressure limiting (reducing) valve will
be required.
Note: Each SysteMate 2000 is fitted with a
strainer and ow regulator on the cold mains
supply connection. If the supply pressure is
less than 2 bar 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.
No check valve or similar device should be
tted on the cold water supply branch to the
SysteMate 2000.
Because of the innovative method of hot water
production no scale reducer is required on the
branch to the appliance. However, to comply
with the Benchmark Guidance Note for Water
Treatment in Heating and Hot Water Systems
the installer should check the hardness level
of the water supply and if necessary t a scale
reducer to provide protection to the whole of
the domestic water system.
The hot water ow 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
should be calculated using procedures dened
in BS 6700.
If a water meter is tted 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.
1.0 DESIGN
Note: The diagram below shows the F & E cistern with a ballvalve and warning/
overow pipe which can be tted if required. However, the standard preferred
arrangement is for the cistern to be manually lled from a temporary hose connection
tted with a double check valve.
Supplied By www.heating spares.co Tel. 0161 620 6677
Page 10
Page 11
SYSTEMATE 2000
1.3 SYSTEM DETAILS
Hot and Cold Water System
Pipe Sizing / Materials
To achieve even distribution of the available supply of hot and cold water, it is
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. These MUST be fitted in cases where the final branch pipe sizes
are not as recommended in item 3 or 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 ow
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/overow 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 tted with a double check valve and removed once
the appliance is lled.
All the recommendations with regard to pipework systems in this manual are generally
based on the use of BS/EN Standard copper pipework and ttings.
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.
This is particularly important in relation to use of push t connections when using the
optional exible hose kits - see 2.2 Installation, Pipework connections.
It is also essential that if an alternative pipework material/system is chosen the
manufacturer conrms that the design criteria of the new system is at least equivalent
to the use of BS/EN Standard copper pipework and ttings.
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 dynamic
changes particularly when other hot and cold taps/showers are opened and closed.
To minimise the impact of this we would always recommend the use of thermostatic
showers with this appliance.
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.
The appliance has not been designed to suit a
re-circulating domestic hot water circuit.
Please consult Gledhill Technical Department
for further details.
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.
Hot and Cold Water System.
The shower head provided must also be
suitable for mains pressure supplies.
The hot water supply to a shower-mixing
valve should be fed wherever practical
directly from the SysteMate 2000 or be the
rst draw-off point on the hot circuit. The
cold supply to a shower-mixing valve should
wherever practical be fed directly from the
rising mains via an independent branch. The
shower must incorporate or be tted with
the necessary check valves to provide back-
syphonage protection in accordance with
the Water Regulations.
The supply of hot and cold mains water
directly to a bidet is permitted provided that
it is of the over-rim ushing type and that a
type ‘A’ air gap is incorporated.
Supplied By www.heating spares.co Tel. 0161 620 6677
Page 12
Page 13
SYSTEMATE 2000
1.0 DESIGN
Heating System
General
A schematic layout of the heating system in a typical small dwelling is shown
above.
The ow and return from the boiler must always run directly to the SysteMate 2000
and the ow should rise continuously to facilitate venting. The heating circuit is taken
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 tted at high level in
the same cupboard as the SysteMate 2000. However, it can be tted 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 tted at high level in the appliance
cupboard alongside the F & E cistern.
The performance of the system pump and the pressure losses through the SysteMate
2000 primary coil circuit are shown in1.2 Technical Data. The nett pump head
available for the heating circuit can be determined from these gures and this nett
pump head should be used for sizing the heating circuit pipework.
1.3 SYSTEM DETAILS
For example: At 24 litres/min primary ow
rate, the pressure loss through the SysteMate
2000 model SM210 (coil and ttings) is 2.1m
W.G. (21kPa). The maximum pump head
available at 24 litres/min and setting 3 is 3.2m
H2O (32kPa), therefore 1.1m W.G. (11kPa) is
available for the 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.
The overow/warning pipe should be installed
in a material suitable for a heating system
feed and expansion cistern in accordance with
BS 5449.
An automatic bypass is tted on the SysteMate
2000 to compensate for pressure (i.e. ow) rate
changes in the heating circuit e.g. when the
thermostatic radiator valves close. The system
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 lling 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) which this should be disconnected after
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.
Supplied By www.heating spares.co Tel. 0161 620 6677
Page 12
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. tted 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 specied 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
ow 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
ow 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
pipework systems in this manual are generally
based on the use of BS/EN Standard copper
pipework and ttings.
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 recommend the use of barrier pipe
for these systems.
It is also essential that if an alternative pipework
material/system is chosen the manufacturer
conrms that the design criteria of the new
system is at least equivalent to the use of BS/EN
Standard copper pipework and ttings.
Boiler Size
It is only necessary to calculate the heating
requirements in accordance with BS 5449. The
allowances shown below should be added
for domestic hot water. The control system
automatically gives priority to hot water when
necessary.
Boiler Sited Below SysteMate 2000
The ow pipe from the boiler to the SysteMate
2000 must rise continuously. No valve shall be
tted in the primary ow pipe as this forms the
expansion pipe to the expansion vessel.
The size of the primary pipework connecting
the boiler to the SysteMate 2000 must not be
less than 22mm (or that specied by the boiler
manufacturer).
toHcitsemoDrofecnawollA
retaW
ledoM )Wk(
521MS 2
541MS 3
581MS 3
012MS 5.3
522MS 4
Supplied By www.heating spares.co Tel. 0161 620 6677
Page 14
Page 15
SYSTEMATE 2000
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.
It is important that the ow rates through these
radiators is adjusted to the minimum required
at the lockshield valves on the radiators. If this
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 ow and return pipes
A gravity check valve should be tted 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 ow immediately adjacent to
the boiler.
Heating System
Supplied By www.heating spares.co Tel. 0161 620 6677
Page 14
Page 15
SYSTEMATE 2000
1.3 SYSTEM DETAILS
Heating System
Expansion Vessel 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 gure 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 ow 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 specied
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.
If the system volume is greater than that shown in the table at the selected operating
conditions then an additional expansion vessel must be tted.
1.0 DESIGN
‘Switch’
The SysteMate 2000 can be ordered with
the option of ‘Switch’ which provides a 9kW
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.
Switch can operate on ‘hot water’ or ‘hot water
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
manually switched back to the ‘hot water’ only
position.
It also means that wherever Switch is
being used the normal domestic hot water
temperature controls are over-ridden. Initially
dependent on the ow rate/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, once the initial store temperature has
been reduced the Switch element thermostat
will reduce the temperature at the tap to no
more than 65°C. Full details of how to operate
the system are provided on a label xed to the
front of the appliance.
581/541/521MS.e.ilesseVertiL21
semuloVmetsySgnitaeHdednemmoceRmumixaM
0.3)rab(gnittesevlavytefaS
)rab(erusserpegrahclesseV 5.0 0.1 5.1
)rab(erusserpmetsyslaitinI 5.0 0.1 5.1 0.1 5.1 0.2 5.1 0.2
metsy
sdettimrepmumixaM
)sertil(emulov 041 08 04 011 06 72 07 53
522/012MS.e.ilesseVertiL52
semuloVmetsySgnitaeHdednemmoceRmumixaM
0.3)rab(gnittesevlavytefaS
)rab(erusserpegrahclesseV 5.0 0.1 5.1
)rab(erusserpmetsyslaitinI 5.0 0.1 5.1 0.1 5.1 0.2 5.1 0.2
metsy
sdettimrepmumixaM
)sertil(emulov 072 061 58 002 511 05 041 56
Supplied By www.heating spares.co Tel. 0161 620 6677
Page 16
Page 17
SYSTEMATE 2000
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 tted 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/oor.
Installation and maintenance access is needed to the front of the appliance and
above the F & E cistern. See Technical 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 oor 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.
The appliance is designed to operate as quietly as practicable. However, some noise
(from pumps etc) is inevitable in any heating system. This will be most noticeable
in cupboards formed on bulkheads, or at the mid span of 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
the design of the cupboard and door will need to take this into account. No ventilation
is normally required to the cupboard.
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
SysteMate 2000. The dimensions and clearances are provided in section 1.2 Technical
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/overow pipe and the ballvalve supply
from the mains cold water system if these are being tted.
Note: The standard appliance is supplied with a cistern without a ballvalve/
overow for lling 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
BS 7671.
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.
The supply to the standard appliance shall be fused at 3 amp - nominal maximum full
load current for all SM models = 1.4 amps (this does not include the boiler).
Electrical Supply requirements for
SysteMate 2000 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.
lanimoN
daollluf
tnerruc
fognitarniM
gnitalosi
hctiws
eziselbaC
dednemmocer.xaM
nodesab-nurelbac
4.0dnapordV2.9
noitcennocsiddnoces
epytagnisuemit
rekaerbBro1
spmA0.14 spmA54 mm01
2
sertem94
tiucricdednemmoceR
desab-ecivednoitcetorp
noitcennocsiddnoces4.0no
emit
1783SBot.B.C.M-1epytA54
NESBotrekaerbtiucricBepytA54
89806
Supplied By www.heating spares.co Tel. 0161 620 6677
Page 16
Page 17
SYSTEMATE 2000
2.2 INSTALLATION
2.0 INSTALLATION
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
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. The appliance
is supplied shrink wrapped on a timber
installation base. Carrying handles are also
provided in the back of the casing.
The feed and expansion cistern complete with
ballvalve, cold feed/expansion and overow/
warning fittings are provided in a separate
box along with the system expansion vessel. If
exible connections have been ordered these
will also be 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 requirements should be checked and
confirmed as acceptable. The plastic cover
and protective wrapping should be removed
from the appliance 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. The feed and expansion
cistern support shall be installed ensuring that
the base is fully supported and the working
head of the appliance is not exceeded. The
recommended access for maintenance must
also be provided - see section 1.2 Technical
Data.
Note: Although the above guidance is
provided any manual handling/lifting
operations will need 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 storeys we would recommend that
the appliances are moved vertically in a
mechanical lift.
If it is proposed to use a crane expert advice
should be obtained regarding the need for
slings, lifting beams etc.
Supplied By www.heating spares.co Tel. 0161 620 6677
Page 18
Page 19
SYSTEMATE 2000
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 exible connections
(available as an optional extra).
When using push fit connectors with the
exible hose kits it is important to check that
they are compatible. Written approval has
already been obtained for:-
Hepworth - Hep2O BiTite
John Guest - Speedt
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 ttings.
Connection K is a RC (” BSPT internal)
A - Safety open vent
B - Cold feed/expansion
C - Expansion vessel pipe
D - Central heating ow
E - Central heating return
F - Primary ow (from boiler)
G - Primary return (for summer use bathroom
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 ow (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.
2.0 INSTALLATION
2.2 INSTALLATION
Pipework connections
Supplied By www.heating spares.co Tel. 0161 620 6677
Page 18
Page 19
SYSTEMATE 2000
2.2 INSTALLATION
2.0 INSTALLATION
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) should be used to connect to the F &
E cistern and pipework site run by the installer
to connect this to the appliance,
Obviously, any pipework in the roof space and
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 ttings for the feed and expansion cistern should be installed following the
instructions provided by the manufacturer in a position to suit the particular location
and the cistern tted 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 tted 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 overow can be easily
observed. It shall also be installed in a size and material suitable for use with heating
feed and expansion cisterns in accordance with BS 5449 and should not have any
other connections to it.
Supplied By www.heating spares.co Tel. 0161 620 6677
Page 20
Page 21
SYSTEMATE 2000
WIRING DIAGRAM - STANDARD SYSTEMATE 2000 APPLIANCE
2.0 INSTALLATION
2.2 INSTALLATION
YEK
LB EULB
RB NWORB
Y/G WOLLEY/NEERG
R DER
This manual suits for next models
4
Table of contents
Other gledhill Water Heater manuals
gledhill
gledhill PULSACOIL III User guide
gledhill
gledhill Stainless Lite Direct 90-300 litres User guide
gledhill
gledhill StainlessLite Plus Direct D90 User manual
gledhill
gledhill PLATINUM D120 User manual
gledhill
gledhill StainlessLite HP180IND User guide
gledhill
gledhill Torrent Stainless OV User manual
gledhill
gledhill BOILERMATE 2000 User manual
gledhill
gledhill PulsaCoil ECO Stainless User manual
gledhill
gledhill Xstream User manual
gledhill
gledhill 120IND User guide
