gledhill PulsaCoil PCS 120, PulsaCoil PCS 180, PulsaCoil PCS 150, PulsaCoil PCS 220 Design, Installation & Servicing Instructions
Design, Installation & Servicing Instructions
Models covered in this manual
PulsaCoil PCS 120
PulsaCoil PCS 150
PulsaCoil PCS 180
PulsaCoil PCS 220
PulsaCoil Stainless
Hot water cylinder utilising off-peak electric
Page 2
Section Page
DESIGN
Introduction 3
Technical Data 5
System Details 9
INSTALLATION
Site Requirements 13
Installation 14
Commissioning 18
SERVICING
Annual Service 19
Changing Components 19
Short Parts List 20
Fault Finding 21
ADDENDIX
Addendix A 24
Addendix B 25
Addendix C 26
Notes 27
Terms & Conditions 28
BENCHMARK
Commissioning Checklist 30
Service Record 31
ISSUE 2: JANUARY 2014
The Gledh ill Pul saCoi l range is a WBS
li ste d pro duc t an d co mpl ies with the
HWA Spec ifi cation for hot w ate r only
thermal storage products. The principle was
developed in conjunction with British Gas.
This product is manufactured under an ISO
9001:2008 Quality System audited by BSI.
Gledhill’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.
Benchmark places responsibilities on both manufacturers and installers. The purpose is to
ensure that customers are provided with the correct equipment for their needs, that it is
installed, commissioned and serviced in accordance with the manufacturers instructions
by competent persons and that it meets the requirements of the appropriate Building
Regulations. The Benchmark Checklist can be used to demonstrate compliance with
Building Regulations and should be provided to the customer for future reference.
Installers are required to carry out installation, commissioning and servicing work in
accordance with the Benchmark Code of Practice which is available from the Heating
and Hot Water Industry Council who manage and promote the Scheme. Visit www.
centralheating.co.uk for more information.
Page 3
DESIGN
INTRODUCTION
Any wate r distrib ution system/installation must comp ly 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
BS EN 806:1-5: BS EN 8558:2011
The Building Regulations (England & Wales) require that the installation of a heating
appliance be notied to the relevant Local Authority Building Control Department.
From 1st April 2005 this can be achieved via a Competent Person Self Certication
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.
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 Stainless is not covered by section G3 of the current Building Regulations
and is therefore only notiable to Building Control as part of the domestic water
installations.
The PulsaCoil Stainless 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 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 eectiveness 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 PulsaCoil range, Gledhill Building
Products Ltd reserve the right to modify the product without notice, and in these
circumstances this document, which is accurate at the time of printing, should be
disregarded. It will however be updated as soon as possible after the change has
occurred.
Page 4
The PulsaCoil Stainless shown schematically above is designed to provide an improved
method of supplying mains pressure hot water when used with a suitable o peak
electric supply/tari.
An important feature of the concept 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 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 tted in-line scale inhibitor should
be specied 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 specied at the time of order. However, this will need to
be 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 suer
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 dierently in SAP. This is because the
unvented and vented cylinders are tested at
65°C and the thermal store at 75°C.
Figure 1.1
1. Bottom (Off-Peak) immersion heater
(1H_1)
2. Top (On-Peak) immersion heater (IH_2)
3. PHE pump
4. Cold Feed
5. CW inlet
6. HW outlet
7. Drain
8. Return from PHE to store
9. Flow from store to PHE
10. Feed and expansion tank
1
7
2
3
9
5
8
6
4
10
DESIGN
INTRODUCTION
Page 5
Technical Specication PulsaCoil Stainless
Model PCS 120 PCS 150 PCS 180 PCS 220
Height (mm) 1075 1145 1275 1575
Width (mm) 530 560 560 560
Depth (mm) 595 630 630 630
Min cupboard height (mm) 1825 1895 2025 2325
Min cupboard width (mm) 570 600 600 600
Min cupboard depth (mm) 610 645 645 645
Weight (empty) (kg) 40 45 48 55
Weight (full) (kg) 154 192 213 265
Volume of water heated by on-peak heater (litres) 66 80 85 111
Model Selection Guide PulsaCoil Stainless
Dwelling Type
Bedroom 1-2 2-3 2-3 2-4
Bathroom 1 or 1 1 2
En-suite shower rooms 1 1 2 1
Standard Economy-7 tari PCS120 PCS150 PCS180 PCS220
Economy-10 tari PCS120 PCS120 PCS150 PCS180
Notes:-
1. Plastic top up cistern will be supplied separately.
2. The ow rates are based on a 35°C temperature rise and assume that recommended
pressures and adequate ow are available at the appliance. The actual ow rate
from the appliance is automatically regulated to a maximum of 15 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, and the temperature is not user adjustable.
Table 1.2
Table 1.1
DESIGN
TECHNICAL DATA
Page 6
Standard Equipment
The standard configuration of the PulsaCoil
Stainless is sh own oppo sit e. The Printed
Circuit Control Board (A.C.B.), mounted inside
the appliance, controls the production of the
domestic hot water. This is pre-wired to a
terminal strip where all electrical connections
terminate. The installer must t components to
control the operation of the immersion heaters.
It is supplied with the following factory tted
equipment:-
1. 3kW O-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. DHW temperature sensor
7. Incoming cold water sensor
8. Strainer and ow regulator
9. Screwed connection for a drain tap
10. Top up cistern complete with cold feed/
open vent pipework assembly is supplied
separately
11. Store sensor
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 Spares.
The immersion heaters are tted with control
th erm ost ats and over hea t th erm ost ats .
Immersion heaters without these components
must not be tted to the unit.
Optional Extra Equipment
• In line scale inhibitor for mains water
services with hardness levels between 200
and 300ppm (mg/l) tted but ready for
wiring by the installer to the suitable 230V
ac supply.
• Polyphosphate scale inhibitor for tting on
site by the installer.
• Ballvalve/overow connector fortop up
cistern.
Figure 1.2
7
8
4
6
5
11
3
10
2
1
9
DESIGN
TECHNICAL DATA
Page 7
Note: The 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 (tted with a
ballvalve) being in the same cupboard. If the
manual 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
PCS120 1075 530 595
PCS150 1145 560 630
PCS180 1275 560 630
PCS220 1575 560 630
Minimum Cupboard Dimensions
Model
HeightDWidthEDepth
F
PCS120 1825 570 610
PCS150 1895 600 645
PCS180 2025 600 645
PCS220 2325 600 645
B
E
C
PulsaCoil Stainless
Top up
cistern
Top up
cistern
300 *350A100
D
F
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.
DESIGN
TECHNICAL DATA
Page 8
Connection Details/Dimensions For Top Of Unit
Figure 1.4
95
148
156
103
Open Vent (22mm)
Cold Feed (22mm)
Connection Details/Dimensions For Bottom Of Unit
Mains Cold Water Inlet (15mm/22mm)
Hot Water Outlet (18mm/22mm)
70
35
546
558
Plan Of Appliance Connections
The PulsaCoil Stainless 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 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 / overow pipe (if the optional
extra ball valve and overow connector have
been specified. If a warning/overflow pipe
is NOT provided the F&E Cistern should be
fill ed from a temp orary hose co nnecti on
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 lled.
Note: All dimensions are shown in mm and
are to the centre line of the pipework.
DESIGN
TECHNICAL DATA
Page 9
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 Stainless 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. 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 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 ow rates are
poor please contact our technical helpline for details of an eective solution.
Note : Each Pulsacoil Stainless is tted with a strainer and ow regulator on the cold
mains supply connection. If the supply pressure is less than 2 bar or if all taps are
provided with ow regulators the ow 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 PulsaCoil Stainless.
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 tted in-line scale inhibitor should
be specied at the time of order for hardness levels between 200 and 300 ppm (mg/l).
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
SV
a a a a
Bath
H C
Hand basin
H C
WC - fitted
with BS1212
ballvalve
C
Figure 1.5
Typical hot and cold water distribution
PULSACOIL
STAINLESS
Check valve
NOT REQUIRED unless
chemical water
treatment unit is fitted
a
Top up cistern
DESIGN
TECHNICAL DATA
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 tted by
the installer at a suitable point in the cold water
supply to the appliance.
The hot water flow rate from the PulsaCoil
Stainless 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 EN 806:1-5: BS EN 8558:2011.
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 EN 806:1-5:
BS EN 8558:2011. This could be up to 60ltr/min
in some properties.
Note: The diagram below shows the top up
cistern with ballvalve and warning/overow
pipe which can be supplied as an optional extra
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.
The cistern must not be tted more than 10
metres above the PulsaCoil Stainless appliance
itself.
Page 10
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 EN 806:1-5: BS EN 8558:2011. 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 sucient for a small 1
bathroom dwelling (depending upon the 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 Stainless
should be run in 22mm pipe. The cold main and hot draw-o should also be run
in 22mm as far as the branch to the bath tap.
3. The 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 tting appropriate 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 ow regulators are provided in
Appendix A.
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 installation section of this manual.
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, 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 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
Stainless
or be the rst draw-o 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.
Hot and Cold Water System
If the length of the hot water draw o 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: 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.
DESIGN
TECHNICAL DATA
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