Gledhill PulsaCoil A-Class Owner's manual

Gledhill PulsaCoil A-Class Owner's manual
A mains pressure hot water supply
system incorporating an off peak
electric thermal store
Design, Installation
& Servicing
Instructions
Model Numbers
PulsaCoil 145
PulsaCoil 185
PulsaCoil 215
PulsaCoil 235
All models comply with the water heater manufacturers
specification for thermal stores
ISSUE 9: 06-08
ISSUE 9: 06-08
Section
The code of practice for the installation,
commissioning & servicing of central heating systems
Page
DESIGN
Introduction
Technical Data
System Details
3
5
9
INSTALLATION
Site Requirements
Installation
Commissioning
13
14
19
SERVICING
Annual Service
Changing Components
Short Parts List
Fault Finding
20
20
21
22
ADDENDIX
Addendix A
Addendix B
Addendix C
Addendix D
25
26
28
29
Terms & Conditions
30
Building Regulations and Benchmark Commissioning
The Building Regulations (England & Wales) require that the installation of a heating
appliance be notified to the relevant Local Authority Building Control Department.
From 1st April 2005 this can be achieved via a Competent Person Self Certification
Scheme as an option to notifying the Local Authority directly. Similar arrangements
will follow for Scotland and will apply in Northern Ireland from 1st January 06.
CORGI operates a Self Certification Scheme for gas heating appliances.
These arrangements represent a change from the situation whereby compliance with
the Building Regulations was accepted if the Benchmark Logbook was completed and
this was then left on site with the customer).
With the introduction of a self certification scheme, the Benchmark Logbook is being
replaced by a similar document in the form of a commissioning check list and a service
interval record is included with all gas appliance manuals. However, the relevant
Benchmark Logbook is still being included with all Thermal Storage products and
unvented cylinders.
Gledhill fully supports the Benchmark aims to improve the standards of installation
and commissioning of central heating systems in the UK and to encourage the regular
servicing of all central heating systems to ensure safety and efficiency.
Building Regulations require that the heating installation should comply with the
manufacturer’s instructions. It is therefore important that the commissioning check
list is completed by the competent installer. This check list only applies to installations
in dwellings or some related structures.
Page 2
The Gledhill PulsaCoil range is a WBS
listed product and complies with the WMA
Specification for hot water only thermal
storage products. The principle was
developed originally in conjunction with
British Gas. This product is manufactured
under an ISO 9001:2000 Quality System
audited by BSI.
The Gledhill Group’s first 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.
DESIGN
Any water distribution system/installation must comply with the relevant
recommendations of the current version of the Regulations and British Standards
listed below:Building Regulations
Requirements for Electrical Installations
Water Regulations
Manual Handling Operations Regulations
British Standards
BS6700 and BS7671.
A suitably competent trades person must install the PulsaCoil and carry out any
subsequent maintenance/repairs. In fact the appliance front cover is secured by
2 screws and this should only be removed by a competent trades person. The
manufacturer’s notes must not be taken as overriding statutory obligations.
The PulsaCoil A-Class is not covered by section G3 of the current Building Regulations
and is therefore not notifiable to Building Control.
The PulsaCoil A-Class is not intended for use by persons (including children) with
reduced physical, sensory or mental capabilities, or lack of experience or knowledge,
unless they have been given supervision or instruction concerning use of the appliance
by a person responsible for their safety.
Children should be supervised to ensure that they do not play with the appliance.
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 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 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.
INTRODUCTION
In the interest of continuously improving the PulsaCoil 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 3
DESIGN
Cistern can be provided
with a ballvalve and
overflow connector as an
optional extra if required.
Top up cistern
14
15
3, S1/S2
20
11
4, S6
2
8
13
7, S4
PULSACOIL
A-CLASS
10
6, S3
12
9
5, S5
11
19
17
Appliance
case
1
18
16
Schematic Hydraulic Arrangement
Figure 1.1
The PulsaCoil A-Class shown schematically above is designed to provide an improved
method of supplying mains pressure hot water when used with a suitable off peak
electric supply/tariff.
An important feature of the 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
through a plate heat exchanger. The outlet temperature of the domestic hot water is
maintained by a printed circuit control board, which controls the speed of the pump
circulating the primary water from the store through the plate heat exchanger.
The Building Regulations L1A: New dwellings/L1B: Existing dwellings and the
requirements set out in the Domestic Heating Compliance Guide specify that “where
the mains water hardness exceeds 200ppm provision should be made to treat the
feed water to water heaters and the hot water circuit of combination boilers to reduce
the rate of accumulation of lime scale”.
INTRODUCTION
1. Bottom (Off-Peak) immersion heater
(1H_1)
2. Top (On-Peak) immersion heater (IH_2)
3. Overheat sensor pocket (Sensor S1/S2)
4. Top/middle sensor pocket (Sensor S6 for
IH_2)
5. Bottom sensor pocket (Sensor S5 for
IH_1)
6. Cold water inlet sensor, S3
7. DHW outlet sensor, S4
8. Grundfos UPR 15-50 pump
9. Filter & flow regulator
10. Plate heat exchanger
11. Pump isolating valve
12. Non-Return valve
13. Pre-expansion chamber
14. Open vent
15. Cold Feed
16. CW inlet
17. HW outlet
18. Drain
19. Return from PHE to store
20. Flow from store to PHE
To comply with this requirement the hardness of the mains water should be checked by
the installer and if necessary the optional factory fitted in-line scale inhibitor should be
specified at the time of order for hardness levels between 200 and 300 ppm (mg/l).
Where the water is very hard ie 300ppm (mg/l) and above the optional polyphosphate
type, inhibitor should be specified at the time of order. However, this will need to be
fitted by the installer at a suitable point in the cold water supply to the appliance.
Page 4
THE PRINTED CIRCUIT BOARD INCORPORATES
THE FACILITY TO AUTOMATICALLY RUN
THE D.H.W. PRIMARY PUMP FOR ABOUT
3 SECONDS EVERY 30 HOURS TO HELP
PREVENT IT STICKING. FOR THIS REASON
WE WOULD RECOMMEND THAT ONCE THE
APPLIANCE IS INSTALLED IT SHOULD BE
COMMISSIONED AND THE ELECTRICITY LEFT
ON TO THE APPLIANCE.
Because this product does not require a safety
discharge from a temperature and pressure
relief valve, any installations will be easy to
incorporate into the building and will not suffer
from the problems associated with using PVCu
soil stacks to take the discharge from unvented
cylinders.
The heat losses from thermal stores should not
be directly compared with heat losses from
unvented or vented cylinders because they are
treated differently in SAP. The SAP calculator
takes account of the type of store and various
correction factors are included to reflect the
different ways that the hot water and heating
operates.
DESIGN
Table 1.1
Technical Specification PulsaCoil A-Class
Model
PCA145
PCA185
PCA215
PCA235
Height (mm)
1042
1142
1300
1440
Width (mm)
530
530
530
550
Depth (mm)
595
595
595
595
Min cupboard height (mm)
1800
1900
2050
2200
Min cupboard width (mm)
550
550
550
570
Min cupboard depth (mm)
600
600
600
600
Weight (empty) (kg)
40
42
44
48
Weight (full) (kg)
187
206
230
258
Volume of water heated by on-peak heater (litres)
65
65
70
75
Table 1.2
Model Selection Guide PulsaCoil A-Class
Dwelling Type
Bedroom
1-2
2-3
2-3
2-4
Bathroom
1 or
1
1
2
1
1
2
1
Standard Economy-7 tariff
PCA145
PCA185
PCA215
PCA235
10hr Heatwise tariff
PCA145
PCA145
PCA185
PCA215
En-suite shower rooms
Notes:-
TECHNICAL DATA
1. Plastic top up cistern will be supplied separately.
2. The flow rates are based on a 35°C temperature rise and assume that recommended
pressures and adequate flow are available at the appliance. The actual flow rate
from the appliance is automatically regulated to a maximum of 28 litres/min.
3. Unit is supplied on a 100mm high installation base.
4. The domestic hot water outlet temperature is automatically regulated to
approximately 52°C at the bath flow rate of 18 litres/min recommended by BS
6700. The temperature is not user adjustable.
Page 5
DESIGN
Standard Equipment
11
The standard configuration of the PulsaCoil
A-Class is shown opposite. The Printed Circuit
Control Board (A.C.B.), mounted inside the
appliance, controls the operation of the
complete system. This is pre-wired to a terminal
strip where all electrical connections terminate.
It is supplied with the following factory fitted
equipment:1.
2.
3.
4.
5.
6.
3
15
16
17
12
7.
8.
9.
10.
11.
12.
13.
14.
15.
16.
17.
3kW Off-Peak immersion heater
3kW On-Peak boost immersion heater
Printed Circuit Board
Plate heat exchanger
Domestic hot water primary (plate heat
exchanger) pump
Isolating terminal connectors for dry fire
protection
DHW temperature sensor
Incoming cold water sensor
Strainer and flow regulator
Screwed connection for a drain tap
Top up cistern complete with cold feed/
open vent pipework assembly is supplied
separately
Overheat thermostat
Middle store control sensor
Bottom store control sensor
Operation/warning light
Boost/reset button
On/Off switch
6
13
5
2
Note : Both immersion heaters are low watts
density type with incaloy 825 sheaths and are
specially manufactured to suit Thermal Stores. It
is recommended that any replacements should
be obtained from Gledhill Water Storage.
7
Optional Extra Equipment
•
Scale inhibitor for mains water services with
hardness levels above 200 ppm (mg/l)
•
Hot and cold water manifolds for use with
plastic pipework.
•
Ballvalve/overflow connector for top up
cistern.
4
TECHNICAL DATA
14
8
1
10
9
Figure 1.2
Page 6
DESIGN
Appliance Dimensions
300
*350
*Min maintenance
access to comply with
the Water Regulations
(ballvalve model only)
Top up
cistern
Height
A
Width
B
Depth
C
PCA145
1042
530
595
PCA185
1142
530
595
PCA215
1300
530
595
PCA235
1440
550
595
Model
Note: The Appliance dimensions above do not
allow for the100mm high installation base.
B
D
The following table of minimum cupboard
dimensions only allow the minimum space
required for the appliance (including the F & E
cistern). Any extra space required for shelving
etc in the case of airing cupboards etc must
be added.
Minimum Cupboard Dimensions
Height
D
Width
E
Depth
F
PCA145
1800
550
600
PCA185
1900
550
600
PCA215
2050
550
600
PCA235
2200
570
600
A
Model
PulsaCoil A-Class
Note: The above dimensions are based on the
Appliance and the Top up cistern (fitted with a
ballvalve) being in the same cupboard. If the
manual fill method is chosen the heights can
be reduced by 125mm.
100
If pipework needs to rise vertically adjacent
to the appliance the width/depth will need
increasing to accommodate this.
E
Maintenance
access
C
The cupboard door
opening will need
to take into
account the various
sizes of appliances.
Figure 1.3
Page 7
TECHNICAL DATA
The minimum
clear opening in
front of the
appliance to be
at least the
same depth as
the appliance.
Top up
cistern
420
F
280
DESIGN
Plan Of Appliance Connections
Connection Details/Dimensions For Top Of Unit
595
120
53
530
The PulsaCoil A-Class units are supplied on
an installation base to allow the pipe runs to
connect to the appliance from any direction.
It is easier if all pipes protrude vertically in the
cut out area shown. Compression or push fit
connections can be used. All pipe positions
are approximate and subject to a tolerance of
+/- 10mm in any direction. Space will also be
required for a 15mm cold water supply and a
22mm warning / overflow pipe (if the optional
extra ball valve and overflow connector have
been specified. If a warning/overflow pipe
is NOT provided the F&E Cistern should be
filled from a temporary hose connection
incorporating a double check valve. This can
be from a temporary hose connection supplied
from a cold water tap or a permanent cold
branch provided adjacent to the Top up Cistern.
The temporary connection must be removed
once the appliance is filled.
Note: All dimensions are shown in mm and
are to the centre line of the pipework.
323 - Open Vent
385 - Cold Feed/Expansion
Connection Details/Dimensions For Bottom Of Unit
TECHNICAL DATA
595
550
530
455 - Mains Cold Water Inlet
490 - Hot Water Outlet
Figure 1.4
Page 8
DESIGN
Hot and Cold Water System
General
A schematic layout of the hot and cold water services in a typical small dwelling is
shown below. PulsaCoil A-Class will operate at mains pressures as low as 1 bar and as
high as 5 bar although the recommended range is 2-3 bar dynamic at the appliance.
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 pressure limiting (reducing) valve set to 3 bar will be required.
If you encounter a situation where the water pressure is adequate but flow rates are
poor please contact our technical helpline for details of an effective solution.
Note : Each Pulsacoil A-Class is fitted with a strainer and flow 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 fitted on the cold water supply branch to
the PulsaCoil A-Class.
The Building Regulations L1A: New dwellings/L1B: Existing dwellings and the
requirements set out in the Domestic Heating Compliance Guide specify that “where
the mains water hardness exceeds 200ppm provision should be made to treat the feed
water to water heaters and the hot water circuit of combination boilers to reduce the
rate of accumulation of lime scale”.
To comply with this requirement the hardness of the mains water should be checked by
the installer and if necessary the optional factory fitted in-line scale inhibitor should be
specified at the time of order for hardness levels between 200 and 300 ppm (mg/l).
Where the water is very hard ie 300ppm (mg/l)
and above the optional polyphosphate type,
inhibitor should be specified at the time of
order. However, this will need to be fitted by
the installer at a suitable point in the cold water
supply to the appliance.
The hot water flow rate from the PulsaCoil AClass 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 defined
in BS 6700.
If a water meter is fitted in the service pipe,
it should have a nominal rating to match the
maximum hot and cold water peak demands
calculated in accordance with BS 6700. This
could be up to 60ltr/min in some properties.
Note: The diagram below shows the top up
cistern with ballvalve and warning/overflow
pipe which can be supplied as an optional extra
if required. However, the standard preferred
arrangement is for the cistern to be manually
filled from a temporary hose connection fitted
with a double check valve.
The cistern must not be fitted more than 10
metres above the PulsaCoil A-Class appliance
itself.
Safety/open vent
Warning/
overflow
pipe
Top up cistern
‘a’ - flow regulator recommended for
better balance of hot and cold
water supplies
Expansion/
cold feed
Shower
MCWS
a
PULSACOIL
A-CLASS
Pressure limiting valve
NOT REQUIRED at
pressures below 5 bar
unless any components
have a lower
maximum working
pressure
MCWS
supply
pipe
Double check valve
NOT REQUIRED unless
pipe supplies more
than one dwelling
Bath
H C
Sink
H C
a
a
a
Hand basin
H C
a
a
WC - fitted
with BS1212
ballvalve
C
a
SV
Check valve
NOT REQUIRED unless
chemical water
treatment unit is fitted
Typical hot and cold water distribution
Page 9
Figure 1.5
SYSTEM DETAILS
Second
dwelling
DESIGN
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.
1. A 15mm copper or equivalent external service may be sufficient for a small 1
bathroom 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 PulsaCoil A-Class
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 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 pressures are above the recommended
water pressure range. Details of suitable flow regulators are provided in
Appendix A.
The supply of hot and cold mains water directly
to a bidet is permitted provided that it is of the
over-rim flushing type and that a type ‘A’ air gap
is incorporated.
Hot and Cold Water System
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. Please consult Gledhill
Technical Department for further details.
Note: If manifolds (available as an optional extra) are being used suitable flow
regulators are automatically provided in the manifold and do not need to be
provided at each outlet. See Appendix B for further details.
Note: A conventional pumped secondary
circulation system is NOT suitable for use with
this appliance.
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.
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.
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 fit connections when using the
optional flexible hose kits - see installation section of this manual.
It is also essential that if an alternative pipework material/system is chosen the
manufacturer confirms that the design criteria of the new system is at least equivalent
to the use of BS/EN Standard copper pipework and fittings.
Taps/Shower Fittings
Aerated taps are recommended to prevent splashing.
TECHNICAL DATA
The hot water supply to a shower-mixing
valve should be fed wherever practical directly
from the PulsaCoil A-CLASS or be the first drawoff 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 fitted with the necessary check
valves to provide back-syphonage protection in
accordance with the Water Regulations.
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, 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 strongly recommend the use of thermostatic
showers with this appliance.
The shower head provided must also be suitable for mains pressure supplies.
However, if it is proposed to use a ‘whole body’ or similar shower with a number of
high flow/pressure outlets please discuss with the Gledhill technical department.
Page 10
DESIGN
Electrical Installation
DHW Outlet Sensor
PHE Inlet Sensor
Control for Off-Peak I.H.
Control for On-Peak I.H.
Store Overheat Sensor
C1
ON PEAK L
230V, 50Hz N
E
15A
DHW
Pump
C2
OFF PEAK L
230V, 50Hz N
E
15A
The whole of the electrical installation shall be
designed and installed by a competent person
fully in accordance with the latest edition of
the Requirements for Electrical installations
BS 7671.
The PulsaCoil A-Class appliance is provided with
two side entry 3kW immersion heaters and has
been designed to generally operate with an off
peak supply.
C1 and C2 : Contactors
Immersion
(Off Peak)
The Schematic arrangement of the wiring within
the PulsaCoil A-Class is shown above.
The lower immersion heater heats the whole of
the contents and is normally connected to the
off peak supply.
Immersion
(On Peak)
PulsaCoil A-Class Schematic Wiring Diagram
The upper immersion heater is positioned at a
level on the PulsaCoil A-Class to heat the top 65
- 75 litres of the store - see Technical Data Table
on page 5. This is connected to the unrestricted
on peak supply and is switched manually by
the householder using the button provided on
the front of the appliance. When pressed the
on-peak boost will remain active until the next
time the off-peak becomes available (unless
switched off again manually).
The size of the appliance and the need to use
the on peak boost facility is reduced if a better
off peak tariff can be agreed with the electrical
supply company - see Model Selection Guide
on page 5.
Wiring The PulsaCoil With A Split Consumer
Unit I.e. Separate On And Off Peak Supplies.
Twin Tariff Consumer Only
METER
On Peak
Element
24 HOUR
DOMESTIC
SUPPLY
Off Peak
Element
B16
ON
ON
OFF
OFF
B16
ON
ON
ON
ON
OFF
OFF
OFF
OFF
MCB
RESTRICTED
OFF PEAK
SUPPLY
ON
ON
ON
OFF
OFF
OFF
MCB
ON PEAK 3KW
20 Amp
Installer
Terminals
Double Pole
Isolator
20 Amp
Control
Supply
Boost
Control
Installer
Terminals
Double Pole
Isolator
OFF PEAK 3KW
Twin Tariff Restricted Off Peak Connections
Page 11
SYSTEM DETAILS
Rate1
Rate 2
Historically this has been the typical supply
method and no special wiring arrangements
are required.
DESIGN
Wiring The Pulsacoil A-Class With Combined
On And Off Peak Supplies
Rate1
Rate 2
METER
With this arrangement the dwelling has a single
supply to the consumer unit from the meter
and the whole dwelling goes off-peak or onpeak when the tariff changes at the meter. In
this case a single channel clock will need to be
fitted in the off peak supply to the PulsaCoil. The
off-peak time clock will need to be synchronised
with the tariff times set on the meter and be
rated for at least 3kW at 230V.
On Peak Off Peak
Element Element
24 HOUR
DOMESTIC
SUPPLY
B16 B16
ON
ON
OFF
OFF
ON
ON
ON
ON
ON
ON
ON
OFF
OFF
OFF
OFF
OFF
OFF
OFF
MCB MCB
Off Peak During
00:00 - 07:00 E7
ON PEAK 3KW
Installer
Terminals
20 Amp
Double Pole
Isolator
Control
Supply
Installer
Terminals
20 Amp
Timer Programmed to Synchronized with
Off Peak Availabilty EG. 00:00 - 07:00 E7
Boost
Control
Double Pole
Isolator
Immersion Heater
Timeswitch
3KW
Although the PulsaCoil A-Class appliance is
primarily designed to operate with an off peak
supply it will also operate quite successfully
if it is only supplied with an on peak supply.
However, this will substantially increase the
running costs of the appliance and should
only be considered if an off peak supply is not
available.
OFF PEAK 3KW
Twin Tariff Un-Restricted Off Peak Connections
Wiring The Pulsacoil A-Class When Only An
On Peak Supply Is Available
Rate1
METER
With this arrangement the dwelling has no offpeak tariff available. Because the appliance will
continuously sense the presence of a supply at
the bottom immersion heater (normally offpeak) the controller will always use the bottom
immersion heater to charge the store and
boost will not be available unless the bottom
immersion heater fails.
On Peak Off Peak
Element Element
24 HOUR
DOMESTIC
SUPPLY
B16 B16
ON
ON
OFF
OFF
ON
ON
ON
ON
ON
ON
ON
OFF
OFF
OFF
OFF
OFF
OFF
OFF
MCB MCB
ON PEAK 3KW
20 Amp
Installer
Terminals
Double Pole
Isolator
20 Amp
Double Pole
Isolator
Control
Supply
Boost
Control
Installer
Terminals
OFF PEAK 3KW
SYSTEM DETAILS
Single Tariff Domestic Supply No Off Peak Connections
Page 12
To allow the appliance to operate successfully
with on peak only supplies, two separate 16A
230V 50Hz supplies MUST be provided with
one wired into the on peak connections in the
normal way and the other wired into the off
peak connections.
In all cases the two switches/isolators must be
clearly labelled for the householders use.
INSTALLATION
The appliance is designed to be installed in an airing/cylinder cupboard and the
relevant minimum dimensions are provided in the Technical Data section of this
manual.
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.
Installation and maintenance access is needed to the front of the appliance and above
the Top up cistern. See the Technical Data section of this manual for further details.
The minimum dimensions contained in the Technical Data section of this manual
allow for the passage/connection of pipes to the appliance from any direction as long
as the appliance is installed on the installation base provided. If the installation base
is not used extra space may be needed to allow connection to the pipework and the
whole of the base area should be continuously supported on a material which will
not easily deteriorate if exposed to moisture.
The floor of the cupboard needs to be level and even and capable of supporting the
weight of the appliance when full. Details of the weight when full is provided in the
Technical Data section of this manual.
The appliance is designed to operate as quietly as practicable. However, some
noise (from pumps etc) is inevitable when hot water is being used. This will be most
noticeable if the cupboards are located adjacent to bedrooms, on bulkheads, or at
the mid span of a suspended floor. Some noise may also be experienced from the
immersion heaters as the store approaches its design temperature.
Cupboard temperatures will normally be slightly 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.
The separate Top up cistern will need to be located on top of the appliance or at high
level in the cupboard housing the PulsaCoil A-Class. The dimensions and clearances
are provided in the Technical Data section of this manual. The location will need to
provide a suitable route for the cold feed expansion pipe as well as the open safety
vent pipe. The location will also need to provide a suitable route and discharge position
for the warning/overflow pipe and the ballvalve supply from the mains cold water
system (if provided) if these have been ordered as an optional extra.
Note: The standard appliance is supplied with a cistern without a ballvalve/
overflow for filling manually.
The electrical mains supply needs to be 230V/50Hz.
The sizes/types of electrical supplies must be as detailed in System Details section
of this manual. A means for disconnection from the supply mains having a contact
separation in all poles that provides full disconnection under over voltage category
III conditions must be incorporated in the fixed wiring in accordance with the wiring
rules. This shall be located within 1m of the appliance and only serve the appliance.
The hot and cold water ‘first fix’ pipework should be terminated 50mm above the
finished floor level in accordance with the dimensions provided in the Technical Data
section of this manual.
Page 13
SITE REQUIREMENTS
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.
INSTALLATION
1
2
3
4
S1 & S2
1
0
S3
RELAY R2
Y
G
Br
Wh
Br
Wh
200 - 240Vac 50Hz
Br
S4
Wh
S5
Br
Wh
4
2
6
8
Br
S6
Wh
1
0
RELAY R1
200 - 240Vac 50Hz
2
4
8
6
Bl
COM
NL
11
14
ON
IH
L
ON
ON
ON
PEAK PEAK PEAK
N
PE
L
ON
IH
N
OFF
IH
L
OFF
PEAK
L
OFF
OFF
PEAK PEAK
PE
N
L
N
ON
E
RELAY
R3
1 2 3 4
N
OFF
PEAK
F2
SPD1/2A
ON
PEAK
F1
L
PART No.
XB142
12
OFF
IH
N
Br
E
A2
A1
DRN.
Off Peak Supply
2
1.5mm Flex
DATE
S. McGachie
08-06-07
DATE : JUNE 2007
OFF PEAK
On Peak Supply
2
1.5mm Flex
ON PEAK
INSTALLATION
SCALE INHIBITOR
CH'KD.
SIGN.
DATE.
08-06-07
S. McGachie
ISSUE No : 6
APPROVED
APP'D.
SIGN.
S. Gataora
08-06-07
DO NOT SCALE FROM THIS DRAWING. COPYRIGHT OF THIS DRAWING
IS RESERVED. IT IS NOT TO BE REPRODUCED COPIED OR DISCLOSED
TO A THIRD PARTY EITHER WHOLLY OR IN PART WITHOUT OUR
WRITTEN CONSENT.
© GLEDHILL WATER STORAGE LTD.
Page 14
DATE
INSTALLATION
5
6
7
8
R
Bl
R
FRONT PANEL
Bl
Y
Y
B
R
B
Bl
R
Or
Or
R
R
Or
Br
B
Or
Br
ID_RESISTOR
Br
Bl
R
Br
Y
Y
B
A
Red LED
Push Button
R
B
B
Off - On Green Neon Rocker
1B
Or
Or
J9
J31
0
Br
Br
1
B
1A
1
J30
C
J29
(ON PEAK SIGNAL)
J3
V
Br
(ON PEAK IMMERSION HEATER)
R
(OFF PEAK IMMERSIONHEATER)
J33
J28
(OFF PEAK SIGNAL) V
J32
G/Y
J34
DHW
Pump
B
Bl
E
Bl
D
N
Br
Br
L
J5
M
G/Y
E
Off Peak
Immersion
On Peak
Immersion
3kW
* All wire sizes 0.5mm² unless otherwise stated
GLEDHILL WATER STORAGE LTD.
SYCAMORE TRADING ESTATE
SQUIRES GATE LANE
BLACKPOOL
LANCASHIRE
FY4 3RL
TITLE
JOB NAME
'A' CLASS PULSACOIL APPLIANCE
'A' CLASS PULSACOIL APPLIANCE
ELECTRICAL SCHEMATIC DRAWING
DRG. SIZE
A3
Page 15
DRG. NAME
'A' Class Pulsacoil ver 6.ai
INSTALLATION
BOTTOM
TOP
3kW
INSTALLATION
Preparation/placing The Appliance In
Position.
The ‘first fix’ pipework positions should be
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 overflow/
warning pipe fittings are provided in a separate
box.
The appliance should be handled carefully to
avoid damage and the recommended method
is shown above.
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 require a team lift.
A specific manual handling assessment is shown in Appendix D
at the rear of this manual.
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.
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, ready for connection
of the pipework and electrical supplies.
INSTALLATION
The feed and expansion cistern support shall
be installed ensuring that the base is fully
supported, the working head of the appliance
is not exceeded and the recommended access
is provided for maintenance - see the Technical
Data section of this manual for details.
Page 16
INSTALLATION
Pipework Connections
The position of the pipework connections is
shown opposite. The exact location dimensions
are listed in the Technical Data section of this
manual.
All the connections are also labelled on the
appliance. It is essential that the pipework is
connected to the correct connection.
Connections A and B are plain ended copper
pipe.
Connection C and D compression fittings.
Connection E is RC½ (½ in BSPT internal)
A
B
A
B
C
D
E
-
22mm Safety open vent
15mm Cold feed/expansion
22mm Incoming mains cold water
22mm Domestic hot water
½” Drain tap connection
Note: The safety open vent and cold feed/
expansion must be connected to the top up
cistern using the pipework assembly provided.
Do not alter or connect any pressure-relief
device to the vent pipe of this water heater.
All factory made joints should be checked after
installation in case they have been loosened
during transit.
The fittings for the top up cistern should be
installed following the instructions provided
and the cistern fitted on its supports/top of
the appliance.
The cold feed/expansion and safety open vent
should be installed between the appliance and
the top up cistern.
E
C
Figure 1.6
Page 17
INSTALLATION
D
INSTALLATION
Combined Feed And Open Vent Pipe
Electrical Connection - Standard Appliance
It is normally envisaged that the top up cistern will be located in the same cupboard
as the PulsaCoil A-Class appliance itself to maintain a dry roof space.
The PulsaCoil A-Class is pre-wired internally,
strictly in accordance with the IEE Requirements
for Electrical Installations BS 7671. The external
wiring/connections should be carried out by a
competent person to the same standard. The
arrangement of the internal wiring is shown on
the previous page.
The cold feed/open vent pipework assembly (as supplied) should be used to install
the top up cistern directly on top of the appliance.
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 top
up cistern and pipework site run by the installler 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 the terminals are suitably labelled.
Note: Do not attempt the electrical work unless
you are competent to carry it out to the above
standards.
Combined Feed And Open Pipe Arrangements Must Not Be Used.
No valves should be fitted in the safety open vent which must be a minimum of 22mm
copper pipe or equivalent throughout its length.
The mains cold water supply to the ballvalve (if provided) shall be provided with a
suitable servicing valve.
The overflow/warning pipe (if provided) shall have a continuous fall, be fitted to
discharge clear of the building and be sited so that any overflow can be easily observed.
It shall also be installed in a size and material suitable for use with heating feed and
expansion cisterns in accordance with BS 5449 (e.g 22mm copper) and should not
have any other connections to it.
Note: If a warning/overflow pipe is NOT provided the top up 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 top up cistern. The
temporary hose must be fitted with a double check valve and removed once
the appliance is filled.
Before commencing check that the power
source is in accordance with the Site
Requirements section of this manual and
ensure that it is isolated as shown in the System
Details section.
Run the external wiring from the adjacent
isolator through the service slot provided in the
base of the appliance.
Make the connections as shown below.
ON
IH
L
The store may fill more slowly than the feed tank. It is important to check the
water level again in the cistern after commissioning.
L
E
ON
IH
N
OFF
IH
L
OFF
PEAK
L
L
OFF
OFF
PEAK PEAK
PE
N
N
OFF
IH
N
E
OFF PEAK
Off Peak Supply
2
1.5mm Flex
Clamp the cables in the grips provided and
ensure all cables are routed to avoid hot
surfaces.
Note: The appliance pipework should be bonded
to earth to comply with the IEE Requirements
for Electrical Installations BS 7671.
Interconnecting
Pipework
(By Installer)
Before switching on the electrical supply check
all the factory made terminal connections to
ensure they have not become loose during
transit.
PulsaCoil
INSTALLATION
N
ON PEAK
On Peak Supply
2
1.5mm Flex
Cold feed / open vent
pipework
(as supplied)
ON
ON
ON
PEAK PEAK PEAK
N
PE
L
Figure 1.7
Page 18
INSTALLATION
Open the incoming stop valve and fill the domestic mains cold and hot water systems
including the PulsaCoil A-Class appliance.
Check the water level in the top up cistern and if a ballvalve is fitted adjust if
necessary.
Put the on/off switch on the front control panel
to the on position to activate the appliance
control board. The switch will glow green when
in the on position.
Check the whole of the domestic hot and cold distribution systems for leaks. Fully
flush and if necessary chlorinate the hot and cold water system in accordance with
the recommendations in the Water Regulations and BS 6700.
If an off peak supply is not available the onpeak boost immersion heater will need to be
switched on by pressing the black button. The
red light will change to permanently on.
Please note that the whole of the domestic hot and cold water systems including the
appliance must be adequately flushed after chlorination. Failure to do this can cause
damage to the plate heat exchanger/immersion heaters etc. If there are any doubts
regarding this or the quality of the water being used to fill the PulsaCoil appliance an
inhibitor such as Fernox MBI or Sentinel X100 should be added to the appliance when
filling in line with the manufacturers instruction for these products.
It can be checked that the boost immersion
heater is drawing current by use of a clamp
meter on the live supply when boost is active
or by interrogating the printed circuit control
board in accordance with the instructions in the
fault finding section of this manual.
Check that the top up tank is filled up to the water level shown on the label. If it is a
manual fill model, this is most important.
The sensor control set points are shown on
page 25 and can be checked on the 2 digit ACB
display.
If a ballvalve is provided, turn down the servicing valve once the system is finally
filled to the point where the warning/overflow pipe will cope with the discharge
arising from a ballvalve failure.
If an overflow is not provided ensure the temporary filling hose is isolated and
removed from its connection to the cold water supply.
It is essential that all systems function properly for optimum performance.
To achieve this the flow rate from each tap should be checked and a suitable number
of taps run simultaneously to check the impact of this on the flow rate at individual
taps.
OFF
ON
FLASHING
Normal
On-Peak boost active
Fault attention required
PUSH BUTTON
To activate On-Peak boost
ON/OFF SWITCH
Control circuit power
supply
The boost immersion heater can be switched
off by pressing again the black button.
If an off peak supply is available at the time
the appliance is switched on the appliance will
automatically switch on the off peak immersion
heater. Its operation can be checked in the
same way as described above for the on peak
immersion heater. When the off peak supply
is available the on peak immersion heater
operation can still be checked as described
above by switching off the off peak supply.
Note: If the on and off peak supplies have been
connected wrongly (“crossed”) at the appliance
it will not operate properly (it may charge if off
peak is available but will not carry out any other
operations)
If the appliances has been connected with the
polarity incorrect it will not operate at all.
See the fault finding section of the manual for
further details.
We recommend that flow regulators are provided for each tap/terminal fitting
to ensure that the available flow is shared evenly - See Appendix A for further
details.
Run a tap and using a digital thermometer
check that the temperature of the hot water is
about 52°C. This temperature is factory set and is
independent of the store temperature assuming
the store is above 55°C and typical hot water
flow rates of 6-25l/min are being drawn.
Once the PulsaCoil A-Class is filled with water, check the on/off switch on the front is
in the off position. The electrical supplies can then be switched on and the switches
on the two isolating terminal connectors can be pushed home.
WARNING - Pushing home these switches will complete the electrical circuit to the
immersion heaters. DO NOT PUSH HOME THESE SWITCHES AND SWITCH ON THE
ELECTRICITY SUPPLY UNTIL YOU HAVE CHECKED THAT THERE IS WATER IN THE F
& E CISTERN. Failure to do this can result in dry firing and premature failure of the
immersion heaters, which will invalidate the warranty.
Page 19
This product is covered by the ‘Benchmark’
scheme and a separate commissioning/
service log book is included with this
product. This must be completed during
commissioning and left with the product
to meet the Warranty conditions offered by
Gledhill.
COMMISSIONING
Commissioning the PulsaCoil Control System
SERVICING
Important Do’s and Don’ts
Annual Servicing
1. DO check the incoming mains water pressure. The preferred range of mains
pressure is 2 -3 bar.
2. DO check the flow rate of the incoming cold water main is adequate to meet the
maximum hot and cold water simultaneous demands.
3. DO check that all connections are in accordance with the labelling on the thermal
store.
4. DO NOT push home the 2 switches on the isolating terminal connectors and
switch on the electricity supply until you have checked that the appliance is full
of water i.e. there is water in the top up cistern.
5. DO check the water level is correctly set in the top up cistern when cold and if
fitted that there is no overflow when the appliance is up to temperature.
6. DO check that the sensors switch the immersion heaters off at the correct set
point i.e. approx 70°C.
7. DO insulate any exposed hot water pipework in the PulsaCoil cupboard.
8. If the ballvalve in the F & E cistern is permanently connected to the mains cold
water supply DO plumb the overflow/warning pipe in a 20mm internal diameter
pipe and ensure it discharges in a conspicuous external position. Use a material
which is suitable for use with heating F & E cisterns in accordance with BS 5449
(such as copper).
9. DO ensure the green light ‘on/off’ switch glows.
10. Once the appliance is filled and commissioned DO leave the electricity switched
on to the appliance to ensure the automatic pump run facility can operate to
prevent the pump sticking.
11. DO ensure that the functioning and control of the system is explained to the
occupant.
12. DON’T place any clothing or other combustible materials against or on top of this
appliance.
No annual servicing of the PulsaCoil A-Class is
necessary.
These instructions should be placed along with the component manufacturers
instructions in the pocket provided on the rear of the front panel. The front
panel should then be refitted.
However, if required, the operation of the
controls and a hot water performance test can
be carried out to prove the appliance is working
satisfactorily and within its specification.
If it is decided to carry out the above tests the
water level in the top cistern should also be
checked and if necessary topped up.
Changing Components
Free of charge replacements for any faulty
components are available from Gledhill during
the in-warranty period on return of the faulty
part (normally 12 months).
After this, spares can be obtained direct from
Gledhill using the ‘Speed Spares’ service, or
through any of the larger plumbers merchants/
specialist heating spares suppliers.
Help and advice is also available from the
Technical Helpline on 08449 310000.
However, all components are readily accessible
and can be changed quickly and easily by the
installer using common plumbing/electrical
practice.
ANNUAL SERVICE/CHANGING COMPONENTS
Note: All maintenance work on the PulsaCoil
appliance must be carried out by a competent
trades person.
Note:
The pump is a Grundfos UPR 15-50 4 wire
pattern and any replacement must be the
same model.
Page 20
SERVICING
Supplier & Model
1
PHE pump
Grundfos, UPR 15-50
2
Plate heat exchanger (PHE)
SWEP, 24 Plate heat exchanger
3
Pump isolating valve - outlet
Watt Industries, 90° valve
4
Pump isolating valve - inlet
Watt Industries
5
Top immersion heater
6
Bottom immersion heater
7
Main PCB controller
8
Middle sensor
9
Top (OHT) sensor
10
11
Part Number
Stock Code
5950543
GT089
E8T/24
GT017
7308123
GT135
GT133
Shell, 14” Immersion heater - no stat
Incalloy 825
XB083
Argus Vision 147/4GS controller
147/4GS
GT490
Tasseron, Single sensor
TSK10B4
GT198
Tasseron, Duplex sensor
TSK11B4
GT199
Front panel display
RH Technical, Membrane overlay
P210328
XB411
Front panel display harness
RH Technical, Membrane harness
12
Off-Peak circuit fuse holder
Phoenix, (Part of DIN rail assembly-non stock item)
13
Control & off-peak circuit fuses
RS Components, 5A FF
14
Off-Peak/On-Peak contactor
Duracool
XB178
15
Bracket
Duracool
XB179
16
Complete DIN rail assembly
Phoenix, Bespoke terminal and component
assembly
XB180
17
Complete wiring harness
18
On-Off switch (part of panel)
Arcoelectric, Green illuminated rocker switch
C5503-ALNAK
CA006
19
DHW inlet & outlet sensors
Tasseron, single sensor complete with nut & olive
Wet pocket
sensor, comes
as a kit.
GT198
+
GT295
20
Relay
Relpol
RM87N-231135-5230
XB424
21
DIN rail socket
Relpol
GZT92
XB425
XB057
415-626
XB382
1
2
3
4
5/6
7
8/19
9
10
11
12
13
14/15
16
17
18
20
21
Page 21
SHORT PARTS LIST
Description
SERVICING
The PulsaCoil A-Class appliance control panel and printed circuit control board/display
have been designed to be fully automatic whilst able to provide functional and
diagnostic information to the householder/installer.
S1/S2
The panel/board work in conjunction with a number of sensors (thermistors) located
as shown in the diagram below.
Automatic Control Operation
S6
Heating of the store is controlled by sensors S1/S2 and S5 and S6. The control set
points are shown in the table on page 25.
S4
On/P Heater
During normal charging cycle sensor S5 will control the bottom off peak I.H. in the
same way S6 will control the top on peak I.H. when manually activated.
In the event of either of these sensors failing, control will be taken over by sensors
S1/S2.
Normally, sensors S1/S2 are used to detect an overheat condition (over 95ºC) which
will cause the red LED on the front control panel to flash (rapid).
This condition should not normally be reached as sensors S1/S2 will also switch off
the supplies to the I.H’s if a temperature above 85ºC is detected. Normal operation will
automatically resume when the temperature at the sensors drops below 78ºC.
The hot water temperature is controlled by sensors S3 and S4.
S3 checks for a drop in temperature every second and if the drop is more than 2ºC,
it switches on the hot water pump to raise the domestic hot water temperature to
52ºC (± 2°C).
The control of the hot water temperature is carried out by sensor S4 adjusting the
speed of the hot water pump.
Off/P Heater
Sensors
S1/S2 Store/OH sensors
S3 DHW inlet sensor
S4 DHW outlet sensor
S5 Control sensor for Off peak Htr
S6 Control sensor for On peak Htr
Fault Condition
Possible Causes
DHW temperature
remains cold
exiting the taps.
- Thermal store is cold/DHW
pump is permanently stuck
- Temperature sensor or
printed circuit control
board is faulty.
- The water level is low in the
F&E Cistern
- Overheat stat tripped
- One or both immersion
heaters have failed
DHW temperature
fluctuates wildly
when flow is
steady
- DHW pump keeps sticking
intermittently
- Hot & cold crossed at
appliance.
The pump is stopped once S3 reaches a temperature of above 30°C.
The following checks should be carried out by the installer before calling the
manufacturer.
Noise When Hot Water Tap Is Opened/closed
If the plate heat exchanger pump is noisy when the hot water tap is opened, then
check the level of water in the F & E cistern and vent the pump if necessary.
Water hammer - loose pipework and/or tap washers and/or washing machine
valves.
- DHW printed circuit control
DHW temperature
board and/or temperature
sensor is/are faulty.
exceeds and
remains well above - Immersion heater
60°C when the
thermostat temperature
flow rate is low.
setting too high should
be 70°C.
Causes of ‘Unsatisfactory Hot Water Service’
See table opposite.
Overflow from Feed and Expansion Cistern
FAULT FINDING
S3
S5
Check that the controlled level of water in the cistern is at the correct level. Adjust if
required and check the ballvalve is shutting off the water supply.
Store not heating
Page 22
- The two switches on
the isolating terminal
connectors are not pushed
home - i.e. unit is not
commissioned.
- No power supplies/fuses
are blown.
- Overheat stat has tripped.
- One or both immersion
heaters have failed.
SERVICING
Normal - standby state
Indicate system status
S2
S1
2 digit
display
Press S2
Sensor temperature
reading
Press
Press
Press
Press
S1
S1
S1
S1
Press
Press
Press
Press
S1
S1
S1
S1
Press
Press
Press
Press
S1
S1
S1
S1
Press
Press
Press
Press
S1
S1
S1
S1
S2 S1
2 push
buttons
Main
processor
Press S2
Control set-point
reading
Press S2
Fault code indicator
block outs
2 DIGIT ACB BOARD DISPLAY FLOW CHART
Appliance Control Board
The appliance control board (shown opposite) has a 2 digit display and 2 push buttons
which are used to check the status of the appliance, check and set its identity and
interrogate it for the current faults and the fault history.
The 2 digit display is controlled by 2 buttons S1 and S2. The flow chart of display modes
is shown above. Generally, each press of button S2 cycles the display from top to
bottom and each press of button S1 cycles the display functions from left to right.
The button S2 is also used to reset the appliance i.e. clear the lockout errors and reset
the appliance. (Note: Appliance resetting can also be carried out using the push
button on the front panel)
Note: The board is used on a range of products and not all terminals are used on
every appliance.
Display in Normal (Standby) Mode
In the standard/normal mode the 2 digit display indicates the status of the appliance
inputs and outputs by switching on the appropriate segments of the display - see
page 24 for details.
Appliance Type Selection
The PulsaCoil is fitted with an identity (ID) resistor which is read by the controller for
comparison with the appliance type (code) set on the controller. The two must match
for the controller/appliance to function. Therefore if either the appliance code setting
or the ID resistor is wrong, the appliance will shut down safely and flag the error code
until the fault is rectified.The controller codes and the ID resistor values for the PulsaCoil
Page 23
APPLIANCE CONTROL BOARD (A.C.B)
are 03 and 3K3 respectively. The procedure for
checking and setting the appliance code on the
controller is described below.
• The appliance selection menu (A0 ... A9) on
the controller is hidden. It is only possible to
get to the appliance selection using the reset
button (Left hand, S2) on the main board.
• When going from the show ‘ locking error’ to
show ‘blocking error’ menu (see opposite),
do not release the button but hold it for 10
seconds. The display will change from ‘c’ to
‘A’. At this stage the push button (S2) can be
released.
• The appliance type can now be selected by
using right hand push button, S1, e.g. for this
appliance A03.
Press the reset button, S2, to accept the
setting.
If the selected appliance code does not match
with the ID resistor fitted to the appliance, then,
an error ‘33’ will be displayed.
FAULT FINDING
Fault code indicator
lock outs
Fuse T3.15L 250V
Press S2
SERVICING
Control panel - (on the
front of the appliance)
OFF
ON
FLASHING
Normal
On-Peak boost active
Fault attention required
Red LED indicator
PUSH BUTTON
To activate On-Peak boost
Black push button
ON/OFF SWITCH
Control circuit power
supply
Green rocker switch illuminated when in the
‘ON’ position
S6 sensor (top)
calling
Off peak supply
present
DHW pump on
On peak heater
on
On peak supply
present
Off peak heater
on
S5 sensor
(bottom) calling
If flashing on its own, the system
is running normal
This is designed for operation by the householder
and the operation is in line with the instructions
on the panel.
If a sensor error is detected one of the following
three error codes flash alternately with the
sensor number instead of the temperature
E1 Open circuit
E2 Short circuit
E3 Temperature greater than 99°C
A code of FF indicates the fault location is
empty.
If flashing on its own system has
locked out and needs a reset
If both flashing indicates a fault but unit is still working
S1
Top immersion heater sensor on
(S6)
70°C
S2
Top immersion heater sensor off
(S6)
78°C
The set point reading mode is normally only
used by the Gledhill engineer to check the
sensor set points are still correct. The set point
alternately flashes with S1-S6.
S3
DHW in
(S6)
35°C
See table opposite for set points.
S4
DHW out
(S6)
52°C
S5
Bottom immersion heater sensor on
(S6)
75°C
S6
Bottom immersion heater sensor off
(S6)
79°C
Sensor Control Set Points
The two fault code indication modes are again
mainly for use by the Gledhill engineer and can
only be used with a reference table.
Sensor Control Set Points
FAULT FINDING
Code
Note: The S1-S6 reference display does not
correspond with the S1-S6 sensor references
used earlier. These are shown in brackets on
the table opposite.
Code
10
Overheat error
45
S1 overheat 1 shorted
30
Phase error
48
I.D. resistor shorted
33
Appliance selection
49
S4 sensor shorted
37
S1 overheat 1 open
50
S5 sensor shorted
40
I.D. resistor open
51
S6 sensor shorted
41
S4 sensor open
52
S2 overheat 2 shorted
42
S5 sensor open
55
Top IM failure
43
S6 sensor open
56
Bottom IM failure
44
S2 overheat 2 open
Any other code displayed should be checked against the full chart.
The Blocking errors will clear automatically
when the fault is cleared/component changed.
The Locking errors can only be cleared by
resetting the controller.
In each case there are 16 fault locations stored
in date order with C0 being the latest and CF
the first.
The most common fault codes are shown
opposite. Not all appliances use all the error
codes available.
For further assistance please call the Gledhill
Technical Helpline on 08449 310000.
Page 24
APPENDIX
Water Savings
Water Related Costs Can Be Reduced By Good Plumbing Practice
1
2
1
1
2 tap
half open
Unregulated
Over
20 l/m
Fitted with regulator
5, 6 or
8 l/m
2
2
TAPS & MIXERS
4 Fixing Options For Taps & Mixers
1. MK Range - Combined Regulators & Aerator
for screwing onto Taps & Mixers with internal
or external threads on their noses.Anti Vandal
models also available.
Unregulated
25 - 30 l/m
Regulated
10 - 12 l/m
SHOWERS
Vast quantities of water are needlessly run off to waste due to Taps, Mixers and Showers
discharging flow rates far in excess of the rates required for them to perform their
duties.
The contrasting flow rates shown on this leaflet clearly illustrate the savings that can
be made whilst still providing a good performance.
British made Aquaflow Regulators provide constant flow rates by automatically
compensating for supply pressure changes between 1 bar & 10 bars.
To facilitate installation into the wide range of plumbing equipment which is
encountered in the U.K, Four Fixing Options are available:-
2. MR05-T Range - Internal Regulators. Pushfit into Tap or Mixer seats. Produced in
three sizes - 12.5mm (BS1010), 12mm &
10mm, Flangeless models also available for
Taps with Low Lift washers.
3. MXF Standard Range - Screw on tail
models for Taps & Mixers. Fix onto the tails
before fitting the tap connectors. Available
in 3/8", 1/2", 3/4" and 1" BSP.
4. Compression Fitting Range - “In Line”
regulators housed in 15mm & 22mm CXC
Couplers & Isolating Valves.“ ”UK WFBS listed
by the Water Research Centre. Isolation valves
available for slotted screwdriver operation or
with coloured plastic handles. Now available
also in plastic bodied push-fit couplers &
valves.
3
3
Options For Showers
1. MXF “DW” Range - For fitting behind Fixed Shower Heads or onto Flexible Hoses for
Handshowers (preferably onto the inlet end when lightweight hoses are used).
2. Compression Fitting Range. “In Line” regulators as in Option 4 for Taps & Mixers.
4
Information by courtesy of
AQUAFLOW REGULATORS LTD
Haywood House, 40 New Road, Stourbridge, West Midlands DY8 1PA
TELEPHONE (01384) 442611 FAX: (01384) 442612
Page 25
APPENDIX A
1
APPENDIX
Manifolds
Two sets of manifolds are available as an
optional extra. Each set comprises a separate
hot and cold water manifold. Both are provided
with a 22mm inlet connection located centrally.
All outlet connections are 15mm compression.
The centre to centre dimension of each branch
is 55mm.
Manifold type: 1 - Stock Code MIP 050
(one bathroom, one en suite shower room, one cloakroom, one kitchen)
Flow regulator
(litres/minutes)
Terminal fitting
Hot water
manifold outlets
Quantity
Cold water
manifold outlets
Quantity
18
Bath tap
1
1
9
Hand basin
3
3
12
Kitchen sink
1
1
9
Toilet cistern
None
3
9
Shower
1
1
12
Washing machine
1
1
9
Dishwasher
None
1
Total
7
11
595mm
595mm
A (hot)
Hot water
manifold outlets
Quantity
Cold water
manifold outlets
Quantity
18
Bath tap
2
2
9
Hand basin
4
4
12
Kitchen sink
2
2
9
Toilet cistern
None
4
9
Shower
1
1
12
Washing machine
1
1
9
Dishwasher
None
1
Total
10
15
The manifolds are designed to be used with
plastic pipework and are supplied complete
with isolation valves and flow regulators on
each branch. They would normally be installed
in the same cupboard as the thermal storage
appliance (as shown below) but can be installed
in another cupboard close to the appliance if
required.
595mm
55mm
Page 26
85mm
90mm
18 l/min
9 l/min
12 l/min
90mm
9 l/mm
9 l/mm
9 l/min
9 l/min
85mm
9 l/mm
9 l/min
12 l/min
9 l/mm
12 l/min
9 l/mm
18 l/min
9 l/mm
18 l/min
12 l/min
9 l/min
9 l/min
inlet
9 l/min
9 l/min
C (hot)
9 l/min
12 l/min
12 l/min
18 l/min
APPENDIX B
595mm
D
(cold)
195 mm
Terminal fitting
The arrangement of each manifold is supplied as
shown. This provides the best balance of flows
but the flow regulators/duty of each branch can
be changed if required as long as a reasonable
balance is maintained. If it is necessary to
change or clean the flow regulator this can be
done without needing to drain the system by
closing the valve and removing the screwed
cover below the white plastic cover.
inlet
Flow regulator
(litres/minutes)
9 l/mm
B (cold)
165mm
Manifold type: 2- Stock Code MIP 060
(two bathrooms, one en suite shower room, one cloakroom, one kitchen,
one utility room)
12 l/mm
9 l/mm
9 l/mm
9 l/mm
9 l/mm
inlet
9 l/mm
9 l/mm
12 l/mm
18 l/mm
blank
12 l/mm
9 l/mm
9 l/mm
9 l/mm
55mm
9 l/mm
inlet
9 l/mm
12 l/mm
18 l/mm
blank
2 No 6mm
fixing holes
APPENDIX
The pressure loss through a flow regulator at the
designated flow rate is about 1.8 bar. Therefore
for the flow regulator to control the flow rate at
pre-set level, the inlet pressure must be greater
than 1.8 bar. If the inlet pressure is lower, the
flow rate will be correspondingly less than the
pre-set values.
The maximum equivalent pipe lengths from
the manifold to the terminal fittings can be
estimated from the above information and
the resistance characteristics of the pipes.
The examples presented below are for 15mm
copper pipe in table 1 and for plastic pipework
in table 2.
The size of the distribution pipes supplying
the manifold should be calculated using
the method set out in BS 6700. A typical
diagrammatic arrangement of a system using
Manifold Type 1 is shown below.
An optional location where
cupboard space is tight
The preferred solution where
space will allow
Table 1: Maximum equivalent pipe length in 15mm copper
Inlet pressure
(bar)
@ 9 l/m
@ 12 l/m
@ 18 l/m
2.0
25
10
5
2.5
75
30
15
3.0
150
60
30
This is only meant to show the principles
involved and the actual connection of fittings to
the manifold will need to suit the arrangements
shown on page 42.
Maximum equivalent length of pipe (m)
Note: If it is proposed to fit chemical water
treatment such as a water softener this should
be fitted in this location and the cold water
branch in the sink should be branched off the
cold water main prior to the treatment device
instead of the cold water manifold.
Table 2: Maximum equivalent pipe length in plastic pipe
Inlet pressure
(bar)
Maximum equivalent length of pipe (m)
@ 9 l/m
@ 12 l/m
@ 18 l/m
2.0
1.5
15mm : 10
15mm : 4.5
22mm : 40
2.5
3.0
15mm : 20
15mm : 9.0
22mm : 80.0
3.0
4.5
15mm : 30
15mm 13.5
22mm : 120
Pressure limiting valve NOT REQUIRED
at pressures below 5 bar unless any
system components have a lower
maximum working pressure
See Note 1
DW
WM
Scale
inhibitor
NOT REQUIRED
Any other isolating/control valves and backflow
protection devices should be provided as
n e ce s s a r y to co m p l y w i t h t h e Wate r
Regulations.
Airing
cupboard
Thermal
Store
Kitchen sink
Mains
supply
Kitchen
Double check
valve NOT REQUIRED
unless supply pipe
services more than
one dwelling
Check valve
NOT REQUIRED
unless chemical
water treatment
is fitted
Toilet Hand
Shower cistern basin
Bath Toilet Hand
cistern basin
Bathroom
Toilet Hand
cistern basin
Page 27
Cloak room
APPENDIX B
En-Suite
APPENDIX C
APPENDIX
Page 28
APPENDIX
MANUAL HANDLING OF APPLIANCE PRODUCTS
Description
Manual handling means any transporting or supporting of a load (including lifting,
putting down, pushing, pulling, carrying or moving) by hand or bodily force.
Scope
This assessment will cover the largest Appliance, namely ElectraMate, GulfStream,
BoilerMate, SysteMate, PulsaCoil, Accolade and Stainless Lite manufactured by
Gledhill.
The maximum weight of the largest product in each range is 98kg and the size is
595 x 595 x 2020 mm high.
Main Hazards
Vision may not be clear due to the size of the products.
Adopting an incorrect method of lifting may cause injury, attempting to lift these
products will require help from others. (Team lifts)
Control Measures
Manual lifting procedure
The lift, key factors in safe lifting are:
e. Taking the lead for team lifts- As
more than one person is required
for these products ensure that one
person is taking the lead. This may
be you so ensure that each person
that is helping is made aware of the
weight and of the items listed within
this assessment. Make sure you and
any others helping know the route
you intend to take that it is clear of
any obstructions. Never jerk the load
as this will add a little extra force and
can cause severe strain to the arms,
back and shoulders. If there are steps
involved decide on where you will
stop and take a rest period. Move
smoothly and in unison taking care to
look and listen to others helping with
the lift. Where possible use a sack
truck to move the product over long
flat distances, only lift the products
when necessary. If in doubt stop and
get more help. The unit handles and
packaging with the pallet have been
designed to ensure that two-four
people can assist when lifting up
stairs or over longer distance.
Individual capability
Balance
Position of back
Positioning of the arms and body
The hold
Taking the lead for team lifts
a.
Balance - Since balance depends essentially upon the position of the feet,
they should be apart about hip breadth with one foot advanced giving full
balance sideways and forward without tension. In taking up this position,
lifting is done by bending at the knees instead of the hips and the muscles
that are brought into use are those of the thigh and not the back.
b.
Position of back - Straight - not necessary vertical. The spine must be
kept rigid, this coupled with a bent knee position, allows the centre line of
gravity of the body to be over the weight so reducing strain.
c.
Positioning of arms and body - The further arms are away from the side,
the greater the strain on the shoulders, chest and back. Keep elbows close
to the body arms should be straight.
d.
The hold - Before lifting ensure you have a good hold. Two handles are
provided on Appliance products at the top rear side, these allow one or
two persons to have a purposely-designed hold at the top of the appliance
to ensure easy lifting at the top of the product. Each appliance is supplied
with a pallet, which has been attached to the unit via the packaging. The
pallet will also allow for one or two persons to get a good hold.
Page 29
Individual capability plays an important
part in handling these products. Persons
above average build and strength will
find it easier and should be in good
health. Persons below average build and
strength may require more rest periods
during the handling process.
Pregnant women should not carry out
this operation.
Persons who are not in good health
should seek medical advice prior to
commencing any lifting or manual
handling operation.
Residual risk
Following the guidelines given above will
reduce any risk to injury.
All persons carrying out this operation
must be fully trained and copies of the
specific risk assessment made available
for inspection and use in their training
process.
Further guidance on Manual Handling
can be obtained from the Health and
Safety Executive.
Manual Handling
Operations Regulations 1992.
APPENDIX D
a.
b.
c.
d.
e.
Page 30
TERMS AND CONDITIONS
Page 31
TERMS AND CONDITIONS
The code of practice for the installation,
commissioning & servicing of central heating systems
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