gledhill GB10 Installation And Servicing Instructions Download Page 34

Page: 34 / 41

Supplied By www.heating spares.co Tel. 0161 620 6677

Diagram 8.3 GWS Wall mounted boiler internal wiring diagram (Version: 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

SL_B

L_P

N_P

Boiler switched live - 230V, ac

Mains supply to
boiler, 230V, ac

L (J2-3)

N (J2-2)

E (J2-1)

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)

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

HT lead

Boiler return sensor

Boiler flow sensor

Control bus

connector

Digimaster Controller
Type B794_3

Flue gas sensor

5
4

230V, 5A

On-Off switch

ID Resistor

Flying lead

ID Resistor values

Boiler

Resistor

T_ID

GB_10

100

GB_15

1K5

GB_20

2K2

GB_25

3K3

GB_30

4K7

Jumper 1 – 9

Frost protection

Off (normal)

active

On Not

active

Diagram 8.3 GWS Wall mounted boiler internal wiring diagram (Version: 190105)

Sensors

Ref: 03EN-15S040-5x6 95+-4/80 +-4

SL_B

L_P

N_P

Boiler switched live - 230V, ac

Mains supply to
boiler, 230V, ac

L (J2-3)

N (J2-2)

E (J2-1)

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)

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

HT lead

Boiler return sensor

Boiler flow sensor

Control bus

connector

Digimaster Controller
Type B794_3

Flue gas sensor

5
4

230V, 5A

On-Off switch

ID Resistor

Flying lead

ID Resistor values

Boiler

Resistor

T_ID

GB_10

100

GB_15

1K5

GB_20

2K2

GB_25

3K3

GB_30

4K7

Jumper 1 – 9

Frost protection

Off (normal)

active

On Not

active

VER: 02.3 _260505

Page:34/41

Summary of Contents for GB10

Page 1: ...uctions 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 The Gas Safety Installation and use Regulations 1998 In your own interest a...

Page 2: ...1 IMPORTANT INFORMATION 3 2 OPERATING THE BOILER 7 3 INSTALLATION DESIGN PLANNING INFORMATION 9 4 BOILER INSTALLATION 21 5 ELECTRICAL WIRING 23 6 COMMISSIONING 26 7 SERVICING 28 8 FAULT FINDING 30 9 REPLACEMENT OF PARTS 35 10 SPARE PARTS 38 VER 02 3 _260505 Page 2 41 ...

Page 3: ...authorised by Gledhill Ltd 1 3 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 c...

Page 4: ...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 7 ELECTRICITY SUPPLY FAILURE a T...

Page 5: ...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 13 CLEANING This boiler contains metal parts and therefore care should be taken when handling and cleaning with particular regard to edges The boiler casing can be cleaned using a mild liquid detergent with a damp cloth and then a...

Page 6: ...lable from our Technical Help Line on 01253 474401 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 16 CONTINUOUS IMPROVEMENTS In the interest of continuously improving the Gledhill Boiler range Gledhill Water Storage Ltd reserves the right to modify the product without noti...

Page 7: ...he controller as shown in diagram 2 2 S3 S2 Set Reset S1 Mains Reset Switch D1 D2 0 I Diagram 2 1 a1 a2 S3 S2 Set Reset S1 Mains Reset Switch D1 D2 0 I Diagram 2 1 a1 a2 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...

Page 8: ...ntroller on standby Boiler off D1 flashing D2 Boiler in Ignition sequence Boiler heat demand present Boiler pump on D1 ON D2 Boiler has lit Boiler heat demand present Boiler pump on D1 flashing D2 Boiler off Heat demand not present Boiler pump on D1 on D2 Frost protection program on Boiler pump on D1 D2 On flashing Boiler lockout error Reset required D1 flashing D2 D1 flashing D2 Controller on sta...

Page 9: ...ontrol 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 ...

Page 10: ...own 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 Table 3 1 Connection Electrical and Weight ...

Page 11: ...e 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 4 ELECTRICITY SUPPLY ...

Page 12: ... 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 ...

Page 13: ...nce 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 e Expansion Vessel A diaphragm type expansion vessel conforming to the current issue of BS4814 See also BS7074 Parts 1...

Page 14: ...requires a pressure differential to operate and this should be taken into account when selecting the device and the system operating pressures There must be no permanent connection to the mains supply even through a non return valve Boiler Flow Return 1 Control Isolating valve 2 Double check valve 3 Hose unions 4 Temporary connection Diagram 3 5 Sealed system filling method 1 1 1 2 3 3 4 Supply pi...

Page 15: ... 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 3 5 4 Gledhill SysteMate Heating System The Gledhill Boiler is also suitable for use with a Gledhill SysteMate an integrated sealed heating system and mains pressure hot water appliance The SysteMate uses an indirectly heated open vented hot water only ...

Page 16: ...ce K Flow rate Litres Pressure loss m WG 11 2342 6 66 GB30 20 1288 2 30 11 1951 4 79 GB25 20 1073 1 69 11 1561 3 22 GB20 20 858 1 17 11 1171 3 91 GB15 20 644 1 47 11 780 2 00 GB10 20 429 0 80 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 t...

Page 17: ... to take its total weight given in table 3 1 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 giv...

Page 18: ...tlet 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 3 o to allow the condensate to run to drain via the boiler 3 11 2 Internal Flu...

Page 19: ...e 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 minim...

Page 20: ...m 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 For optimum performance after installation of the new syste...

Page 21: ... 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 ...

Page 22: ...e 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 Internal pipe work should have a bore diameter no smaller than 20mm The external pipe work should be kept to a minim...

Page 23: ... in this appliance have been tested to meet the requirements of the BEAB 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 1 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 unsc...

Page 24: ... 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 electricity supply d The boiler has integrated frost protection ...

Page 25: ...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 2...

Page 26: ...imes before showing ignition lockout initially this may be due to air in the gas supply line 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 Be...

Page 27: ...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 ...

Page 28: ...lectrode 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...

Page 29: ... of the seal replace as required To replace remove the old seal thoroughly clean the casing surfaces Fit the new seal it is supplied the correct length 7 7 Combustion Check Once the appliance has been reassembled apart from the front and inner panel connect a CO2 combustion analyser to the test point on the flue elbow VER 02 3 _260505 Page 29 41 ...

Page 30: ...r 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 pr...

Page 31: ...lt 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 8 1 3 Level 3 Display Operations The level 3 is used for s...

Page 32: ... 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 E prior to the error ...

Page 33: ...ement incorrect 19 E2PROM_READ_ERROR 0 Not able to read e2prom contents 20 FLAME_ERROR_2 33 Flame detected with a closed gas valve 21 PHASE_ERROR 41 Mains supply live and neutral are reversed 22 50HZ_ERROR 42 Mains frequency is not 50Hz 42 WD_COMUNICATION_ERROR 44 problems with communicating with watchdog 51 RESET_BUTTON_ERROR 65 Reset button pressed to many times in a short time 8 3 SERIAL SOFTWA...

Page 34: ...K2 73 GB_25 3K3 61 GB_30 4K7 51 J3 Jumper 1 9 Frost protection Off normal active On Not active Diagram 8 3 GWS Wall mounted boiler internal wiring diagram Version 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 ...

Page 35: ... 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 9 1 1 The burner fan gas va...

Page 36: ...f 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 GB15 104 6 221 022 001 B GB20 135 8 221 023 001 B GB25 167 0 221 024 001 B GB30 167 0 221 024 001 B 9 6 Temperature Sensors For access refer to section General 9 1 The flow and return sensors have bui...

Page 37: ...e 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 tempered 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 t...

Page 38: ...er GB_15 GM xx xx xxx Burner GB 10 GM10 25 074 07 Gasket for burner All models GM10 25 062 02 Boiler door insulation GT339 Air gas inlet pipe Venturi for GB 30 GT340 Air gas inlet pipe Venturi for GB 25 GB 20 and GB 15 GM xx Air gas inlet pipe Venturi for GB 10 GT451 Ignition lead GT451 Flame sensing lead 1 GT335 Fan assembly 2 GT185 Gas control valve GT107 Control PCB 3 GT333 Temperature sensors ...

Page 39: ...ame 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 ...

Page 40: ...ded 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 nothing in these Conditions shall confer on the purchaser any rights or remedies to ...

Page 41: ...of 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 addr...

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