Gledhill GB10 Benutzerhandbuch

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_____________________________________________________________________________________

A wall mounted high efficiency condensing Gledhill Boiler

DESIGN, INSTALLATION AND SERVICE INSTRUCTIONS

_____________________________________________________________________________________

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.

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.”

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 and the ‘Benchmark’ Log Book must be handed to the user on completion of the installation.

VER: 02.3 _260505 Page:1/41

Gledhill wall mounted condensing boiler models

Model

Reference SEDBUK Rating Gas Council

Number

GB10 90.1 % - Band ‘A’

GB15 90.3 % - Band ‘A’

GB20 90.4 % - Band ‘A’

GB25 90.4 % - Band ‘A’

GB30 90.3 % - Band ‘A’

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Contents

Page

1. IMPORTANT INFORMATION 3

2. OPERATING THE BOILER 7

3. INSTALLATION, DESIGN & PLANNING INFORMATION 9

4. BOILER INSTALLATION 21

5.ELECTRICALWIRING 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

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1. IMPORTANT INFORMATION

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.

compatibility.

1.2. SPARE 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.

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 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.

1.4. 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

1.5. 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.

VER: 02.3 _260505 Page:3/41

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(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.

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

CO2settings 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.

1.6. 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.

1.7. 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.

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.

1.8. 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 4oC.

(b) Any other exposed areas of the heating and hot water system should be protected by a separate frost

thermostat.

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.

VER: 02.3 _260505 Page:4/41

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(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.

1.9. 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.

1.10. 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.

1.11. CONDENSATE DRAIN

The condensate drain must not be modified or blocked (See section 3.13)

1.12. 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.

1.13. 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 dry cloth to

polish. Do not use any form of abrasive or solvent cleaner as you may damage the finish.

1.14. 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.

VER: 02.3 _260505 Page:5/41

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1.15. REPLACEMENT PARTS

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 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 notice and in these circumstances this booklet, which is accurate at the

time of printing, should be disregarded.

VER: 02.3 _260505 Page:6/41

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2. OPERATING THE BOILER

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 80±2oC and is not user adjustable. (Note: The boiler flow temperature can be adjusted

between 60 and 80oC by the installer for special applications)

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.

Set/Reset

Mains/Reset

Switch

D1 D2

Diagram 2.1

Set/Reset

Mains/Reset

Switch

D1 D2

Diagram 2.1

(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 either be either 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.

VER: 02.3 _260505 Page:7/41

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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.

flashing D2

Controller on standby

Boiler off

flashing D2

Boiler in Ignition sequence

Boiler heat demand present

Boiler pump on

ON D2

Boiler has lit

Boiler heat demand present

Boiler pump on

flashing D2

Boiler off

Heat demand not present

Boiler pump on

on D2

Frost protection program on

Boiler pump on

D1 D2

On/flashing

Boiler lockout error

Reset required

Diagram 2.2 Boiler display indication

flashing D2

Controller on standby

Boiler off

flashing D2

Boiler in Ignition sequence

Boiler heat demand present

Boiler pump on

ON D2

Boiler has lit

Boiler heat demand present

Boiler pump on

flashing D2

Boiler off

Heat demand not present

Boiler pump on

on D2

Frost protection program on

Boiler pump on

D1 D2

On/flashing

Boiler lockout error

Reset required

flashing D2

Controller on standby

Boiler off

flashing D2

Boiler in Ignition sequence

Boiler heat demand present

Boiler pump on

ON D2

Boiler has lit

Boiler heat demand present

Boiler pump on

flashing D2

Boiler off

Heat demand not present

Boiler pump on

on D2

Frost protection program on

Boiler pump on

D1 D2

On/flashing

D1 D2

On/flashing

Boiler lockout error

Reset required

Diagram 2.2 Boiler display indication

VER: 02.3 _260505 Page:8/41

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3. INSTALLATION DESIGN AND PLANNING INFORMATION

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.

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.

CONDENSATE

DRAIN

INSIDE WALL

FIXING FACE

BOILER

Centre Line

GAS

CONDENSATE

DRAIN

Dia

ram 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

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

130mm

85mm

150mm

140mm

580mm

100mm

150mm

70 mm

50mm

Cut flue terminal at

plain end to length

required allowing

40mm extra for

socket elbow joint

730mm

360mm

VER: 02.3 _260505 Page:9/41

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Dia

ram 3.2 Boiler Models GB10 and GB15

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

Clearances From Fixed surfaces

:220mm

:20mm

:600mm

Top–From ‘A’

Bottom

Sides–

Front–

–From ‘B’

From ‘C’

From ‘D’

50mm

GAS

CONDENSATE

DRAIN

INSIDE WALL

FIXING FACE

F+R

70 mm

FLOW

& RETURN

BOILER

Centre Line

GAS

140mm

85mm

150mm

100mm

210mm

730mm

Cut flue terminal at

plain end to length

required allowing

40mm extra for

socket elbow joint

580mm

CONDENSATE

DRAIN

300mm

140mm

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.

Table 3.1. Connection, Electrical and Weight data of the boiler

Boiler ModelGB30, GB25, GB20 GB15, GB10

Height (mm) 580 580

Width (mm) 380 380

Overall dimensions

including flue spigot Depth (mm) 360 300

Height (mm) 1000 1000

Width (mm) 420 420

Clear space required

for installation Depth (mm) 500 440

Weight (kg) 33 31

Water content (litres) 1.5 1

Minimum 1.0 / (0.1) 1.0 / (0.1)Working pressure

(m wg / (bar)) Maximum 30.0 / (3.0) 30.0 / (3.0)

Gas Rc1/2, (1/2in BSP) Rc1/2, (1/2in BSP)

Water 22mm copper 22mm copper

Connections Condensate Drain 22mm Plastic pipe 22mm Plastic pipe

Electricity supply 230V, ~50Hz, Fused at 3A 230V, ~50Hz, Fused at 3A

Electrical rating 60W @230V ac 60W @230V ac

Electrical data Internal fuse rate Main PCB 3.15AT Main PCB 3.15AT

VER: 02.3 _260505 Page:10/41

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