DESIGN, INSTALLATION
AND SERVICING INSTRUCTIONS
THE GAS SAFETY (INSTALLATION AND USE)
REGULATIONS
In your own interest and that of safety, it is
law that all gas appliances are installed by
competent persons and in accordance with the
above regulations.
Gledhill High Efficiency
Condensing Boiler
Models: GB10 GB15 GB20 GB25 GB30
ISSUE 5: 06-08
Page 2
TM
benchmark
The code of practice for the installation,
commissioning & servicing of central heating systems
GENERAL
This high efficiency wall mounted condensing boiler is designed to provide
central heating from a fully pumped open vented or sealed water system when
coupled to a thermal store or an indirect cylinder.
The central heating water temperature can be adjusted by the installer to suit
special applications.
Once the controls are set, the boiler operates automatically and the boiler
controller automatically activates the frost protection program to prevent the
boiler from freezing.
This boiler is for use with Natural Gas (G20) only at 20mbar inlet pressure and
is for use in GB &IE only.
Appliance category: I2H
Appliance types: C13, C73, C33
These instructions cover the following boiler models and only apply to the
appliances sold and installed in Great Britain (GB) and Ireland (IE).
These appliances have been certified for safety and therefore it is important
these instructions must be followed. Both the appliance and the installation
specifications must not be modified unless recommended and approved by
Gledhill Limited in writing. Any alteration not approved by Gledhill Ltd., could
invalidate the certification, boiler warranty and may also infringe the current
issue of statutory requirements.
Gledhill wall mounted condensing boiler models
Model Reference SEDBUK Rating Gas Council Number
GB10 90.0 % - Band ‘A’ 41-317--01
GB15 90.3 % - Band ‘A’ 41-317-02
GB20
90.4 % - Band ‘A’ 41-317-03
GB25
90.4 % - Band ‘A’ 41-317-04
GB30 90.3 % - Band ‘A’ 41-317-05
The Gas Safety (Installation and use) Regulations 1998
“In your own interest, and that of safety, it is law that all gas appliances are
installed by competent persons, in accordance with the above regulations.
Failure to install appliances correctly could lead to prosecution.”
IMPORTANT NOTES
ISSUE 5: 06-08
Control of Substances Harmful to Health
When working with insulation materials, avoid
inhalation as it may be harmful to health. Avoid
contact with skin, eyes, nose and throat. Use disposable
protection. Dampen the material and ensure that the
area is well ventilated.
INSTRUCTIONS
The instructions are an integral part of the appliance
and therefore read these Instructions before installing
or lighting the appliance. Also to comply with the
current issue of the Gas Safety (Installation and Use),
these instructions must be handed to the user on
completion of the installation,
It is a requirement of the Building Regulations that
an approved commissioning checklist is completed
by the installer. The approved Benchmark checklist is
included on page 35.
Gledhill Water Storage Limited
Sycamore Estate
Squires Gate
BLACKPOOL
Lancs
FY4 3RL
Page 3
CONDENSING BOILER
CONTENTS Page
1. IMPORTANT INFORMATION
4
1.1 Gas Testing and Certification and CE Mark
1.2 Handling and Storing Appliance
1.3 System Installation
1.4 Warnings
1.5 Equipment Selection
1.6 Electricity Supply Failure
1.7 Protection Agenst Freezing
1.8 Boiler Installation in a Compartment or Cupboard
1.9 Boiler Casing
1.10 Condensate Drain
1.11 Pluming from Flue Terminal
1.12 Cleaning
1.13 Maintenance and Servicing
1.14 Replacement Parts
1.15 Continuous Improvements
4
4
4
4
4
4
4
5
5
5
5
5
5
5
5
2. OPERATING THE BOILER 6
2.1 Heating System and Boiler
2.2 User Controls
2.3 To Turn the Boiler Off
6
6
7
3. INSTALLATION, DESIGN & PLANNING INFORMATION 8
3.1 Important Notice
3.2 Technical Data of Boilers
3.3 Gas Supply
3.4 Electricity Supply
3.5 Central Heating and Water System
3.6 System/Boiler Pump
3.7 Flow rate
3.8 Bypass Valve
3.9 Domestic Hot Water Storage Cylinder
3.10 Boiler Location and Ventilation
3.11 Flue location and Ventilation
3.12 Heating System Controls
3.13 Condensate Drain
3.14 Water Treatment
8
9
11
11
11
16
16
16
16
16
17
18
18
18
4. BOILER INSTALLATION 19
4.1 Installation Preparation
4.2 Hanging Bracket Fixing
4.3 Boiler Fixing
19
19
19
5. ELECTRICAL WIRING 21
5.1 General
5.2 External Controls
21
21
CONTENTS Page
6. COMMISSIONING 24
6.1 General
6.2 Inital Lighting
6.3 Testing - Gas
6.4 Testing - Heating System
6.5 Testing - User Controls
6.6 Frost Protection
6.7 Instruct the User
24
24
24
24
24
24
24
7. SERVICING 25
7.1 General
7.2 Spart & Flame Sensing Electrodes
7.3 Burner
7.4 Combustion Chamber and Heat Exchanger
7.5 Condensate Drain
7.6 Inner Casing Panel Seal Check
7.7 Combustion Check
25
25
25
25
25
25
25
8. FAULT FINDING 26
8.1 Controller Display
8.2 Error / Fault Codes
8.3 Serial Software
8.4 Internal Wiring Diagram
26
28
29
32
9. REPLACEMENT OF PARTS 33
9.1 General
9.2 Spark & Flame Sensing Electrodes
9.3 Ignition & Flame Sensing Leads
9.4 Fan
9.5 Burner
9.6 Temperature Sensors
9.7 Heat Exchanger
9.8 Insulation
9.9 Overheat Thermostat
9.10 Fuses
9.11 On-Off Switch
9.12 Gas Valve
9.13 Controller PCB
34
34
34
34
34
34
34
34
34
34
34
10. SPARE PARTS
38
11. GAS BOILER COMMISSIONING CHECKLIST
39
11. TERMS & CONDITIONS OF TRADING
41
CONTENTS
Page 4
1.1. GAS TESTING AND CERTIFICATION AND CE MARK
These boilers have been tested and certified for safety and performance. It
is important that no alteration is made to the boiler unless it is approved in
writing by Gledhill Ltd.
The boiler meets the requirements of Statutory Instrument No 3083 i.e.
‘The Boiler (Efficiency) Regulations’ and therefore it is deemed to meet the
requirements of Directive 92/42/EEC. The product has been certified by the
Notified body Advantica 0087 and the production is certified by the notification
body BSI 0086.
The CE mark on this appliance shows compliance with:
(a) Directive 90/396/EEC on the approximation of laws relating to appliances
burning gaseous fuels.
(b) Directive 73/23/EEC on the harmonisation of laws of the Member States
relating to electrical equipment designed for use within certain voltage
limits.
(c) Directive 89/336/EEC on the approximation of the laws of Member States
relating to electromagnetic compatibility.
1.2. HANDLING AND STORING THE APPLIANCE
This appliance should be handled carefully to avoid damage and any manual
handling/lifting operations will need to comply with the requirements of the
Manual Handling Operations Regulations issued by the H.S.E.
During the appliance installation it will be necessary to employ caution
and assistance whilst lifting as the appliance or component exceeds the
recommended weight for a one man lift.
Take care to avoid trip hazards, slippery or wet surfaces. In certain situations it
may be necessary to use mechanical handling aids.
If the unit needs to be stored prior to installation it should be stored upright
in a dry environment and on a level base.
1.3. SYSTEM INSTALLATION
Any installation must be in accordance with the relevant requirements of the
current issue of Gas Safety (Installation and Use) Regulations, Local Building
Regulations, Local Water Company Bylaws and Health & Safety Document No.
635 – The Electricity at Work Regulations 1989. The detailed recommendations
are contained in the current issue of the following British Standards and Codes
of Practices: -
BS 5440 Pts. 1 & 2; BS 5449; BS 5546; BS 7074 Part 1; BS 6700; BS 6798; BS 6891,
BS 7593, IGE/UP/7/1998
1.4. WARNINGS
(a) Gas Leak or Fault
If a gas leak or fault exists or is suspected, turn the boiler mains electricity supply
off and turn off the gas supply at the meter. Consult your local gas company
or your local installation/servicing company.
IMPORTANT INFORMATION
(b) Clearances
If fixtures are positioned close to the boiler, space must
be left as shown in figure 3.10.2. Enough space must
also be left in front of the boiler to allow for servicing.
(c) Sheet Metal Parts
This boiler contains metal parts (case & components)
and therefore care should be taken when handling and
cleaning, with particular regard to edges.
(d) Sealed Components
This boiler uses fully premix burner with air/gas ratio
controller therefore the burner input i.e. CO and CO2
settings and the burner off set pressure are factory set
and sealed and require no onsite adjustments during
installation or routine servicing.
Under no circumstances the user should interfere
with the sealed components as this could result in
a potentially dangerous situations arising. If sealed
components in the appliance are replaced and/or re-
commissioned in the field then these must be done
strictly in accordance with manufacturer’s instructions
and these components must be re-sealed.
(e) Bench Mark Log Book
As part of the industry wide ‘Benchmark’ initiative
all Gledhill appliances now include a Benchmark
Installation, Commissioning and Service Record
Logbook. Please read this carefully and complete all
sections relevant to this appliance. Failure to do so
may affect warranty.
1.5. EQUIPMENT SELECTION
This information is provided to assist generally in the
selection of equipment. Responsibility for selection and
specification of our equipment must, however, remain
that of our customers and any expert or consultants
concerned with the installation(s). Therefore please
note that: -
(a) We do not therefore accept any responsibility for
matters of design selection or specification for the
effectiveness of an installation containing one of our
products.
(b) All goods are sold subject to our Conditions of Sale,
which are set out in the Appendix to this document.
1.6. ELECTRICITY SUPPLY FAILURE
(a) This boiler must be earthed and the boiler will not
work without an electricity supply.
(b) Reset any external controls to resume normal
operation of the central heating.
Page 5
CONDENSING BOILER
(c) Normal operation of the boiler should resume when the electrical supply is
restored. If the boiler does not resume normal operation turn the mains switch
off and on. If the boiler does not resume normal operation after this, the overheat
thermostat may have operated. The overheat thermostat would only operate
under abnormal conditions and, under these circumstances it would be advisable
to consult your installation/servicing company.
1.7. PROTECTION AGAINST FREEZING
(a) The boiler has built in frost protection programme as long as the electricity and
gas are left switched on. The boiler controller operates the burner and the system
pump when the temperature inside the boiler falls below 5ºC.
(b) Any other exposed areas of the heating and hot water system should be
protected by a separate frost thermostat.
(c) If the mains electricity and gas supplies to the boiler system are to be turned
off for any long periods during severe weather, it is recommended that the whole
system including the boiler should be drained to avoid risk of freezing. In this case
ensure that the immersion heater in the cylinder if fitted is switched off.
(d) If you have a sealed heating system, contact your installation/service company as
draining, refilling and pressurising MUST be carried out by a competent person.
(e) As a safety feature, the boiler will stop working if the condensate drain becomes
blocked. During freezing conditions this may be due to the forming of ice in the
condensate drain external to the house. Release ice blockage by use of warm
cloths on the pipe. Contact your installation/service company if the fault persists.
1.8. BOILER INSTALLATION IN A COMPARTMENT OR CUPBOARD
If the boiler is fitted into a compartment or a cupboard, it does not require ventilation
openings. However, do not use the compartment or cupboard for storage.
1.9. BOILER CASING
Do not remove or adjust the casing in any way, as the incorrect fitting may result
in incorrect operation or failure to operate at all.
1.10. CONDENSATE DRAIN
The condensate drain must not be modified or blocked (See section 3.13)
1.11. PLUMING FROM FLUE TERMINAL
This is a high efficiency-condensing boiler and hence flue gas temperature will be
low. Therefore like all condensing boilers this appliance will produce a plume of
condensation in cool weather. It is normal and not a fault condition, but this should
be taken into account when positioning the boiler.
1.12. CLEANING
This boiler contains metal parts and therefore care should be taken when handling
and cleaning, with particular regard to edges.
IMPORTANT INFORMATION
The boiler casing can be cleaned using a mild liquid
detergent with a damp cloth and then a dry cloth
to polish. Do not use any form of abrasive or solvent
cleaner as you may damage the finish.
1.13. MAINTENANCE AND SERVICING
This appliance must be serviced and installed by a
competent person e.g. CORGI Registered installer.
All CORGI registered installers carry a CORGI ID Card
and have a registration number. You can call CORGI
direct on 01256 372300.
For the continued efficient and safe operation of
the boiler, it is recommended that it is checked
and serviced at regular intervals. The frequency of
service will depend upon the installation condition
and usage, but in general, once a year should be
enough.
If this boiler is installed in a rented property, there
is a duty of care imposed on the owner of the
property by the current issue of the Gas Safety
(Installation and Use) regulations, Section 35.
The installation / service engineer should complete
the ‘Benchmark’ logbook on completion of
commissioning and service work.
1.14. REPLACEMENT PARTS
When replacing spare parts on this appliance,
remember to use only spare parts that you
can be assured to conform to the safety and
performance specification that we require. Do not
use reconditioned or copy parts that have not been
clearly authorised by Gledhill Ltd.
Free of charge replacement for any faulty
components are available from Gledhill Ltd during
the in-warranty period (normally 12 months).
After this the spares can be obtained direct from
Gledhill Ltd using the ‘Speed Spares’ service. Help
and advice is also available from our Technical Help
Line on 08449 310000.
Please quote the name and model of the appliance
when requesting for help or ordering spares. This
information will be on the front of the appliance
next to the main switch.
1.15. CONTINUOUS IMPROVEMENTS
In the interest of continuously improving the
Gledhill Boiler range, Gledhill Water Storage Ltd
reserves the right to modify the product without
notice and in these circumstances this booklet,
which is accurate at the time of printing, should
be disregarded.
Page 6
2.1. HEATING SYSTEM AND BOILER
(a) Sealed Systems
A sealed heating system must be filled and pressurised by a competent person.
Only light the boiler when you are sure that the system and the boiler have
been filled and pressurised.
The pressure should read at least 0.5bar, anything less than this figure could
indicate a leak and you MUST contact your installation / servicing company.
(b) All Systems
Check that the electrical supply to the boiler is ON at the external system
isolator. Set any remote controls as required.
This is a fan flued appliance and therefore the fan operation may be heard. The
boiler flow temperature is factory set at 77°C and is not user adjustable. (Note:
The boiler flow temperature can be adjusted between 55°C and 85°C by the
installer for special applications)
OPERATING THE BOILER
S3
S2
Set/Reset
-
+
S1
Mains/Reset
Switch
$
$
0
I
Diagram 2.1
a1
a2
S3
S2
Set/Reset
-
+
S1
Mains/Reset
Switch
$
$
0
I
Diagram 2.1
a1
a2
2.2. USER CONTROLS
The appliance control panel is shown in diagram 2.1. The appliance on-off
switch should be left in the ON position (indicated by flame symbol) for normal
operation otherwise the built in boiler frost protection will not function.
The two-digit display indicates the status of the boiler and the push buttons
are used for setting and resetting the controller as shown in diagram 2.2.
(a) Central heating and hot water
- Switch the boiler on-off switch to position ‘ON’ position indicated by a ‘flame’
symbol and the dot D1 will begin to flash to indicate that the boiler controller
is active.
- Set the remote user controls e.g. programmer and room thermostat so that
hot water heating and/or central heating demands are active.
- When the boiler senses the heating demand, indicated by horizontal bar ‘a2’,
the boiler switches on the boiler pump (indicated by bar ‘a1’) and starts the
boiler firing sequence.
- When the boiler has lit, the dot D1 will stop flashing and will be on
constantly.
- If the boiler fails to ignite, the dot D1 will switch off and
dot D2 will be flashing or be on constantly (depending
upon the error type) and reset will be required.
- When the demand for boiler firing stops i.e. heat is
not required for space heating or hot water, the boiler
will stop firing and this will be indicated by flashing dot
D1 and bar a2 will switch off. After a period of about
3 minutes the boiler pump will switch off indicated
by bar a1.
(b) To Reset Boiler
Press reset button S1. If the dot D1 starts to flash and
the dot D2 switches off, the boiler has reset. If the fault
persists contact your installer/service provider.
2.3. TO TURN THE BOILER OFF
Turn the mains /reset switch to the off position
(indicated by disc). Turn the gas supply off at the gas
service cock if the boiler is to be out of use for some
time.
Page 7
CONDENSING BOILER
OPERATING THE BOILER
$IAGRAM"OILERDISPLAYINDICATION
$$
$$
$$
$$
$$ $$
FLASHING
FLASHING
/NFLASHING
FLASHING
/.
FLASHING
FLASHING
v#ONTROLLERONSTANDBY
v"OILEROFF
v&ROSTPROTECTIONPROGRAM&ON
v"OILERPUMPON
v"OILERBLOCKINGLOCKOUTERROR
v2ESETREQUIRED
v&ROSTPROTECTIONPROGRAM&ON
v"OILERPUMPON
v"OILERBURNERISON
v"OILERINIGNITIONSEQUENCE
BOILERCONTROLTHERMOSTATSATISFIED
v"OILERHEATDEMANDPRESENT
v"OILERPUMPON
v"OILERHASLIT
v"OILERHEATDEMANDPRESENT
v"OILERPUMPON
v"OILEROFF
v(EATDEMANDNOTPRESENT
v"OILERPUMPOVERRUNON
/N
Page 8
3.1. IMPORTANT NOTICE
(a) The boiler is supplied in one pack. The flue and fixing jig are supplied
separately.
(b) This boiler is for use on G20 natural gas only. The boiler is certified to the
current issue of EN483 for performance and safety. It is important that no
alteration is made to the boiler, without written permission of Gledhill Ltd.
(c) Where no British Standards exist, materials and equipment should be fit for
their purpose and of suitable quality and workmanship.
(d) The installation of this boiler must be carried out by a competent person e.g.
CORGI Registered installer, must comply with the relevant requirements of : -
Manufacturer’s instructions supplied
• The Gas Safety (Installation and use) Regulations,
• The Building Regulations and local Water Company Bylaws. The Health and
Safety at Work Act, Control of Substances Hazardous to Health, The Electricity
at Work Regulations and any other applicable local regulations.
• The detailed recommendations are contained in the current issue of BS
5440 Pts. 1 & 2; BS 5449; BS 5546; BS 7074 Part 1; BS 6700; BS 6798; BS 6891, BS
7593, IGE/UP/7/1998
(e) When installing the boiler, care should be taken to avoid any possibility of
personal injury when handling sheet metal parts.
(f) Refer to Manual Handling Operations, 1992 regulations.
INSTALLATION DESIGN AND PLANNING INFORMATION
CONDENSATE
DRAIN
INSIDE WALL
FIXING FACE
BOILER
Centre Line
GAS
CONDENSATE
DRAIN
Diagram 3.1 Boiler Models GB30, GB25, GB20
Clearances From Fixed surfaces
Top
–
From ‘A’
:220mm
Bottom
–
From ‘B’
:200mm
Sides
–
From ‘C’
:20mm
Front
–
From ‘D’
:600mm
A
B
C
D
C
GAS
CONDENSATE
DRAIN
INSIDE WALL
FIXING FACE
F+R
FLOW
& RETURN
BOILER
Centre Line
GAS
CONDENSATE
DRAIN
Clearances From Fixed surfaces
Top
–
From ‘A’
:220mm
Bottom
–
From ‘B’
Sides
–
From ‘C’
:20mm
Front
–
From ‘D’
:600mm
A
B
C
D
C
130mm
85mm
150mm
140mm
580mm
100mm
100mm
150mm
70 mm
50mm
Cut flue terminal at
plain end to length
required allowing
40mm extra for
socket elbow joint
730mm
360mm
MM
Page 9
CONDENSING BOILER
INSTALLATION DESIGN AND PLANNING INFORMATION
3.2. TECHNICAL DATA OF BOILERS
The main dimensions and the clearances required for the boilers are shown in
diagram 3.1 for models GB30, GB25 and GB20 and diagram 3.2 for models GB15
and GB10. The technical data of the boilers is shown in tables 3.1 and 3.2. The boiler
data badge is positioned on the inner door.
The Seasonal Efficiency Domestic Boilers UK (SEDBUK) of Gledhill Boilers (all models)
is Class ‘A’. The values used in the UK Government’s Standard Assessment Procedure
(SAP) for energy rating of dwellings. The test data from which it has been calculated
has been certified by Advantica.
CONDENSATE
DRAIN
INSIDE WALL
FIXING FACE
BOILER
Centre Line
GAS
CONDENSATE
DRAIN
Clearances From Fixed surfaces
Top
–
From ‘A’
:220mm
Bottom
–
From ‘B’
:200mm
Sides
–
From ‘C’
:20mm
Front
–
From ‘D’
:600mm
A
B
C
D
C
GAS
CONDENSATE
DRAIN
INSIDE WALL
FIXING FACE
F+R
FLOW
& RETURN
BOILER
Centre Line
GAS
CONDENSATE
DRAIN
Clearances From Fixed surfaces
Top
–
From ‘A’
:220mm
Bottom
–
From ‘B’
Sides
–
From ‘C’
:20mm
Front
–
From ‘D’
:600mm
A
B
C
D
C
140mm
85mm
150mm
140mm
580mm
100mm
100mm
210mm
70 mm
50mm
Cut flue terminal at
plain end to length
required allowing
40mm extra for
socket elbow joint
730mm
300mm
MM
$IAGRAM"OILER-ODELS'"AND'"
Page 10
Table 3.1. Connection, Electrical and Weight data of the boiler
Boiler Model
GB30, GB25, GB20
GB15, GB10
Overall dimensions including
flue spigot
Height (mm) 580 580
Width (mm) 380 380
Depth (mm) 360 300
Clear space required for
installation
Height (mm) 1000 1000
Width (mm) 420 420
Depth (mm) 500 440
Weight (kg) 29.5 24.5
Water content (litres) 1.5 1
Working pressure
(m wg / (bar))
Minimum 1.0/(0.1) 1.0/(0.1)
Maximum 30.0/(3.0) 30.0/(3.0)
Connections
Gas Rc1/2, (1/2in BSP) Rc1/2, (1/2in BSP)
Water 22mm copper 22mm copper
Condensate Drain 22mm plastic pipe 22mm plastic pipe
Electrical data
Electricity supply 230V, ~50Hz Fused at 3A 230V, ~50Hz Fused at 3A
Electrical rating 60W @230V ac 60W @230V ac
Internal fuse rate Main PCB 3.15AT Main PCB 3.15AT
Table 3.2. Thermal, combustion and gas data
Rating
Boiler Model
GB30 GB25 GB20 GB15 GB10
Gross heat input (kW)
Maximum 34.2 28.3 22.6 17.0 11.4
Minimum 10.0 8.5 6.8 5.1 4.6
Net heat input, Q (kW)
Maximum 30.8 25.5 20.4 15.3 10.3
Minimum 9.0 7.7 6.1 4.6 4.1
Heat output, P Non condensing (kW) Maximum 30.2 25.0 20.0 15.0 10.0
Heat output
Condensing mode (kW)
Maximum 32.0 27.2 22.0 16.4 10.84
Minimum 9.8 8.4 6.6 4.9 4.4
Burner CO2 (%) at maximum rate
Case off 9.0 - 9.6 9.0 - 9.6 9.0 - 9.6 8.8 - 9.4 9.0 - 9.6
Case on 9.2 - 9.8 9.2 - 9.8 9.2 - 9.8 9.0 - 9.6 9.2 - 9.8
Approximate Gas rate (m3/h)
- After 10min from cold
Maximum 3.3 2.7 2.2 1.6 1.1
Off-set pressure at minimum rating (Pa) - 8.0 -10.0 -10.0 -8.0 -6.0
Minimum water flow rate (m3/h) 1.37 1.17 0.94 0.70 0.48
INSTALLATION DESIGN AND PLANNING INFORMATION
Page 11
CONDENSING BOILER
3.3. GAS SUPPLY
(a) The Local Gas Supplier should be consulted at the installation planning stage
in order to establish the availability of an adequate supply of gas.
(b) An existing service pipe MUST NOT be used without prior consultations with
the gas supplier.
(c) A gas meter can only be connected by the Local Gas Supplier or by his
Contractor.
(d) An existing meter should be of sufficient size to carryout the maximum boiler
input plus the demand of any other installed gas appliance, (BS 6891:1988). The
supply from governed meter must provide steady inlet working pressure of
20mbar (8in wg) at the boiler. See section Technical Data for the gas required for
each specific model.
(e) The gas supply line must be purged. WARNING: before purging open all doors
and windows and also extinguish any cigarettes, pipes and any other naked
lights.
(f) The complete gas installation must be tested.
3.5. CENTRAL HEATING AND WATER SYSTEM
The Gledhill boiler is suitable for use with both vented and unvented traditional
heating systems and also for use with the thermal storage systems e.g. Gledhill
BoilerMate OV and Gledhill BoilerMate SP (SysteMate).
Plastic Pipes
When plastic pipe is to be used for the heating system, this must be suitable for
the maximum pressures and temperatures for the intended application. The class
‘S’ pipes and fittings are defined in BS 7279-1.
Some plastics are permeable to the oxygen and to prevent corrosion of system
components (e.g. heat exchanger) due to build up of oxygen, a barrier type pipe
must be used i.e. pipes incorporating a polymer barrier layer.
When plastic pipe is used, the first 2m of pipe work from the boiler (both flow and
return) must be in copper.
INSTALLATION DESIGN AND PLANNING INFORMATION
3.4. ELECTRICITY SUPPLY
(a) The boiler must be permanently connected
to a 230V~, 50Hz supply. This appliance MUST BE
EARTHED.
(b) All external wiring to the boiler must be in
accordance with the latest I.E.E. Wiring Regulation,
and any local regulations, which may apply.
(c) There must be only one common isolator for
the boiler and its control system, and it must
provide complete electrical isolation via a double
pole isolator fused at 3A maximum with a contact
separation of at least 3mm in both poles.
(d) The fused spur box should be readily accessible
and preferably adjacent to the appliance and it
should be identified as to its use.
(e) Alternatively the connection can be made
through an unswitched shuttered socket and 3A
fused 3-pin plug both to the current issue of BS
1363 may be used, provided they are not used in
a room containing bath or shower.
(f) In the event of an electrical fault after installation
of the appliance, preliminary electrical checks must
be carried out i.e. Earth Continuity, Short Circuit,
Polarity, and Resistance to Earth.
"OILER
MM
(7
#YLINDER
"OILER
MM
MINIMUM
HEIGHT
MM-INIMUM
/PEN6ENT
MM-INIMUM
COLDFEEDANDEXPANSION
MM-INIMUM
M-AXIMUM
&LOW
2ETURN
$IAGRAM/PEN6ENTED3YSTEM
2ECOMMENDEDRELATIONSHIPBETWEENPUMPCOLDFEEDANDOPENVENT
!UTOMATICBYPASS
VALVERECOMMENDED
IFREQUIRED
MM
-AXIMUM
!IRRELEASE
POINT
(7
#YLINDER
(IGHESTPOINT
OFTHESYSTEM
0UMP
Page 12
3.5.1. Open vented heating system
(a) The open i.e. vented heating system is shown schematically in diagram 3.3.
It is important that the relative positions of the pump, cold feed and the open
vent are as shown in diagram 3.3 to minimise the chances of air ingress and
pump over conditions arising.
(b) The cold feed must be 15mm minimum size. The 22mm (minimum) open
vent must rise continuously and be unrestricted.
(c) The boiler must be supplied from an unrestricted water supply taken from
feed and expansion cistern situated at a maximum height of 30 meters above
the boiler.
(d) A safety valve need not be fitted to an open vented heating system.
(e) A draining tap conforming to the current issue of BS 2879, must be provided
at the lowest point of the system, which will allow the entire central heating
and hot water system to be drained.
(f) The overflow/warning pipe should be in 20mm internal diameter pipe of
suitable material for use in heating systems in accordance with BS 5449 (such as
copper). It should have continuous fall and discharge in a conspicuous external
position. It should not have any other pipework directly branched into it.
(g) The water level in the F & E cistern should be at least 250mm above the
highest point on the system including the radiators
INSTALLATION DESIGN AND PLANNING INFORMATION
3.5.2. Sealed heating system
(a) Design Standards
The sealed heating system is shown schematically
in diagram 3.4. The sealed system installation must
comply with the appropriate requirements of current
issues of BS5449, BS6759, BS6798 and BS7074.
(b) Safety Valve
A non-adjustable safety valve must be fitted to a sealed
system. It shall be pre-set with a lift pressure of 3 bar
and incorporate a seating of resilient material, a test
device and a connection to the drain
(c) Safety Valve Drain
The drain from a safety valve must be routed outside
the building and positioned so that any discharge can
be seen. It must not discharge above an entrance or
window or any type of public area and be clear of any
electrical fittings.
(d) Pressure Gauge
A pressure gauge with a set pointer and covering at
least 0 – 4 bar shall be fitted permanently to the sealed
system. It should be positioned where it can be seen
when filling the system.
"OILER
2ETURN
&LOW
(7
#YLINDER
0UMP
!UTOMATICBYPASS
VALVERECOMMENDED
)FREQUIRED
$IAGRAM3CHEMATIC$IAGRAMOFA3EALED3YSTEM
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!
!
$RAIN
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&ILLINGPOINT
3EEDIAGRAMS
0RESSURE
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%XPANSION
VESSEL
3AFETY
VALVE
"OILER
(7
#YLINDER
Page 13
CONDENSING BOILER
3.5.2. Sealed heating system(Cont)
(e) Expansion Vessel
A diaphragm type expansion vessel, conforming to
the current issue of BS4814 (See also BS7074 Parts
1 and 2) must be connected to the inlet side of
the circulating pump (see diagram 3.4) unless laid
down differently by the manufacturer.
The water content of the boiler is given in table 3.1.
The expansion vessel volume depends on the total
water volume of the system and the initial system
design pressure as shown below in table 3.3. For
any system an accurate calculation of vessel size
is given in the current issue of BS5449 and BS7074
Part 1. For example; A higher initial design charge
pressure requires a larger volume vessel.
The initial vessel charge pressure must not be
less than the static head of the system, that is the
height of the highest point of the system above
the expansion vessel.
(f) Water Makeup
Provision should be made for replacing the water
loss from the system using a makeup bottle
mounted in a position higher than the highest
point of the system, connected through the non-
return valve to the return side of either central
heating or hot water cylinder circuit.
Alternatively, provision for water makeup can
be made using a filling loop, in an accessible
position on the return, or an approved CA device
as discussed below.
(g) Filling a Sealed Heating System
Provision for filling a sealed system at low level
must be made and the method selected must
comply with the Water regulations. The temporary
filling loop method is shown in diagram 3.5 and the
CA-device method is shown in diagram 3.6.
The CA device normally requires a pressure
differential to operate and this should be taken
into account when selecting the device and the
system operating pressures.
For the temporary filling loop method there must
be no permanent connection to the mains supply,
even through a non-return valve.
INSTALLATION DESIGN AND PLANNING INFORMATION
Table 3.3 Expansion vessel volume required
Safety valve setting (bar) 3.0
Vessel charge pressure (bar) 0.5 1.0 1.5
Initial system fill pressure (bar) 0.5 1.0 1.5 2.0 1.0 1.5 2.0 1.5 2.0
Total system water content (l) Expansion vessel volume (litres)
25 2.1
3.5 6.5 13.7 2.7 4.7 10.3 3.9 8.3
50 4.2 7.0 12.9 27.5 5.4 9.5 20.6 7.8 16.5
75 6.3 10.5 19.4 41.3 8.2 14.2 30.9 11.7 24.8
100 8.3 14.0 25.9 55.1 10.9 19.0 41.2 15.6 33.1
125
10.4 17.5 32.4 68.9 13.6 23.7 51.5 19.5 41.3
150 12.5 21.0 38.8 82.6 16.3 28.6 61.8 23.4 49.6
Boiler
Return
1. Control/Isolating valve
2. Double check valve
3. Hose unions
4. Temporary connection
$IAGRAM3EALEDSYSTEMFILLINGMETHOD
1
1
23
3
4
Supply pipe
"OILER
&LOW
1
1
23
3
4
Boiler
Flow
Return
1.
Control/Isolating valve
2. Type CA Backflow
Prevention device
3. Tundish
4. Air Gap
5. Pressure regulator
(optional)
$IAGRAM3EALEDSYSTEMFILLINGMETHOD
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1
4
Supply
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2
3
5
Boiler
1.
2.
3.
4.
5.
1
1
4
Supply
pipe
2
3
5
Page 14
3.5.3. Gledhill BoilerMate OV Heating System
The Gledhill Boiler is also suitable for use with a Gledhill BoilerMate OV;
an integrated open vented heating system and mains pressure hot water
appliance. This appliance is supplied with factory fitted and wired system
controls and equipment e.g. pumps, valves etc. The BoilerMate OV uses a
directly heated open vented primary store and is suitable for only vented
heating systems as shown schematically in diagram 3.7. For further details
refer to Gledhill BoilerMate OV manual.
The BoilerMate OV acts as the neutral point of the system and therefore the
cold feed and open vent must be piped to the appropriate connections on
the BoilerMate OV.
A draining tap conforming to the current issue of BS 2879, must be provided
at the lowest point of the system, which will allow the entire central heating
and hot water system to be drained.
The overflow/warning pipe should be in 20mm internal diameter pipe of
suitable material for use in heating systems in accordance with BS 5449 (such as
copper). It should have continuous fall and discharge in a conspicuous external
position. It should not have any other pipework directly branched into it.
The height of the F & E cistern above the BoilerMate OV should not be greater
than 10m and the water level in the F & E cistern should be at least 450mm
above the highest point on the system including the radiators
INSTALLATION DESIGN AND PLANNING INFORMATION
Boiler
BoilerMate
250mm
Highest point
of the system
Warning/Overflow pipe
Open vent
Cold feed
Mains
cold supply
•No bypass is required in the boiler circuit
•Bypass valve on heating circuit not required unless the heating
circuit incorporates 2-
port zone valve or
TRVs on all radiators
$IAGRAM3CHEMATICSOFA"OILER-ATE/6HEATINGSYSTEM
Remote
F &E Cistern
Return
Flow
Boiler
250mm
•
•
-
Page 15
CONDENSING BOILER
3.5.4. Gledhill BoilerMate SP Heating System
The Gledhill Boiler is also suitable for use with a Gledhill BoilerMate SP; an integrated
sealed heating system and mains pressure hot water appliance The BoilerMate SP
uses an indirectly heated open vented hot water only primary store. The central
heating circuit is suitable for sealed heating systems as shown schematically in
diagram 3.8. For further details refer to Gledhill BoilerMate SP manual.
When using the boiler with a BoilerMate SP, the pressure safety valve must be
fitted on the boiler flow pipe adjacent to the boiler. The expansion vessel should
be fitted adjacent to the BoilerMate SP and connected to the connector on the
top of the BoilerMate SP.
The sealed central heating system design and component selection and sizing
including filling arrangements should follow the guidelines discussed in section
3.5.2 ‘Sealed Heating Systems’.
Although the heating system is sealed, the primary store in the BoilerMate SP must
be filled via a feed and expansion cistern supplied with the appliance as shown
in diagram 3.8. The height of the F & E cistern above the BoilerMate SP should not
be greater than 10m.
"OILER
/PENVENT
#OLDFEED
-AINS
COLDSUPPLY
$IAGRAM3CHEMATICSOFA"OILER-ATE30HEATINGSYSTEM
2EMOTE&%
#ISTERNFORSTORE
(EATINGCIRCUIT
EXPANSIONVESSEL
2ETURN
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0RESSUREGAUGE
3AFETYVALVE
"OILER
"OILER-ATE
!UTOMATIC
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VALVE
INSTALLATION DESIGN AND PLANNING INFORMATION
Page 16
3.6. SYSTEM / BOILER PUMP
The variable duty pump should be fitted on the flow pipe from the boiler
and have isolating valves on each side as shown schematically in diagrams
3.3 and 3.4.
The pressure loss characteristics of the boilers are shown in diagram 3.9. The
water flow rates and the boiler pressure losses at 11ºC and 20ºC temperature
differences are also tabulated below in table 3.4.
The variable duty pump should be set to give a temperature difference of no
greater than 20ºC between boiler flow and return to give minimum flow rate
through the boiler shown in table 3.4. High resistance micro bore systems may
require a higher duty pump.
Diagram 3.9 Pressure loss characteristics of the boilers
0.0
0.5
1.0
1.5
2.0
2.5
3.0
3.5
4.0
4.5
0 100 200 300 400 500 600 700 800 900 1000 1100 1200 1300 1400 1500
Flow rate (litres/h)
Pressure loss (mWG)
GB_10, GB_15
GB_20, GB_25, GB_30
GB-30:
30kW = 1280 l/h at 20K diff
GB-25
25kW = 1070 l/h at 20k diff
GB-20
20kW = 850 l/h at 20K diff
2.6 m
1.9 m
1.3 m
GB-15
15kW = 640 l/h at 20K diff
0.8 m
GB-10
10kW = 430 l/h at 20K diff
3.7. FLOW RATE
If it is necessary to alter the flow rate in a system, the system can be fitted with
a lockable balancing valve in the main flow or return pipes. The example is
shown as a valve ‘A’ in diagram 3.4.
The flow rate through the boiler must not be allowed to fall below the values
given in table 3.2 for the boiler model selected.
Table 3.4 Boiler pressure loss data
Boiler
Model
Temperature
difference (K)
Flow rate (Litres
per hour)
Pressure loss (m WG)
GB30 11 2342 6.66
20 1288 2.30
GB25
11 1951 4.79
20
1073 1.69
GB20
11 1561 3.22
20
858 1.17
GB15 11 1171 3.91
20
644 1.47
GB10 11 780 2.00
20 429
0.80
3.8. BYPASS VALVE
A bypass is not required on the central heating system
unless the system controls could allow the boiler and
the pump to operate when there is no flow.
When a bypass valve has to be fitted, it must be placed
at least 1.5 meters away from the boiler as shown
schematically in diagrams 3.3 and 3.4. An automatic
bypass valve is recommended.
3.9. DOMESTIC HOT WATER
STORAGE CYLINDER
Single feed indirect cylinders are not suitable.
The domestic hot water cylinder must be of the double
feed fully indirect coil type. It must be suitable for
working at a gauge pressure of 0.35 bar above the
safety valve setting.
The storage vessel does not have a vent to the
atmosphere i.e. unvented cylinder is used, then the
installation must comply with the Building regulations
and Local Water Company bylaws. See also the current
issues of BS5546 and BS6700.
3.10. BOILER LOCATION AND VENTILATION
3.10.1. Boiler Location
The boiler may be installed in any room although
particular attention is drawn to the requirements of the
current issue of BS7671 with respect to the installation
of a boiler in a room containing a bath or a shower.
Any electrical switch or boiler control using mains
electricity supply should be so sited that a person using
the bath or a shower cannot touch it. The electrical
provisions of the Building Standards (Scotland)
Regulations are applicable to such installations in
Scotland.
These boilers are not suitable for fitting outdoors.
The boiler must be mounted on a flat wall, which is
sufficiently robust to take its total weight given in
table 3.1.
INSTALLATION DESIGN AND PLANNING INFORMATION
Page 17
CONDENSING BOILER
3.10.2. Clearances
The boiler should be positioned and installed so that at least minimum clearances
shown in diagram 3.10, required for servicing and correct operation are provided.
Additional clearances may be useful around the boiler for installation and
servicing.
For flue installations where external access is not practical, considerations should
be given for the space required to insert the flue internally, which may require
clearances larger than those specified in diagram 3.10.
220
20 20
200
5*
Flue
Front
600
5*
5*
$IAGRAM-INIMUMCLEARANCESFROM
PERMANENTFIXEDSURFACES
All dimensions in mm
* Increase to 25mm clearances from combustible surfaces
220
20
5*
Flue
Front
600
5*
5*
Front
5*
5*
*
3.10.3. Timber Frame Buildings
If the boiler is to be installed in a timber frame building, it should be fitted in
accordance with the Institute of Gas Engineers document IGE/UP/7/1998. If in
doubt, ask local gas utility company or Gledhill Ltd.
3.10.4. Room ventilation
The boiler is room sealed, so when it is installed in a room or space, a permanent
air vent is not required.
3.10.5. Compartment ventilation
If the boiler is installed in a compartment, a permanent air vent Is not required.
However leave existing air vents.
3.11. FLUE LOCATION AND VENTILATION
3.11.1. Flue Position and Length
The standard horizontal flue is fitted onto the top of the boiler as shown in diagrams
3.11 and 3.12. The dimension “X” for the rear outlet flue and dimension “Y” for the
side outlet flue must be measured and compared against the standard flue supplied
to check if it is suitable.
An extended flue system can be installed with the addition of extension kits (see
section 3.11.3 Flue options). The flue system must always be designed and installed
to have a continuous fall towards the boiler of at least 3º to allow the condensate
to run to drain via the boiler.
3.11.2. Internal Flue Installation
The flue can be installed from inside the building
when access to the outside wall face is not
practical.
3.11.3. Flue Options
The concentric flue systems and kits available for
this boiler are listed below in table 3.4. Additional
accessories and flue systems are also available for
this boiler. See ‘Gledhill Boiler Flue Options Guide’
for configurations that are available.
Table 3.4 Concentric Flue Kits and Options
Description Part No.
Standard horizontal flue kit GT461
Vertical flue terminal kit – pitched AFB001
Flat roof flue kit AFB010
Ridge terminal flue kit AFB020
The concentric flue system can be extended to
a maximum equivalent length of 6.65 metres
(excluding flue terminal) after the flue elbow fitted
to the appliance. This can be horizontal or vertical
but the following allowances should be made for
each component fitted.
Description Equivalent
Length
2m Flue extension 2.0
1m Flue extension 1.0
0.5m Flue extension 0.5
45º Flue bend 1.5
90º Flue bend 1.9
INSTALLATION DESIGN AND PLANNING INFORMATION
Page 18
3.11.4. Terminal Position
The minimum acceptable siting dimensions for the terminal for obstructions,
other terminals and ventilation openings are shown in Gledhill Boiler Flue
Options Guide. The dimensions measured are from the edge of the terminal.
The terminal must b exposed to the external air, allowing passage of air across
it at all times.
This is a condensing boiler and therefore some pluming may occur from the
flue outlet. This should be taken in to consideration when selecting the position
for the terminal.
Carports or similar extensions of roof only, or roof and one wall, require special
consideration with respect to any openings, doors, vents or windows under
the roof. Care is required to protect the roof if it is made of plastic sheeting. If
the carport has a roof and two or more walls, then seek advice from the local
gas supply company before installing a boiler.
3.11.5. Terminal Guard
A terminal guard is required if a person could come into contact with the
terminal or the terminal could be subject to damage. The terminal guard is
required for horizontal flue terminals below 2m above the ground floor or
accessible by the general public from the windows, balconies etc.
If a terminal guard is required, it must be positioned to provide minimum
of 50mm clearance from any part of the terminal and be central over the
terminal.
A terminal guard for this boiler is shown in the Gledhill Boiler Flue Options
Guide and is available from Gledhill Ltd quoting part number GF199.
3.12. HEATING SYSTEM CONTROLS
It is recommended that a programmer and a room thermostat should control
the boiler when there is a demand for central heating and a programmer and
hot water store thermostat should control the boiler when there is a demand
for water heating.
The thermostatic radiator valves may be installed; however they must not be
fitted in a room where the room thermostat is located. (Note: All systems must
have at least one radiator that is not fitted with a thermostatic valve.)
The heating system controls must meet the requirements of the current issue
of the Building Regulations. For further information see: -
• The current issue of “Approved Document L1 – Conservation of fuel and
power in dwellings”
• GIL 59, 2000 : Central heating system specification (CheSS)
• GPG 302, 2001: Controls for domestic central heating system and hot water.
BRECSU.
3.13. CONDENSATE DRAIN
A plastic drainpipe must be fitted to the boiler to allow
discharge of condensate to the suitable drain.
A copper pipe is NOT suitable.
Condensate should, if possible, be discharged into
the internal household drainage system. If this is not
practical, discharge can be made externally into the
household drainage system or a purpose designed
soak away. See section 4 for further details.
Note: Condensate trap inside the boiler casing must
be manually filled with water after installing the boiler
(i.e. before the first firing) and before commissioning
the system.
For long-term corrosion protection, after flushing, an
inhibitor suitable for stainless steel heat exchangers
should be used. Refer to the current issue of BS5449
and BS7593 on the use of inhibitors in central heating
systems. The examples are Sentinel X100 and Fernox
MBI.
3.14. WATER TREATMENT
For optimum performance after installation of the new
system, the boiler and its associated central heating
system should also be flushed.
The flushing should be carried out in accordance with
BS7593:1992 using cleaner such as Sentinel X300 or
X400 or Fernox Superfloc.
In the case of an existing installation, the
system MUST be thoroughly flushed before
installing the new boiler. Power Flushing is
the preferred option for existing installations
because all high efficiency boilers tend to
have smaller waterways than traditional
boilers. A suitable system filter (e.g. Spirovent
SV3-025-T) fitted in the boiler return is
STRONGLY recommended in existing systems.
INSTALLATION DESIGN AND PLANNING INFORMATION
Page 19
CONDENSING BOILER
BOILER INSTALLATION
4.1. INSTALLATION PREPARATION
Unpacking Of Boiler
Important: With regards to the Manual Handling Operations, 1992 Regulations, the
following lift operation exceeds the recommended weight for one man lift.
Stand the boiler carton upright.
Cut and remove the securing straps and lift off the carton sleeve. Place aside any
loose components until required.
Carefully lay the boiler on its back, remove the two front casing panel-securing
screws and lift off the panel from the two retaining lugs.
Remove the two inner casing panel-securing screws at the bottom of the front
panel, and then lift off the two retaining lugs.
4.1.1. Wall Template
A wall template is supplied with the boiler. This should be used to mark the boiler
fixings and flue outlets and for checking the minimum clearances required.
4.1.2. Flue Hole Cutting
The standard horizontal flue is designed with an internal fall of 35mm/metre
towards the boiler for disposal of condensate. If the standard flue length alone
is being used then the flue hole of diameter 105mm can be cut in the position
marked on the wall template.
For standard side flues the horizontal flue centre line on the wall template should
be extended to the side wall, and the vertical centre of the flue hole marked at
176mm from the back wall.
For installations with external access, a 105mm diameter core drill can be used.
For installations with internal access only a 125mm diameter core drill should be
used.
When using extension pipes with the horizontal rear flue, a core drill size of
125mm should be used to allow the extension pieces to slope at 35mm/metre
(2.5°) towards the boiler.
For extended side flues, the flue hole centre should be determined by extending
the dashed inclined line on the template to the side wall. This dashed line is drawn
at 35mm/metre (2.5°) rise from the boiler. Where this line reaches the side wall, a
horizontal line should be marked. The vertical centre line of the flue should then
be marked at 176mm from the back wall, see diagram 5.3.
To allow for the flue passing through the wall at this angle a 125mm hole should
be drilled irrespective of internal or external installation.
If necessary remove the wall template whilst drilling the flue hole.
4.2. Hanging Bracket Fixing
If previously removed, reposition the wall template
over the flue hole and mark the position of the
fixing holes for the hanging bracket.
Mark and drill the fixing holes and secure the
hanging bracket.
4.3. BOILER FIXING
Important: With regards to the Manual Handling
Operations, 1992 Regulations, the following lift
operation exceeds the recommended weight for
a one man lift.
Having previously secured the hanging bracket to
the wall, lift the boiler into position in the following
manner:-
Lean the top of the boiler slightly to the wall and
position just above the hanging bracket. Allow the
boiler to slowly move downwards until engaged in
the hanging bracket.
4.4. CONNECTIONS
4.4.1. Gas Connection
Before connection check the supply of local gas.
The gas supply can be connected from below.
4.4.2. Water Connections
Provision is made for the water connections to be
made from above the boiler.
The position is shown on the wall template.
Flush out the domestic hot water and the central
heating system before connecting to the boiler.
Page 20
4.4.3. Condensate Drain Connection
Before fitting the condensate drainpipe, remove and fill the condensate trap
with water and refit to the appliance.
The condensate will be slightly acidic and the condensate pipe should be run
in a high temperature plastic drainpipe material (e.g. PP, UPVC etc). Copper
tube MUST NOT be used and ‘push fit’ overflow pipe MUST NOT be used.
The actual outlet connection (shown opposite) is stepped to accept either
21 or 22mm O.D. pipework. The connections are designed to be a friction fit
and particularly with 21mm pipe it is important that the pipe is long enough
and pushed firmly home (use a quarter turn)
Internal pipe work should have a bore diameter no smaller than 20mm.
The external pipe work should be kept to a minimum, and have a bore diameter
no smaller than 32mm.
The pipe should not have any upward pipe runs and must fall at least 2º (1:20)
throughout its length towards the discharge point.
It is strongly recommended that the condensate pipe should be run internally
to the house soil or vent stack or to a waste pipe.
Alternatively the condensate may be discharged into a rainwater system,
external gully or a purpose-built soak away. Any local building control authority
requirements must be complied with.
It is recommended that the pipe should not be installed externally but if it is it
should be insulated and terminated below the grating level of the gully or at
least 50mm above the soak away to minimise the effects of freezing.
BOILER INSTALLATION
21mm
22mm
Section
Page 21
CONDENSING BOILER
5.1 GENERAL
Warning: The boiler must be permanently connected to a 230V~, 50Hz supply. This
appliance MUST BE EARTHED.
All external wiring to the boiler must be in accordance with the latest I.E.E. Wiring
Regulation, and any local regulations which may apply
There must be only one common isolator for the boiler and its control system, and
it must provide complete electrical isolation via a double pole isolator fused at 3A
maximum with a contact separation of at least 3mm in both poles.
The fused spur box should be readily accessible and preferably adjacent to the
appliance and it should be identified as to its use.
Alternatively the connection can be made through an unswitched shuttered socket
and 3A fused 3-pin plug both to the current issue of BS 1363 may be used, provided
they are not used in a room containing bath or shower.
Do not interrupt the mains supply to the boiler with a time switch or a
programmer.
In the event of an electrical fault after installation of the appliance, preliminary
electrical checks must be carried out i.e. Earth Continuity, Short Circuit, Polarity,
and Resistance to Earth.
Electrical components in this appliance have been tested to meet the requirements
of the BEAB.
L
SL
_B
E
N
E
L_
P
N_
P
Mains input
cable
Pump output
cable
Cable clamp
Diagram 5.2 Wiring terminals and cable connections
Wiring terminals
See table 5.1
L
SL
_B
E
N
E
L_
P
N_
P
5.2 EXTERNAL CONTROLS
(Mains Voltage: 230V, 50Hz)
(a) The Gledhill boilers are fitted with wiring
terminals inside the control panel as shown in
diagram 5.2. The access to these terminals is gained
by first removing the front cover by removing the
two screws at the bottom (front) and then opening
the hinged control panel by first unscrewing the
retaining screw.
(b) Observe all terminal markings and colour codes
as shown in diagrams 5.2 – 5.4 and table 5.1. Ensure
that all flexible cords are routed through the strain
relief cable glands and clamps located on the
bottom of the boiler and in the control/wiring
panel.
Table 5.1 Description of boiler wiring terminals
(c) Ensure that the separate external mains supply,
control and pump cables are fed to the boiler.
Connect both the mains supply and switched
live supply from the external controls (e.g. room
thermostat, BoilerMate) into the marked terminals
as shown in diagrams 5.2, 5.3 and 5.4. For the
conventional heating systems also connect the
pump supply into the marked pump terminals as
shown in diagrams 5.2 and 5.3
(d) The controller in this boiler is phase sensitive.
Therefore if mains supply ‘Live’ and ‘Neutral’ are
reversed, the controller will not work and the error
message will be displayed.
(e) Electrical Connection Testing
Carry out the preliminary electrical checks below
after wiring and before switching on the supply: -
•The insulation resistance to earth of mains
cables.
•Test the earth continuity and short circuit of
cables.
•Test the polarity of the mains.
Table 5.1 Description of boiler wiring terminals
Terminal Description
L Mains (L) supply – 230V ~ 6A rated cable (0.75mm2)
N Mains (N) supply – 230V ~ 6A rated cable (0.75mm2)
E Mains (GND, E) supply – 0V ~ 6A rated cable (0.75mm2)
SL-B Switched Live (L) supply – 230V~ 6A rated cable (0.75mm2)
L-P Supply to pump (L) – 230V~ 3A rated cable (0.75mm2)
N-P Supply to pump (N) – 230V~ 3A rated cable (0.75mm2)
E Supply to pump (GND, E) – 0V ~ 6A rated cable (0.75mm2)
ELECTRICAL WIRING
Page 22
5.2.1 Wiring – Conventional Systems
(a) The schematic wiring diagram of a conventional heating system with vented
or unvented domestic hot water storage is shown in diagram 5.3. Although
the diagram shows 2 zone valves, the boiler is equally suitable for systems
designed with a 3-port valve.
(b) When designing and planning the system wiring, take into account
recommendations of control manufacturers and requirements of controls
selected.
(c) The boiler incorporates pump overrun control logic. Therefore only feed
the system pump from the boiler wiring terminals marked ‘L-P’, ‘N-P’, and ‘E’ (see
diagrams 5.2 and 5.3) and not from a separate electrical supply.
(d) The boiler has integrated frost protection control logic to prevent the boiler
from freezing. This will be automatically activated if the temperature inside the
boiler drops below 5ºC provided the electricity and the gas supplies to the boiler
are not switched off. (Note: Automatic frost protection is only activated if no
jumper is fitted across terminals 1&9 -J3 on the control PCB.) If frost protection
is required for other parts of the heating circuit, then a 230Vac frost thermostat
should be wired as shown in diagram 5.3.
(e) After completing the wiring carryout electrical testing (section 5.2 (e))
and refit the appliance control panel and front cover. Please ensure that the
ELECTRICAL WIRING
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Page 23
CONDENSING BOILER
5.2.2. Wiring – BoilerMate OV/BoilerMate SP
(a) The schematic wiring diagram of Gledhill BoilerMate based heating and hot
water system is shown in diagram 5.4.
(b) When a boiler is coupled to a BoilerMate, then the mains electricity supply from
the isolator must be to the BoilerMate and the boiler should be supplied from the
BoilerMate via a secondary 3 pole isolator as shown in diagram 5.4.
(c) When designing and planning the system wiring, take into account
recommendations of control manufacturers and requirements of controls e.g.
programmer and room thermostat selected.
(d) The boiler pump overrun is provided by the BoilerMate controller.
(e) The frost protection control logic of the boiler must be disabled by inserting
a jumper on pins 1&9 of connector J3 on the main PCB (see diagram 8.3). If frost
protection is required for any part of the heating circuit, then a 230Vac frost
thermostat should be wired as shown in the BoilerMate manual.
(f) After completing the wiring carryout electrical testing (section 5.2 (e)) and refit
the appliance control panel and front cover. Please ensure that the ‘Benchmark’
logbook is completed and left with the user.
ELECTRICAL WIRING
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Page 24
6.1. General
Commissioning should be carried out by a competent person in accordance
with the current issue of BS6798. Make sure that the system has been
thoroughly flushed out with cold water. Refill the system with water, making
sure that all the air is properly vented from the system. Before operating the
boiler check that all external controls are calling for heat.
With a sealed system fill the system until the pressure gauge registers the
recommended pressure. Clear all air from the system and check for leaks. Check
the operation of the safety valve, preferably by allowing the water pressure to
rise until the valve lifts. This should be within ± 0.14 bar of the preset pressure.
Where this is not possible a manual check should be carried out. The system
pressure should then be reduced to the initial design pressure.
NOTE: A manual air vent is provided on top of the heat exchanger to allow air
to be removed from the boiler during filling/commissioning. The boiler front
panel will need to be removed to gain acess to the vent. The vent should be
closed during normal operation.
6.2. Initial Lighting
Isolate the boiler from the mains electrical supply. Test for gas soundness and
purge any air from the gas supply. The boiler lighting procedure operates
automatically once the switch on the appliance is in the ON position (indicated
by flame symbol) and any external controls are calling. The dot D1 will begin
to flash to indicate that the controller is active. When the burner is lit, the dot
D1 will be on constant. If the boiler fails to light it will attempt to ignite 5 times
before showing ignition lockout at which point D2 will begin to flash. Initially
this may be due to air in the gas supply line and can be reset with button S1.
After the boiler has fired allow it to warm up the system and purge any
remaining air from the system, the appliance will continue to fire until the
user controls are satisfied.
6.3. Testing – Gas
The gas rate can be checked using the gas meter and a stopwatch after the
burner has been running for 10 minutes. Before a gas rate check is made make
sure all other gas burning appliances are turned off and the temperature of
the heating/hot water system is such that the controls will remain calling for
heat.
COMMISSIONING
As a guide the approximate gas rates are:
GB30 3.3 m3/h at maximum fan speed
GB25 2.7 m3/h at maximum fan speed
GB20 2.2 m3/h at maximum fan speed
GB15 1.6 m3/h at maximum fan speed
GB10 1.1 m3/h at maximum fan speed
IMPORTANT
The gas valve and the Venturi are factory set and sealed. These should
not need any adjustment and MUST NOT be tampered with. However,
check that a supply pressure of 20mbar is available at the boiler when it
is firing at full rate.
6.4. Testing – Heating System
Check that all controls are calling for heat, fully open all radiator valves and
allow the heating system to heat up. Balance the radiators as requires giving
the required differential across the heating system and set the bypass. Turn off
all user radiator valves that can be turned off and check that the maximum
differential achievable across the flow and return is less than 20ºC.
Allow the system to achieve full temperature and
then switch off and isolate the appliance. Drain the
system whilst still hot from the lowest part of the
system ensuring all parts of the system are emptied.
Fill and vent the system as described previously.
6.5. Testing – User Controls
Check all external time and temperature controls are
fully operational and give the expected response to
user operation. Check the operations of the on/off and
reset switch on the boiler.
When the burner is lit, the dot D1 will be on constant.
A fault is indicated by flashing dot ‘D2’ . To reset press
‘Set/Reset’ button S1.
6.6. Frost Protection
The boiler has frost protection built into its operation
programme, for conventional heating systems, but
requires the gas and electricity to be switched on.
This programme operates the burner and system
pump if the temperature inside the boiler falls below
5ºC provided no ‘jumper’ is fitted across terminals
1+9_J3 on the control PCB. This device is designed to
protect the boiler only and any other exposed area of
the system should be protected separately by a frost
thermostat.
6.7. Instruct the User
A demonstration of the lighting procedure and advise
of safe and efficient operation should be given to the
user. The use and operation of the heating system
controls should also be demonstrated to the user along
with the use and maintenance of any other equipment
e.g. scale reducers that may be fitted to the system.
Advise that to continue with safe and efficient
operation of the boiler it is recommended that the
boiler is checked and serviced at a regular interval of
a minimum of once a year.
Advise that like all condensing boilers this appliance will
produce a plume from the flue terminal in cold weather
and this is normal for a high efficiency boiler.
Advise the user of the precautions necessary to prevent
damage by frost and freezing conditions if the system
is out of use. Along with a need to keep the electrical
and gas supplies switched on to enable the automatic
frost protection to work.
Draw attention to the law that any servicing should
be carried out only by a competent person and if
applicable to the current issue of the Gas Safety
(Installation & Use) Regulations, Section 35, which
imposes a duty of care on all persons who let out any
property containing a gas appliance.
Page 25
CONDENSING BOILER
SERVICING
7.1. General
IMPORTANT
DO NOT TAMPER WITH THE APPLIANCE OR BREAK ANY SEALS ON THE PRE-
SET CONTROLS (BURNER OFFSET PRESSURE AND THROTTLE SETTINGS) OF
THE APPLIANCE. IF IT IS NECESSARY TO REPLACE ANY OF THE SEALED PARTS,
THEN THESE SHOULD BE REPLACED BY FACTORY SET AND SEALED PARTS
SUPPLIED BY GLEDHILL LTD.
Measurement of the products of combustion can be achieved by connection of
a probe to the combustion analyser test point on the flue elbow connecting the
boiler to the flue system.
Before commencing with a service or replacement of parts the boiler should be
isolated from the electrical supply and the gas supply should be turned off at the
gas isolation valve.
All routine service requirements can be achieved by the removal of the front
cover, inner casing panel and lower casing panel as described in section General
9.1. Unless stated otherwise parts are replaced in the reverse order of removal.
Servicing should always include the removal of any debris from the condensate
trap. After completing any servicing of gas carrying components ALWAYS test for
gas soundness and carry out a functional test of the controls.
It is recommended that all subsequent service calls are recorded on the Service
Interval Record which can be found on page 36.
Details from the Benchmark Checklist and Service Interval Record will be required
when requesting warranty work. Failure to provide these details or the lack of a
current service will delay a warranty visit and may incur a charge for the visit.
7.2. Spark & Flame sensing electrodes
For access refer to section General 9.1
Remove the spark plug style connector from the electrode and earth lead in the
case of the spark electrode. Remove the two retaining screws with a Torx T20 driver,
carefully withdraw the electrode from the combustion chamber. Inspect the tips
for damage, clean away any debris and check the spark gap is 3.5-4.5mm. Check
the electrode gasket for signs of damage and replace if necessary.
7.3. Burner
For access refer to section General 9.1 & 9.1.1
Clean the burner with a soft brush taking great care not to damage the front
insulation. DO NOT use wire or sharp instruments to clean the holes in the burner.
Inspect the burner for any signs of damage.
Removal of the burner is not necessary during a normal service.
NOTE: IF THE BURNER HAS TO BE REMOVED IT WILL REQUIRE A NEW GASKET
WHEN REFITTED.
When replacing the assembly ensure the sealing grommet is correctly fitted.
7.4. Combustion Chamber and Heat Exchanger
For access refer to section General 9.1 & 9.1.1
Remove loose debris from the combustion chamber using a soft brush and vacuum
cleaner. Carefully flush any remaining debris by spraying water through to the
condensate trap (ensuring the water is kept away from electrical components).
7.5. Condensate Drain
For access refer to section General 9.1
Remove the yellow cap from the bottom of the trap
and remove any solids found. Remove the flexible
condense pipe connection from the bottom of
the heat exchanger and the drain connection
downstream of the condense trap. Remove the
condensate trap and flush water through the trap
to remove any remaining solids. Reassemble the
trap and connection ensuring a watertight seal
is achieved.
7.6. Inner Casing Panel Seal Check
For access refer to section General 9.1
Check the condition of the seal, replace as required.
To replace remove the old seal, thoroughly clean
the casing surfaces. Fit the new seal, it is supplied
to the correct length.
7.7. Combustion Check
Once the appliance has been reassembled (apart
from the front and inner panel) connect a CO
2
combustion analyser to the test point on the flue
elbow.
Page 26
FAULT FINDING
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Page 27
CONDENSING BOILER
FAULT FINDING
8.1. CONTROLLER DISPLAY
The controller display unit is equipped with a two digit, 7 segment display and
three push buttons as shown schematically shown in diagram 8.1. The display
shows the system status and can be used to display diagnostic information.
The push buttons can be used to enter the parameter menu and to change
the parameters. The push button S1 is also used to clear locking errors and
reset the controller.
8.1.1. Normal Level-1 (Default) Operation
The information display in normal user (Level-1) mode is described below in
table 8.1. If no input is detected when the display is in level 2 or level 3 mode
for a period of around 20 seconds, it will automatically revert back to default
level 1 mode.
S3
S2
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-
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Diagram 8.1 Controller display
Table 8.1: Level-1 Display description
Display segment Description
D1 On/Off : Indicates that the controller is active and in standby mode
On : Indicates ionisation i.e. burner is on
D2
On/Off : Lockout error – Requires reset
On : Blocking error detected
b Controller is initialising
h Overheat safety trip
a, d, b & f ‘F’ – Frost program active
i Heat demand on
j Pump on
8.1.2. Level-2 Display Operations
The level-2 is used to display the temperatures, set points
and errors. The information flow diagram for level-2 is
shown below in diagram 8.2. Push buttons S2 and S3 are
used to select the parameters vertically and horizontally
respectively.
The level-2 is accessed by pressing and holding push button
S1 for minimum of 10s. The controller display will go back to
level 1 if either there has been no input (i.e. buttons pressed)
for 30s or if push button S1 is pressed and held for 10s.
(a) Temperature display
The temperature of the sensor selected is displayed
by alternatively flashing the sensor number and the
temperature measured by it or ‘Er’ if it is in error. The sensor
definition is shown in table 8.2.
(b) Set point display
The selected set point is displayed by alternatively flashing
the set point number (P1...P6) and the corresponding set
point. The definition of set points is listed in table 8.3.
Table 8.2: Sensor Description
Sensor Description Error Codes
S1 Boiler Flow (NTC)
E1: Sensor or cables shorted
E2: Sensor or cables open circuit
E3: Temperature reading >99ºC
S2 Boiler Return (NTC)
E1: Sensor or cables shorted
E2: Sensor or cables open circuit
E3: Temperature reading >99ºC
S3 Flue Gases (NTC)
E1: Sensor or cables shorted
E2: Sensor or cables open circuit
E3: Temperature reading >99ºC
S4 TID
E1: ID resistor short circuit
E2: ID resistor open circuit
E3: ID resistor >99ºC
Page 28
FAULT FINDING
(c) Lockout fault code display
In this mode the lockout fault codes are displayed. The button S2 is used to select
this mode and the button S3 is used to cycle between the stored faults. Fault code
reading is displayed by alternatively flashing the fault number and the internal
error number.
There are 16 fault codes stored in order of occurrence. The fault code ‘C0’ is the
current or last fault code and the fault code ‘CF’ is that happened the longest time
ago.
When no fault is stored at the displayed fault number, an ‘FF’ is displayed. It is
also possible that ‘EE’ is displayed for an internal error number. This means that
the controller is busy reading the memory. The lockout error codes are listed in
table 8.5.
The locking errors can be cleared by pressing the reset button S1
(d) Block out fault code display
In this mode the block out fault codes can be displayed. The button S2 is used
to select this mode and the button S3 is used to cycle between the stored faults.
Fault code reading is displayed by alternatively flashing the fault number and the
internal error number.
There are 16 fault codes stored in order of occurrence. The fault code ‘c0’ is the
current or last fault code and the fault code ‘cF’ is that which happened the longest
time ago.
When no fault is stored at the displayed fault number, an ‘FF’ is displayed. It is
also possible that ‘EE’ is displayed for an internal error number. This means that
the controller is busy reading the memory. The block out error codes are listed
in table 8.6.
The error will be reset when fault is cleared. To reset some internal errors switch
power off, wait 10 seconds and switch power on again.
Table 8.3: Set point description
Set point number Description
P1 blr_flow_setpoint, (S1)
P2
blr_flow_hysterese, (S1)
P3 blr_return_setpoint, (S2)
P4 blr_return_hysterese, (S2)
P5 max_flue_setpoint, (S3)
P6 blr_flow_overheat
8.1.3. Level - 3 Display Operations
The level 3 is used for setting the boiler flow
temperature and selecting the boiler model. This
level is intended for use by the installer/service
engineer. The level 3 setting menu is accessed by
simultaneously pressing and holding the push
buttons S2 and S3 for at least 10 seconds.
The setting level is indicated by flashing ‘0’ on the
LH digit of the display and solid ‘0’ on the RH digit
of the display.
(a) Boiler model selection
The parameter to be set is selected by using
buttons S2 or S3. The display is cycled using these
buttons until ‘A’ flashes on the LH digit and the
current boiler ID (0…4) is shown on RH digit.
The boiler models and their ID codes are listed in
table 8.4. To change the boiler ID press and hold
button S1 until RH digit starts to flash. Select the
boiler ID using buttons S2 or S3. Press and hold
button S1 to confirm the selected boiler ID.
If the selected boiler ID matches the ID resistor
fitted, the RH digit will stop flashing. The controller
will now be operational and will use the boiler
model specific data (e.g. fan speeds) for future
control actions
If the selected boiler ID does not match the ID
resistor fitted, the RH digit will display flashing ‘E’.
The T_ID values corresponding to the ID resistors
are shown on PC serial screen.
If the controller does not sense any further inputs
from buttons S1, S2 or S3 for a period of 20s, it will
revert back to normal display.
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Table 8.4. ID Data of boiler models
Model Boiler ID ID resistor
GB10 A0 1K, (T_ID=100)
GB15 A1 1K5, (T_ID=66)
GB20 A2 2K2, (T_ID=73)
GB25
A3 3K3, (T_ID=61)
GB30 A4 4K7, (T_ID=51)
Page 29
CONDENSING BOILER
FAULT FINDING
(b) Boiler flow temperature setting
The parameter to be set is selected by using buttons S2 or S3. The display is cycled using these buttons until ‘P’ (on the LH digit) and
the current maximum boiler flow temperature setting (e.g. 77) starts to flash alternatively
To change the maximum boiler flow temperature setting, press and hold button S1 until the digits stop flashing and only the current
set temperature is displayed.
Change the boiler flow set point using buttons S2 or S3. Press and hold button S1 to confirm the setting until ‘P’ (on the LH digit) and
the current maximum boiler flow temperature setting (e.g. 77) starts to flash alternatively.
If the controller does not sense any further inputs from buttons S1, S2 or S3 for a period of 20s, it will revert back to normal display.
8.2. ERROR/FAULT CODES
The errors are divided into two groups; blocking errors which will disappear when error is cleared and the non volatile locking errors
which can only be reset by pressing the reset button.
The locking errors are shown in table 8.5 and these will be indicated with ‘C’ prior to the error number. The blocking errors are shown
in table 8.6 and these will be indicated with ‘c’ prior to the error number.
Table 8.5 Lockout error codes
`C` code Error Description
no Description
0 E2PROM_READ_ERROR Unable to read E2Prom contents
1 IGNIT_ERROR No flame detected after 3 ignition attempts
2 SPARE_LOCK_ERROR
3 SPARE_LOCK_ERROR_0
4 SPARE_LOCK_ERROR_1
5 GV_RELAY_ERROR Gas Valve Relay not opening or closing correctly
6 SAFETY_RELAY_ERROR Safety Relay not opening or closing correctly
7 SPARE_LOCK_ERROR_1A
8 FAN_ERROR Fan does not run at correct speed
9 RAM_ERROR Ram check in processor is not correct
10 WRONG_EEPROM_SIGNATURE E2Prom content does not correspond with main software
11 CH_MAX_ERROR
12 E2PROM_ERROR E2Prom contents corrupt
13 STATE_ERROR Internal software error
14 ROM_ERROR Internal software error
15 OVERHEAT_ERROR S1 sensor above maximum overheat temperature
16 15MS_XRL_ERROR Internal software error
17 SENS_DIFF_ERROR
18 T_MAX_LOCK_ERROR
19 STACK_ERROR Internal software error
20
FLAME_OUT_TOO_LATE_ERROR After closing the gas valve the flame was detected for a period longer than 10 secs
21
FLAME_ERROR_1 Flame detected prior to opening the gas valve
22 20MS_XRL_ERROR Internal software error
23
41MS_ERROR Internal software error
24
TOO_MANY_FLAME_FAILURES Too many flame failures within one heat demand cycle
25
FLAME_FLAG_CPL_ERROR
26
WD_DATABYTE_CPL_ERROR
27
FLAG_BYTE_INTEGRITY_ERROR
28
AD_HI_CPL_ERROR
29
AD_LO_CPL_ERROR
30 REGISTER_ERROR
Page 30
FAULT FINDING
Table 8.6 Blocking error codes
`c` code Error Description
31 REFHI_TOO_LO_ERROR Temperature measurement incorrect
32
REFHI_TOO_HI_ERROR Temperature measurement incorrect
33 REFLO_TOO_LO_ERROR Temperature measurement incorrect
34 REFLO_TOO_HI_ERROR Temperature measurement incorrect
35 SPARE_BLOCK_ERROR
36 FLAME_ERROR_2 Flame detected with a closed gas valve
37 SPARE_BLOCK_ERROR_O
38 FS_NOT_OPEN_ERROR
39 FS_NOT_CLOSED_ERROR
40 SPARE_BLOCK_ERROR_3
41 SPARE_BLOCK_ERROR_4
42
CH_MAX_BLOCK_ERROR
43 SPARE_BLOCK_ERROR_5
44 PHASE_ERROR Mains supply live and neutral reversed
45 50HZ_ERROR Mains frequency is not 50Hz
46 FAULTY_EARTH_ERROR Earth Connection/Ground incorrect
47 WD_COMMUNICATION_ERROR Communication issue between main and watchdog processors
48 APPLIANCE_SELECTION_ERROR Incorrect appliance type selected for appliance ID
49 MULTIPLE_SENSOR_ERROR Errors with more than 1 sensor
50 SENSOR_00_OPEN
51 SENSOR_01_OPEN
52 SENSOR_02_OPEN
53 SENSOR_03_OPEN
54 SENSOR_04_OPEN
55 SENSOR_05_OPEN
56 SENSOR_06_OPEN
57 SENSOR_07_OPEN
58 SENSOR_00_SHORTED
59 SENSOR_01_SHORTED
60 SENSOR_02_SHORTED
61 SENSOR_03_SHORTED
62
SENSOR_04_SHORTED
63 SENSOR_05_SHORTED
64 SENSOR_06_SHORTED
65 SENSOR_07_SHORTED
66 RESET_BUTTON_ERROR Reset button pressed too many times within a short period
255
NO_ERROR
8.3. SERIAL SOFTWARE
In order to check the control and to set the parameters in its E2PROM, serial software
is provided. To use this software a windows PC with serial port (COMP port) or a
USB port is needed.
8.4. INTERNAL WIRING DIAGRAM
The appliance wiring diagram is shown in diagram 8.4. Ensure that wiring details
are followed when a PCB, wiring harness or components are changed.
Page 31
CONDENSING BOILER
FAULT FINDING
.ORMAL,EVEL?MODE
3EESECTION
0RESSHOLDBUTTONS3AND3
SIMULTANEOUSLYFORSECONDS
0RESS3
0RESS3
0RESS3
0RESS3
0RESS3
0RESS3
0RESS3
0RESS3
0RESS3
0RESS3
0RESS3
,EVEL?MODE
3EESECTION
0RESS3
0RESS3
0RESS3
0RESS3
0RESS3
0RESS3
0RESS3
4EMPERATURERE ADINGS
)NDICATEDBY ALTERNATIV ELYF LASHING
33TEMPERATURETABLE
$IAGRAM,EVEL$ISPLAYFLOWDIAGRAM
$ECREASE
4EMPERATURE
#HANGING3ET0OINT
)NDICATEDBY
)NCREASE4EMPERATURE
$ECREASE
)$.UMBER
)NCREASE
)$.UMBER
#HANGING!PPLIANCE4YPE
)NDICATEDBY!
"OILER&LOW3ETPOINT
)NDICATEDBYALTERNATIVELYFLASHING
0
!PPLIANCE4YPE
)NDICATEDBYALTERNATIVELYFLASHING
!
Page 32
FAULT FINDING
sion: 190105)
Sensors
Boiler Flow – Tasseron - type TSE/12K/±3% DWG No: TSC0B10
Boiler return – Tasseron - type TSE/12K/±3% DWG No: TSC0B10
Flue gas – Tasseron – type TS861/12K/ ±3% DWG No: TSSD2050
OHT - Hawco - Auto-Reset thermal cu-out thermostat
Ref: 03EN-15S040-5x6 95+-4/80 +-4
L
SL_B
E
N
E
L_P
N_P
Boiler switched live - 230V, ac
Mains supply to
boiler, 230V, ac
3
2
1
J2
L (J2-3)
N (J2-2)
E (J2-1)
J7
SL-Boiler (J7-3)
L-Pump (J7-4)
N-Pump (J7-2)
E-Pump (J7-1)
Supply to remote
pump, 230V, ac
J13
Gas valve
earth
Gas valve
connector
Auto reset OHT
OHT_2 (J13-5)
OHT_1 (J13-6)
GV-5 : (J13-4)
GV-1 : (J13-3)
Flame
Sensing
electrode
PTFE insulated high temperature & high tension lead (J13-2)
J9
Fan earth
Fan
connector
F-1 : (J9-2)
F-2 : (J9-5)
F-3 : (J9-6)
F-4 : (J9-4)
F-5 : (J9-3)
(J9-1)
1 2 3 4 5 6 7 8
9 10 11 12 13 14 15 16
J12
J11
Spark
electrode
T2
HT lead
J5
Boiler return sensor
Boiler flow sensor
Control bus
connector
Digimaster Controller
Type B794_3
Flue gas sensor
1
5
4
3
2
1
3
2
1
4
5
6
2
3
4
5
6
7
5
4
3
2
1
5
4
3
2
1
230V, 5A
On-Off switch
ID Resistor
Flying lead
ID Resistor values
Boiler Resistor T_ID
GB_10 1K 100
GB_15 1K5 86
GB_20 2K2 73
GB_25 3K3 61
GB_30 4K7 51
J3
Jumper 1 – 9 Frost protection
Off (normal) active
On Not active
Diagram 8.4 GWS Wall mounted boiler internal wiring diagram (Ver
Sensors
Boiler Flow – Tasseron - type TSE/12K/±3% DWG No: TSC0B10
Boiler return – Tasseron - type TSE/12K/±3% DWG No: TSC0B10
Flue gas – Tasseron – type TS861/12K/ ±3% DWG No: TSSD2050
OHT - Hawco - Auto-Reset thermal cu-out thermostat
Ref: 03EN-15S040-5x6 95+-4/80 +-4
L
SL_B
E
N
E
L_P
N_P
Boiler switched live - 230V, ac
Mains supply to
boiler, 230V, ac
3
2
1
J2
L (J2-3)
N (J2-2)
E (J2-1)
J7
SL-Boiler (J7-3)
L-Pump (J7-4)
N-Pump (J7-2)
E-Pump (J7-1)
Supply to remote
pump, 230V, ac
J13
Gas valve
earth
Gas valve
connector
Auto reset OHT
OHT_2 (J13-5)
OHT_1 (J13-6)
GV-5 : (J13-4)
GV-1 : (J13-3)
Flame
Sensing
electrode
PTFE insulated high temperature & high tension lead (J13-2)
J9
Fan earth
Fan
connector
F-1 : (J9-2)
F-2 : (J9-5)
F-3 : (J9-6)
F-4 : (J9-4)
F-5 : (J9-3)
(J9-1)
1 2 3 4 5 6 7 8
9 10 11 12 13 14 15 16
J12
J11
Spark
electrode
T2
HT lead
J5
Boiler return sensor
Boiler flow sensor
Control bus
connector
Digimaster Controller
Type B794_3
Flue gas sensorFlue gas sensor
1
5
4
3
2
1
5
4
3
2
1
3
2
1
4
5
6
2
3
4
5
6
7
5
4
3
2
1
5
4
3
2
1
5
4
3
2
1
230V, 5A
On-Off switch
ID Resistor
Flying lead
ID Resistor values
Boiler Resistor T_ID
GB_10 1K 100
GB_15 1K5 86
GB_20 2K2 73
GB_25 3K3 61
GB_30 4K7 51
J3
Jumper 1 – 9 Frost protection
Off (normal) active
On Not active
!PPLIANCE)$
!
!
!
!
!
0#INTERFACE
*
Page 33
CONDENSING BOILER
REPLACEMENT OF PARTS
9.1. General
A competent person must carry out replacement of parts. Before replacing any
parts the boiler must be isolated from the mains electric supply and the gas
must be turned off at the service valve on the boiler. Unless stated otherwise
parts are replaced in the reverse order of removal. After replacing any parts
always test for gas soundness and if necessary carry out a functional test of
the controls.
For replacement of parts the front cover, inner casing
panel and lower casing panel will need to be removed.
The front cover is held with locating pins at the top and
retaining screws at the bottom. The retaining screws
should be removed from the bottom and the panel
lifted clear of the locating pins. To remove the inner
casing undo the four retaining screws holding the
inner casing panel and the lower casing panel is held
by a further three screws.
NOTE: The gas valve and Venturi are a single assembly
which is factory set and sealed. This must not be
tampered with and must be changed as a single
assembly.
9.1.1
The burner, fan, gas valve and venturi form part of a sub-assembly that must
be removed before one of them can be replaced. To remove the sub-assembly
remove the electrical plugs from the fan and gas valve and remove the earth
connections from the gas valve and fan. Remove the gas connection, then the
six nuts securing the combustion chamber front cover with a 10mm AF spanner.
Carefully withdraw the sub-assembly from the combustion chamber.
Note: The burner will require a new gasket when refitted.
Burner
Venturi
Gas valve
Burner sub assembly
3PARKELECTRODE
4EMPERATURE
SENSORS
(EATEXCHANGER
#OMBUSTION
CHAMBERFRONT
SECURINGNUTSOFF
&LAME
SENSINGELECTRODE
Page 34
REPLACEMENT OF PARTS
9.2. Spark & Flame sensing Electrodes
For access refer to section General 9.1
Remove the spark plug style connector from the electrode and earth lead in the
case of the spark electrode. Remove the two retaining screws with a Torx T20 driver,
carefully withdraw the electrode from the combustion chamber.
9.3. Ignition & Flame sensing Leads
For access refer to section General 9.1
Pull off the spark plug style connector off the electrode and the spade connector
from the control pcb.
9.4. Fan
For access refer to section General 9.1 & 9.1.1
Remove the two slotted screws holding the gas valve and venturi to the fan then
remove the four nuts securing the fan to the gas manifold with a 8mm AF spanner.
Check and replace any seals and gaskets necessary.
9.5. Burner
For access refer to section General 9.1 & 9.1.1. Remove the three screws securing
the gas manifold to the combustion chamber front with a Torx T25 driver. This will
release the burner.
The burner size depend upon the model of the boiler (see table below) therefore
when replacing the burner ensure that the correct replacement burner is used.
Gledhill Boiler
model
Burner length
(mm)
Gledhill Part
number
Gas Council
number
GB10 92.6 GT991
GB15 104.6 GT992
GB20
135.8 GT993
GB25
167.0 GT994
GB30 167.0 GT994
9.6. Temperature Sensors
For access refer to section General 9.1
The flow and return sensors have built in retaining clips and are removed
as follows. Remove the electrical connections from the sensor, the sensor is
removed from the pipe by putting equal pressure on the sensor head and the
clip ends that are located 180
o
from each other. The flue gas sensor is removed
with a 15mm AF spanner after having its electrical connections removed.
9.7. Heat exchanger
For access refer to section General 9.1 & 9.1.1
After removing the burner sub-assembly drain the boiler and remove the
condense pipe from the bottom of the heat exchanger. Remove the clips
securing the flow and return connections onto the heat exchanger. Loosen the
three heat exchanger securing screws and clamps (two at the top and one at
the bottom) to remove the heat exchanger. CAUTION there will still be some
water in the heat exchanger.
9.8. Insulation
For access refer to section General 9.1 & 9.1.1
Remove the sub assembly as described above and
replace the front insulation on the combustion
chamber front cover.
9.9. Overheat thermostat
For access refer to section General 9.1
9.10. Fuses
For access refer to section General 9.1
The fuse is located on the left hand side of the main
control pcb.
9.11. On-Off Switch
For access refer to section General 9.1
Remove the electrical connectors from the rear of
the switch, squeeze the holding tabs on each end
of the switch. The switch will now push through
the front panel.
9.12. Gas Valve
The gas throttle on air/gas venturi (i.e. CO2 level)
and offset pressure settings of the gas valve fitted to
this boiler are factory set and sealed. These settings
should not be adjusted. The gas valve and Venturi
assembly must only be replaced by a factory set and
sealed replacement supplied by Gledhill Ltd.
For access refer to section General 9.1 & 9.1.1
Remove the three screws securing the gas valve
to the venturi using a Torx T25 driver. Check and
replace any seals and gaskets as necessary. After
replacing the gas valve the combustion CO2 will
need to be checked.
9.13. Controller PCB
For access refer to section General 9.1
Remove the four slot screws securing the Perspex
cover and remove the wiring plugs from the pcb.
With a 6mm AF spanner remove the four nylon
stand offs securing the control pcb.
Page 35
CONDENSING BOILER
REPLACEMENT OF PARTS
F
E
D
C
B
1
A 2
Key Description Part No
A1 White front panel WHB 15-030
A2
Stainless front panel WHB 15-031
B Boiler front panel WHB 15-007
C RH boiler bracket WHB 15-014
D LH boiler bracket WHB 15-015
E Bottom boiler bracket WHB 15-006.2
F Lower boiler front panel WHB 15-004
Page 36
REPLACEMENT OF PARTS
14
11
13
15
3
12
Key Description Part No
3 Temperature sensors
flow/return
GT333
11 Control PCB GT107
12
Overheat thermostat GT455
13 Flue temperature sensor GT334
14 On/off switch GT034
Page 37
CONDENSING BOILER
REPLACEMENT OF PARTS
1
a
b
2 c
d
e
9
10
a
b
6 c
d
7
8
5a
5
4a
4
Description Part No
1 Fan GT335
2a
GB10 Gas Valve/Venturi GT515
2b
GB15 Gas Valve/Venturi GT516
2c GB20 Gas Valve/Venturi
GT517
2d GB25 Gas Valve/Venturi
GT518
2e
Gas Valve/Venturi GT519
4 Ionisation Electrode GT996
4a Gasket for Electrode GT995
5 Ignition Electrode GT998
5a Gasket for Electrode GT997
6a GB10 Burner GT991
6b GB15 Burner GT992
6c GB20 Burner GT993
6d GB25 + 30 Burner GT994
7 Gasket for all Burners GT990
8 Boiler insulation GT989
9 Ignition lead GT451
10 Flame sensing lead CA061
Page 38
SPARE PARTS
Key No Part Number Description GC No
5 GT998 Ignition electrode
5a GT997 Gasket for electrode
4 GT996 Ionisation electrode
4a GT995 Gasket for electrode
6d GT994 Burner GB-25, GB-30
6c GT993 Burner GB-20
6b GT992 Burner GB-15
6a GT991 Burner GB-10
7 GT990 Gasket (for burner) – All models
8 GT989 Boiler door insulation
9 GT451 Ignition lead
10 CA061 Flame sensing lead
1 GT335 Fan assembly
11 GT107 Control PCB
3 GT333 Temperature sensors (flow & return)
12
GT455 Overheat thermostat
14 GT034 On-Off switch
GF199 Terminal guard
2a
GT515 Gas Valve and Venturi assembly for GB-10
2b
GT516 Gas Valve and Venturi assembly for GB-15
2c
GT517 Gas Valve and Venturi assembly for GB-20
2d
GT518 Gas Valve and Venturi assembly for GB-25
2e
GT519 Gas Valve and Venturi assembly for GB-30
13 GT334 Flue temperature sensor
&ANNOT
INCLUDED
1
3
4 5
Page 39
CONDENSING BOILER
CONTROLS
T
o comply with the Building Regulations, each section must have a tick in one or other of the boxes
TIME & TEMPERATURE CONTROLTO HEATING ROOM T/STAT & PROGRAMMER/TIMER PROGRAMMABLE ROOMSTAT
TIME &
TEMPERATURE CONTROLTO HOTWATER CYLINDER T/STAT& PROGRAMMER/TIMER
COMBI BOILER
HEATING ZONE VALVES FITTED NOT REQUIRED
HOT WATER ZONE VALVES FITTED NOT REQUIRED
THERMOSTATIC RADIATOR VALVES FITTED
AUTOMATIC BYPASS TO SYSTEM FITTED NOT REQUIRED
FOR ALL BOILERS CONFIRM THE FOLLOWING
THE SYSTEM HAS BEEN FLUSHED IN ACCORDANCE WITH THE BOILER MANUFACTURER’S INSTRUCTIONS?
THE SYSTEM CLEANER USED
THE INHIBITOR USED
FOR THE CENTRAL HEATING MODE, MEASURE & RECORD
GAS RATE ft
3
/hr
BURNER OPERATING PRESSURE (IF APPLICABLE) mbar
CENTRAL HEATING FLOW TEMPERATURE °C
CENTRAL HEATING RETURN TEMPERATURE °C
FOR COMBINATION BOILERS ONLY
HAS AWATER SCALE REDUCER BEEN FITTED? YES NO
WHAT TYPE OF SCALE REDUCER HAS BEEN FITTED?
FOR THE DOMESTIC HOT WATER MODE, MEASURE & RECORD
GAS RATE ft
3
/hr
MAXIMUM BURNER OPERATING PRESSURE (IF APPLICABLE) mbar
COLD W
A
TER INLET
TEMPERA
TURE °C
HOT WATER OUTLET TEMPERATURE °C
W
ATER FLOW RATE
lts/min
FOR CONDENSING BOILERS ONLY CONFIRM THE FOLLOWING
THE CONDENSATE DRAIN HAS BEEN INSTALLED IN ACCORDANCE WITH
THE MANUFACTURER’S INSTRUCTIONS? YES
FOR ALL INSTALLATIONS CONFIRM THE FOLLOWING
THE HEATING AND HOT WATER SYSTEM COMPLIES
WITH CURRENT
BUILDING REGULA
TIONS
THE
APPLIANCE
AND
ASSOCIA
TED EQUIPMENT HAS BEEN INSTALLED AND COMMISSIONED
IN ACCORDANCE WITH THE MANUFACTURER’S INSTRUCTIONS
IF REQUIRED BY
THE MANUFACTURER, HAVE YOU RECORDED ACO/CO
2
RA
TIO READING? N/A YES CO/CO
2
RA
TIO
THE OPERATION OF THE APPLIANCE AND SYSTEM
CONTROLS HAVE BEEN DEMONSTRATED TO THE CUSTOMER
THE MANUFACTURER’S LITERATURE HAS BEEN LEFT WITH THE CUSTOMER
m
3
/hr
m
3
/hr
COMMISSIONING ENG’S NAME
PRINT CORGI ID No.
SIGN DATE
BOILER SERIAL No. NOTIFICATION No.
BENCHMARK No.
GAS BOILER COMMISSIONING CHECKLIST
C O L L E C T I V E M A R K
N/A
N/A
Page 40
SERVICE INTERVAL RECORD
It is recommended that your heating system is serviced regularly
and that you complete the appropriate Service Interval Record Below.
Service Provider. Before completing the appropriate Service Interval Record below
, please ensure you have carried out the service
as described in the boiler manufacturer’s instructions. Always use the manufacturer’s specified spare part when replacing all controls
SERVICE 1
DA
TE
ENGINEER NAME
COMP
ANY NAME
TEL
No.
CORGI ID CARD SERIAL
No.
COMMENTS
SIGNATURE
SERVICE 2
DATE
ENGINEER NAME
COMPANY NAME
TEL No.
CORGI ID CARD SERIAL No.
COMMENTS
SIGNATURE
SERVICE 3
DATE
ENGINEER NAME
COMPANY NAME
TEL No.
CORGI ID CARD SERIAL No.
COMMENTS
SIGNATURE
SERVICE 4
DATE
ENGINEER NAME
COMPANY NAME
TEL No.
CORGI ID CARD SERIAL No.
COMMENTS
SIGNATURE
SERVICE 5
DATE
ENGINEER NAME
COMPANY NAME
TEL No.
CORGI ID CARD SERIAL No.
COMMENTS
SIGNA
TURE
SERVICE 6
DATE
ENGINEER NAME
COMPANY NAME
TEL No.
CORGI ID CARD SERIAL No.
COMMENTS
SIGNATURE
SERVICE 7
DATE
ENGINEER NAME
COMPANY NAME
TEL No.
CORGI ID CARD SERIAL No.
COMMENTS
SIGNATURE
SERVICE 8
DATE
ENGINEER NAME
COMPANY NAME
TEL No.
CORGI ID CARD SERIAL No.
COMMENTS
SIGNA
TURE
SERVICE 9
DA
TE
ENGINEER NAME
COMP
ANY
NAME
TEL
No.
CORGI ID CARD SERIAL No.
COMMENTS
SIGNATURE
SERVICE 10
DATE
ENGINEER NAME
COMPANY NAME
TEL No.
CORGI ID CARD SERIAL
No.
COMMENTS
SIGNA
TURE
Page 41
CONDENSING BOILER
Page 42
Gledhill
(Water Storage)
Ltd
AMD. JUNE 2008
CONDITIONS OF SALE & GUARANTEE TERMS
1. Gledhill (Water Storage) Ltd (“We” or “Gledhills”) only do business upon the Conditions which appear below
and no other. Unless we so agree in writing these Conditions shall apply in full to any supply of goods by us to
the exclusion of any Conditions or terms sought to be imposed by any purchaser. These Conditions of Sale and
Warranty Terms override those which are contained on the Invoice Forms and all Sales are now subject to these
Conditions of Sale and Warranty terms only.
2. PRICE
Once an order or call off has been accepted the price will be held for three months but if delivery is extended
beyond that period at the customer’s request, then we reserve the right to amend the price when necessary.
The company reviews its pricing annually to adjust for changes in our cost base. We reserve the right to alter prices
at any time for severe movements in raw materials (mainly copper and steel). If there is to be a change we will give
customers at least four weeks notice but anything delivered after that date will be at the revised price. An order
may not be cancelled or varied after acceptance without the written consent of the company. Such cancellation or
variation shall be subject to such reasonable charges as may be appropriate.
3. SPECIFICATION
The goods are supplied in accordance with the Specifications (if any) submitted to the Purchaser and any additions
and alterations shall be the subject of an extra charge. Any goods not so specified shall be in accordance with our
printed literature or the literature of any of our component suppliers (subject to any modifications made since
publication). If we adopt any changes in construction or design of the goods, or in the specification printed in our
literature, the Purchaser shall accept the goods so changed in fulfilment of the order.
4. PAYMENT
The invoice price of goods shall be payable within 30 days of despatch by us of our invoice for the goods or such
longer time as may be stated by our quotation or invoice. If we receive payment in full on or before the due date we
will allow an appropriate settlement discount except where we have quoted a special net price. If payment is not
received in full on or before the due date we shall be entitled in addition to the invoice price to:
(i) payment of a sum equal to any increase in the copper price supplement applicable to the particular goods
sold between the date of receipt of order and the date of receipt of payment in full; and
(ii) interest on any part of the invoice price unpaid after the due date at the rate of 3% per annum over the base
rate for the time being of HSBC Bank plc.
5. TIME
We give estimates of delivery dates in good faith and time of delivery is not nor shall be made of the essence of any
contract nor shall we be liable for any loss or damage occasioned by delay in delivery.
6. DELIVERY
We deliver free normally by our own vehicles within 25 miles of any of our manufacturing depots. Delivery to any
place more than 25 miles from one of our manufacturing depots may be subject to our quoted delivery charges. We
reserve the right to make delivery of goods contained in one order by more than one consignment and at different
times. Where a period is agreed for delivery and such period is not extended by our Agreement, the Purchaser shall
take delivery within that period. If the Purchaser fails to take delivery, we shall be entitled at the Purchaser’s risk and
expense to store the goods at the Purchaser’s premises or elsewhere and to demand payment as if they had been
despatched. Off loading at point of delivery shall be the responsibility of and be undertaken by the Purchaser.
7. SHORTAGES OR DAMAGE
Goods must be inspected before signature of delivery note and any damage, shortage or discrepancy noted on the
delivery note and the goods returned on the same vehicle. The buyer must also give us immediate written notice of
the damage, shortage or discrepancy so that we may prompt investigation.
8. RETURN OF GOODS
Goods may not be returned to the Company except by prior written permission of an authorised officer of the
Company and such return shall be subject to payment by the Purchaser of handling and re-stocking charges,
transport and all other costs incurred by the Company.
9. COMPANY LIABILITY AND GUARANTEE
9.1. Subject to the terms of these Conditions of Sale and Guarantee Terms Gledhills provide Guarantees in respect
of specific products as set out in this clause.
9.2. Each Guarantee is strictly conditional upon the following:-
9.2.1. Complaints must be given to us immediately, before any action is taken, as responsibility cannot be accepted
if repairs or renewals are attempted on site without our written approval.
9.2.2. The unit has been installed in accordance with our installation and service instructions and all relevant codes
of practice and regulations in force at the time of installation.
9.2.3. All necessary inlet controls and safety valves have been fitted correctly.
9.2.4. The unit has only been used for the storage of potable water supplied from the public mains.
9.2.5 Where appropriate the unit has been regularly maintained as detailed in the installation and service
instructions
9.2.6. Defects caused by corrosion or scale deposits are not covered by any Guarantee.
9.2.7. Where we agree to rectify any defect we reserve the right to undertake the work on our own premises.
9.3. Guarantees are provided in respect of specified goods supplied by Gledhills as follows:-
(a) Domestic and Commercial Open Vented Cylinders and Tanks.
The copper storage vessel is guaranteed for ten years and if it proves to be defective either in materials or
workmanship, we will either repair or supply replacement at our option with the closest substitute in the case
of any obsolete product to any address in Great Britain.
(i) free of all charge during the first year after delivery by us.
(ii) thereafter at a charge of one-tenth of the then current list price and any copper price supplement and
delivery charge during the second year after delivery by us and increasing by a further one-tenth on the
second and subsequent anniversary of delivery by us.
(b) Domestic Mains Fed Products [Primary Stores]
The copper storage vessel is guaranteed for five years and if it or any integral pipework as part of the storage
vessel assembly proves to be defective either in materials or workmanship, we reserve the right to either
repair or supply replacements or the closest possible substitute in the case of any obsolete product and will
collect and deliver to any address in England, Wales and Scotland (excluding all Scottish Islands).
(i) free of all charge during the first year after delivery by us.
(ii) thereafter at a charge of one-fifth of the then current list price or any copper price supplement and
delivery charge during the second year after delivery by us increasing by a further one-fifth on the second
and subsequent anniversary of delivery by us.
(c) Integrated Boiler and Storage Vessel Products and Stand Alone Boilers
In the case of the GulfStream range of products and the Gledhill boiler range of products, Gledhill guarantees
the heat exchanger (boiler) for material and construction faults for two years. THE RESPONSIBILITY FOR THE
EXECUTION OF THIS GUARANTEE LIES WITH THE INSTALLER.
The guarantee becomes null and void if the appliance is used incorrectly, or in the event of proven negligence
or incorrectly implemented repairs OR FAILURE TO CARRY OUT THE RECOMMENDED INSPECTION/
MAINTENANCE. The guarantee also becomes null and void if changes are made to the appliance without our
knowledge, or if the serial number on the appliance is removed or made illegible.
The annual service must be carried out by a competent
installer in accordance with the advice given by
Gledhill and using Gledhill approved parts.
(d) Stainless Steel Unvented Cylinders
Gledhill guarantee the components including controls,
valves and electrical parts for two years from the date
of purchase. IT SHOULD BE NOTED THAT THE FACTORY
FITTED TEMPERATURE AND PRESSURE RELIEF VALVE
MUST NOT BE REMOVED OR ALTERED IN ANY WAY
OR THE GUARANTEE WILL NOT BE VALID. GLEDHILL
WILL NOT BE RESPONSIBLE FOR ANY CONSEQUENTIAL
LOSS OR DAMAGE HOWEVER IT IS CAUSED.
The guarantee for the stainless steel vessel is for
twenty five years if the original unit is returned to us
AND PROVIDED THAT:
(i) It has been installed as per the Design, Installation
& Servicing Instructions, relevant standards,
regulations and codes of practice.
(ii) It has not been modified, other than by Gledhill.
(iii) It has not been subjected to wrong or improper
use or left uncared for.
(iv) It has only been used for the storage of potable
water.
(v) It has not been subjected to frost damage.
(vi) The benchmark log book is completed after each
annual service.
(vii) The unit has been serviced annually.
It should be noted that the guarantee does not cover:
- the effects of scale build up
- any labour charges associated with replacing the
unit or parts.
If the stainless steel vessel proves to be defective
either in materials or workmanship we reserve the
right to either repair or supply replacements or the
closest possible substitute in the case of any obsolete
product and will collect and deliver to any address in
England, Scotland and Wales (excluding all islands):
(i)
free of charge during the first year after delivery by us.
(ii) thereafter at a charge of one twenty fifth of the
then current list price during the second year
after delivery by us and increasing by a further
one twenty fifth on the second and subsequent
anniversary of delivery by us.
ACTION IN THE EVENT OF FAILURE
If the stainless steel cylinder develops a leak we will
ask for a deposit against the supply of a new one. This
will be refunded if the failure is within the terms of the
warranty when it has been examined by us.
(e) Solar Panels and ancillary equipment
Gledhill provides a five year warranty for defects in
the collectors (except broken glass and collector
accessories eg metal edgings). If the collector
demonstrably fails to meet one of the requirements of
the standard DIN 4757 part 3 we will replace it free of
charge based on the date of invoice. We can not be
responsible for damage caused by mechanical stress
and/or changes caused by weather related influences.
The warranty excludes minor surface damage that
does not affect performance or malfunction due to
improper assembly or installation.
Please note:
- Installation must have been carried out by a
licensed specialized company (heating contractor
or plumber) following the version of installation
instructions in force.
- Gledhill or its representative was given the
opportunity to check complaints on site
immediately after any defect occurred.
- Confirmation exists that the system was
commissioned properly and that the system
was checked and maintenance was performed
annually by a specialised company licensed for
this purpose.
(f) Components of our products other than
Storage Vessels and Integral Pipework.
We will either extend to the purchaser the same terms
of warranty as we are given by the manufacturer of
the component or if the manufacturer does not give
any warranty, replace free of charge any component
which becomes defective within two years after the
date of the delivery by us and is returned to us at the
purchaser’s expense but we shall not meet the cost of
removal or shipping or return of the component or
any other cost charges or damages incurred by the
purchaser.
If the appliance manufactured by Gledhill incorporates
a factory fitted scale inhibitor then during the period
Page 43
CONDENSING BOILER
of three years from the date of delivery Gledhill will replace, free of charge, any plate heat exchanger fitted in
the appliance as original equipment in which scale formation occurs that materially reduces the effectiveness
of the plate heat exchanger. This guarantee does not extend to any other component installed within the
Gledhill appliance or elsewhere in the Purchasers domestic water system.
9.4.
9.4.1. In respect of goods supplied by us and in respect of any installation work carried out by or on our behalf, our
entire liability and the purchaser’s sole remedies (subject to the Guarantees) shall be as follows:-
(a) We accept liability for death or personal injury to the extent that it results from our negligence or that of
our employees
(b) Subject to the other provisions of this clause 9 we accept liability for direct physical damage to tangible
property to the extent that such damage is caused by our negligence or that of our employees, agents or
subcontractors.
(c) Our total liability to the purchaser over and above any liability to replace under the Guarantees (whether
in contract or in tort including negligence) in respect of any one cause of loss or damage claimed to result
from any breach of our obligations hereunder, shall be limited to actual money damages which shall not
exceed £20,000 provided that such monetary limit shall not apply to any liability on the part of ourselves
referred to in paragraph (a) above
(d) Except as provided in paragraph (a) above but otherwise not withstanding any provision herein contained
in no event shall we be liable for the following loss or damage howsoever caused and even if foreseeable
by us or in our contemplation:-
(i) economic loss which shall include loss of profits, business revenue, goodwill or anticipated savings
(ii) damages in respect of special indirect or consequential loss or damage (other than death, personal
injury and damage to tangible property)
(iii) any claim made against the purchaser by any other party (save as expressly provided in paragraph (b)
above)
(e) Except in respect of our liability referred to in paragraph (a) above no claim may be made or action
brought (whether in contract or in tort including negligence) by the purchaser in respect of any goods
supplied by us more than one year after the date of the invoice for the relevant goods.
(f) Without prejudice to any other term we shall not be liable for any water damage caused directly or
indirectly as a result of any leak or other defect in the goods. We cannot control the conditions of use of
the goods or the time or manner or location in which they will be installed and the purchaser agrees to
be fully responsible for testing and checking all works which include the goods at all relevant times (up
to, including and after commissioning) and for taking all necessary steps to identify any leaks and prevent
any damage being caused thereby.
(g) Nothing in these Conditions shall confer on the purchaser any rights or remedies to which the purchaser
would not otherwise be legally entitled
10. LOSS OR INJURY
Notwithstanding any other provision contained herein the purchaser’s hereby agree to fully indemnify us against
any damages losses costs claims or expenses incurred by us in respect of any claim brought against us by any third
party for:-
(a) any loss injury or damage wholly or partly caused by any goods supplied by us or their use.
(b) any loss injury or damage wholly or partly caused by the defective installation or substandard workmanship
or materials used in the installation of any goods supplied by us.
(c) any loss injury or damage in any way connected with the performance of this contract.
(d) any loss resulting from any failure by the purchaser to comply with its obligations under these terms as to
install and/or check works correctly.
PROVIDED that this paragraph will not require the purchaser to indemnify us against any liability for our own acts
of negligence or those of our employees agents or sub-contractors
FURTHER in the case of goods supplied by us which are re-sold and installed by a third party by the purchaser it will
be the sole responsibility of the purchaser to test the goods immediately after their installation to ensure that inter
alia they are correctly installed and in proper working order free from leaks and are not likely to cause any loss injury
or damage to any person or property.
11. VARIATION OF WARRANTY AND EXCLUSION
Should our warranty and exclusion be unacceptable we are prepared to negotiate for variation in their terms but
only on the basis of an increase in the price to allow for any additional liability or risk which may result from the
variation.
Purchasers are advised to insure against any risk or liability which they may incur and which is not covered by our
warranty.
12. RISK AND RETENTION OF TITLE
(a) goods supplied by us shall be at the Purchaser’s risk immediately upon delivery to the Purchaser or into
custody on the Purchaser’s behalf or to the Purchaser’s Order. The Purchaser shall effect adequate insurance
of the goods against all risks to the full invoice value of the goods, such insurance to be effective from the time
of delivery until property in the goods shall pass to the Purchaser as hereinafter provided.
(b) property in the goods supplied hereunder will pass to the Purchaser when full payment has been made by the
Purchaser to us for :-
(i) the goods of the subject of this contract.
(ii) all other goods the subject to of any other contract between the Purchaser and us which, at the time of
payment of the full price of the goods sold under this contract, have been delivered to the Purchaser but
not paid for in full.
(c) until property in the goods supplied hereunder passes to the Purchaser in accordance with paragraph (2)
above.
(i) the Purchaser shall hold the goods in a fiduciary capacity for us and shall store the same separately from
any other goods in the Purchaser’s possession and in a manner which enables them to be identified as our
goods.
(ii) the Purchaser shall immediately return the goods to us should our authorised representative so request.
All the necessary incidents associated with a fiduciary relationship shall apply.
(d) the Purchaser’s right to possess the goods shall cease forthwith upon the happening of any of the following
events, namely :-
(i) if the Purchaser fails to make payment in full for the goods within the time stipulated in clause 4 hereof.
(ii) if the Purchaser, not being a company, commits any act of bankruptcy, makes a proposal to his or her
creditors for a compromise or does anything which would entitle a petition for a Bankruptcy Order to be
presented.
(iii) if the Purchaser, being a company, does anything or fails to do anything which would entitle an
administrator or an administrative receiver or a receiver to take possession of any assets or which would
entitle any person to present a petition for winding up or to apply for an administration order.
(e) the Purchaser hereby grants to us an irrevocable licence to enter at any time any vehicle or premises owned
or occupied by the Purchaser or in the possession of the Purchaser for the purposes of repossessing and
recovering any such goods the property in which
has remained in us under paragraph (2) above. We
shall not be responsible for and the Purchaser will
indemnify us against liability in respect of damage
caused to any vehicle or premises in such repossession
and removal being damaged which it was not
reasonably practicable to avoid.
(f) notwithstanding paragraph (3) hereof and subject to
paragraph (7) hereof, the Purchaser shall be permitted
to sell the goods to third parties in the normal course
of business. In this respect the Purchaser shall act
in the capacity of our commission agent and the
proceeds of such sale :-
(i) shall be held in trust for us in a manner which
enables such proceeds to be identified as such,
and :
(ii) shall not be mixed with other monies nor paid into
an overdrawn bank account.
We, as principal, shall remunerate the Purchaser as
commission agent a commission depending upon
the surplus which the Purchaser can obtain over and
above the sum, stipulated in this contract of supply
which will satisfy us.
(g) in the event that the Purchaser shall sell any of the
goods pursuant to clause (6) hereof, the Purchaser
shall forthwith inform us in writing of such sale and
of the identity and address of the third party to whom
the goods have been sold.
(h) if, before property in the goods passes to the
Purchaser under paragraph (2) above the goods are or
become affixed to any land or building owned by the
Purchaser it is hereby agreed and declared that such
affixation shall not have the effect of passing property
in the goods to the Purchaser. Furthermore if, before
property in the goods shall pass to the Purchaser
under paragraph (2) hereof, the goods are or become
affixed to any land or building (whether or not owned
by the Purchaser), the Purchaser shall:-
(i)
ensure that the goods are capable of being removed
without material injury to such land or building.
(ii) take all necessary steps to prevent title to the
goods from passing to the landlord of such land
or building.
(iii) forthwith inform us in writing of such affixation
and of the address of the land or building
concerned.
The Purchaser warrants to repair and make good
any damage caused by the affixation of the goods
to or their removal from any land or building and
to indemnify us against all loss damage or liability
we may incur or sustain as a result of affixation or
removal.
(i) in the event that, before property in the goods
has passed to the Purchaser under paragraph (2)
hereof, the goods or any of them are lost, stolen,
damaged or destroyed :-
(ii) the Purchaser shall forthwith inform us in writing
of the fact and circumstances of such loss, theft,
damage or destruction.
(iii) the Purchaser shall assign to us the benefit of any
insurance claim in respect of the goods so lost,
stolen, damaged or destroyed.
13. NON-PAYMENT
If the Purchaser shall fail to make full payment for the goods
supplied hereunder within the time stipulated in clause 4
hereof or be in default of payment for any other reason then,
without prejudice to any of our other rights hereunder, we
shall be entitled to stop all deliveries of goods and materials
to the Purchaser, including deliveries or further deliveries of
goods under this contract. In addition we shall be entitled
to terminate all outstanding orders.
14. VALUE ADDED TAX
All prices quoted are exclusive of Value Added Tax which
will be charged at the rate ruling at the date of despatch of
invoice.
15. TRADE SALES ONLY
We are only prepared to deal with those who are not
consumers within the terms of the Unfair Contract Terms
Act 1977, the Sale of Goods Act 1979 and the Supply of
Goods and Services Act 1982. Accordingly any person who
purchases from us shall be deemed to have represented that
he is not a consumer by so purchasing.
16. JURISDICTION
The agreement is subject to English law for products
delivered in England and Scottish law for products delivered
in Scotland and any dispute hereunder shall be settled in
accordance therewith dependent upon the location.
