gledhill PulsaCoil 145, PulsaCoil 185, PulsaCoil 215, PulsaCoil 235 Design, Installation & Servicing Instructions

Design, Installation

& Servicing

Instructions

Model Numbers

PulsaCoil 145 PulsaCoil 185 PulsaCoil 215 PulsaCoil 235

All models comply with the water heater manufacturers

speciﬁ cation for thermal stores

A mains pressure hot water supply

system incorporating an off peak

electric thermal store

ISSUE 9: 06-08

Page 2

Section Page

DESIGN

Introduction 3 Technical Data 5 System Details 9

INSTALLATION

Site Requirements 13 Installation 14 Commissioning 19

SERVICING

Annual Service 20 Changing Components 20 Short Parts List 21 Fault Finding 22

ADDENDIX

Addendix A 25 Addendix B 26 Addendix C 28 Addendix D 29

Terms & Conditions 30

ISSUE 9: 06-08

The code of practice for the installation,

commissioning & servicing of central heating systems

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 ﬁ 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.

Building Regulations and Benchmark Commissioning

The Building Regulations (England & Wales) r equir e that the installation of a heating appliance be notiﬁ ed to the relevant Local Authority Building Control Department. From 1st April 2005 this can be achieved via a Competent Person Self Cer tiﬁ cation 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 Certiﬁ cation 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 certiﬁ cation 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 produc ts 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 efﬁ ciency.

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 3

INTRODUCTION

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 notiﬁ able 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 experienc e 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 speciﬁ cation 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 speciﬁ cation or for the effectiveness of an installation containing one of our products unless we have been speciﬁ cally 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 PulsaCoil range , Gledhill Water Storage Ltd reserve the right to modify the product without notice, and in these circumstances this document, which is accur ate at the time of printing, should be disregarded. It will however be updated as soon as possible after the change has occurred.

Page 4

DESIGN

INTRODUCTION

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 ﬂ 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 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”.

To comply with this requirement the hardness of the mains water should be checked by the installer and if necessary the optional factory ﬁ tted in-line scale inhibitor should be speciﬁ ed 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 speciﬁ ed at the time of order. However, this will need to be ﬁ tted by the installer at a suitable point in the cold water supply to the appliance.

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 reﬂ ect the different ways that the hot water and heating operates.

Figure 1.1

Schematic Hydraulic Arrangement

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

Cistern can be provided

with a ballvalve and overflow connector as an optional extra if required.

Appliance case

Top up cistern

7, S4

6, S3

PULSACOIL

A-CLASS

4, S6

5, S5

3, S1/S2

Page 5

Technical Speciﬁ cation 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

Model Selection Guide PulsaCoil A-Class

Dwelling Type Bedroom 1-2 2-3 2-3 2-4 Bathroom 1 or 1 1 2 En-suite shower rooms 1121 Standard Economy-7 tariff PCA145 PCA185 PCA215 PCA235 10hr Heatwise tariff PCA145 PCA145 PCA185 PCA215

Notes:-

1. Plastic top up cistern will be supplied separately.

2. The ﬂ ow rates are based on a 35°C temperature rise and assume that recommended pressures and adequate ﬂ ow are available at the appliance. The actual ﬂ ow 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 ﬂ ow rate of 18 litres/min recommended by BS

6700. The temperature is not user adjustable.

Table 1.2

Table 1.1

TECHNICAL DATA

DESIGN

Page 6

Standard Equipment

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 ﬁ tted equipment:-

1. 3kW Off-Peak immersion heater

2. 3kW On-Peak boost immersion heater

3. Printed Circuit Board

4. Plate heat exchanger

5. Domestic hot water primary (plate heat exchanger) pump

6. Isolating terminal connectors for dry ﬁ re protection

7. DHW temperature sensor

8. Incoming cold water sensor

9. Strainer and ﬂ ow regulator

10. Screwed connection for a drain tap

11. Top up cistern complete with cold feed/ open vent pipework assembly is supplied separately

12. Overheat thermostat

13. Middle store control sensor

14. Bottom store control sensor

15. Operation/warning light

16. Boost/reset button

17. On/Off switch

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.

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/overﬂ ow connector for top up cistern.

Figure 1.2

15 16 17

DESIGN

TECHNICAL DATA

Page 7

Note: T he Appliance dimensions above 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). Any extra space required for shelving etc in the case of airing cupboards etc must be added.

Note: The above dimensions are based on the Appliance and the Top up cistern (ﬁ tted with a ballvalve) being in the same cupboard. If the

manual ﬁ ll method is chosen the heights can be reduced by 125mm.

If pipework needs to rise vertically adjacent to the appliance the width/depth will need increasing to accommodate this.

Appliance Dimensions

Model

HeightAWidthBDepth

C PCA145 1042 530 595 PCA185 1142 530 595 PCA215 1300 530 595 PCA235 1440 550 595

Minimum Cupboard Dimensions

Model

HeightDWidthEDepth

F PCA145 1800 550 600 PCA185 1900 550 600 PCA215 2050 550 600 PCA235 2200 570 600

PulsaCoil A-Class

Top up

cistern

Top up

cistern

300 *350A10 0

Maintenance

access

Figure 1.3

280

420

*Min maintenance access to comply with the Water Regulations (ballvalve model only)

The minimum

clear opening in

front of the

appliance to be

at least the

same depth as

the appliance.

The cupboard door opening will need to take into account the various sizes of appliances.

TECHNICAL DATA

DESIGN

Page 8

Connection Details/Dimensions For Top Of Unit

Figure 1.4

595

530

120

385 - Cold Feed/Expansion

323 - Open Vent

Connection Details/Dimensions For Bottom Of Unit

595

530

550

455 - Mains Cold Water Inlet

490 - Hot Water Outlet

Plan Of Appliance Connections

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 ﬁ t 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 / overﬂ ow pipe (if the optional extra ball valve and overﬂ ow 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 ﬁ lled.

Note: All dimensions are shown in mm and are to the centre line of the pipework.

DESIGN

TECHNICAL DATA

Page 9

SYSTEM DETAILS

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 ﬁ tted 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 ﬂ ow rates are poor please contact our technical helpline for details of an effective solution.

Note : Each Pulsacoil A-Class is ﬁ tted with a strainer and ﬂ 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 ﬂ ow regulators the ﬂ ow regulator on the cold inlet should be removed.

No check valve or similar device should be ﬁ tted on the cold water supply branch to the PulsaCoil A-Class.

To comply with this requir ement the hardness of the mains water should be checked by the installer and if necessary the optional factory ﬁ tted in-line scale inhibitor should be speciﬁ ed 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 ﬁ tted by the installer at a suitable point in the cold water supply to the appliance.

The hot water ﬂ ow 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 deﬁ ned in BS 6700.

If a water meter is ﬁ 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 60ltr/min in some properties.

Note: The diagram below shows the top up cistern with ballvalve and warning/overﬂ ow pipe which can be supplied as an optional extra if required. However, the standard preferred arrangement is for the cistern to be manually ﬁ lled from a temporary hose connec tion ﬁ tted with a double check valve.

The cistern must not be ﬁ tted more than 10 metres above the PulsaCoil A-Class appliance itself.

Warning/ overflow

pipe

MCWS

Safety/open vent

Shower

Expansion/ cold feed

Second

dwelling

Pressure limiting valve

NOT REQUIRED at

pressures below 5 bar

unless any components

have a lower

maximum working

pressure

Double check valve

NOT REQUIRED unless

pipe supplies more

than one dwelling

‘a’ - flow regulator recommended for better balance of hot and cold water supplies

MCWS supply

pipe

Sink

H C

a a

a a a a

Bath

H C

Hand basin

H C

WC - fitted

with BS1212

ballvalve

Figure 1.5

Typical hot and cold water distribution

PULSACOIL

A-CLASS

Check valve

NOT REQUIRED unless

chemical water

treatment unit is fitted

Top up cistern

Page 10

DESIGN

TECHNICAL DATA

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 dw elling should be sized in accordance with BS 6700. This is particularly important in a large propert y with more than one bathroom.

However , the following rule of thumb guide lines should be adequate f or most smaller property types as long as water pressures are within the recommended range.

1. A 15mm copper or equivalent external service may be sufﬁ cient for a small 1 bathroom dwelling (depending upon the ﬂ ow 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 ﬁ nal 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 ﬁ tting appropriate ﬂ ow 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 ﬂ ow regulators are provided in Appendix A.

Note: If manifolds (available as an optional extra) are being used suitable ﬂ ow regulators are automatically provided in the manifold and do not need to be provided at each outlet. See Appendix B for further details.

All the recommendations with regard to pipework systems in this manual are generally based on the use of BS/EN Standard copper pipework and ﬁ 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 ﬁ t connections when using the optional ﬂ exible hose kits - see installation section of this manual.

It is also essential that if an alternative pipework material/system is chosen the manufacturer conﬁ rms that the design criteria of the new system is at least equivalent to the use of BS/EN Standard copper pipework and ﬁ 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, 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 rec ommend 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 ﬂ ow/pressure outlets please discuss with the Gledhill technical department.

The hot water supply to a shower-mixing valve should be fed wherever practical directly from the PulsaCoil

A-CLASS

or be the ﬁ rst 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 ﬁ 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 ﬂ ushing 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 c onsider using trace heating to the hot water pipework such as the Raychem HWAT system. Please consult Gledhill Technical Department for further details.

Note: A conventional pumped secondary circulation system is NOT suitable for use with this appliance.

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.

+ 22 hidden pages

gledhill PulsaCoil 145, PulsaCoil 185, PulsaCoil 215, PulsaCoil 235 Design, Installation & Servicing Instructions

Specifications and Main Features

Frequently Asked Questions

User Manual