gledhill GB35C Design, Installation And Servicing Instructions
  1. Manuals
  2. Brands
  3. gledhill Manuals
  4. Boiler
  5. GB35C
  6. Design, installation and servicing instructions

gledhill GB35C Design, Installation And Servicing Instructions

High efficiency combination boiler
Hide thumbs
Table of Contents

Advertisement

Quick Links

Download this manual
Gledhill High Efficiency
Combination Boiler
Model: GB35C
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.

Advertisement

Table of Contents
loading

Related Manuals for gledhill GB35C

Summary of Contents for gledhill GB35C

  • Page 1 Gledhill High Efficiency Combination Boiler Model: GB35C 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...
  • Page 2 IMPOrTANT NOTES GENErAL ISSuE 5: 06-08 The Gledhill GB35C is a fully automatic gas fired wall mounted high efficiency condensing combination boiler. This room sealed and fan assisted boiler is designed to provide both central heating and mains pressure domestic hot water.

  • Page 3: Table Of Contents

    cONTENTS CONTENTS PAGE CONTENTS PAGE 1. IMPOrTANT INFOrMATION ANNuAL SErvIcING 1.1. Building Regulations and 8.1. General Benchmark Commissioning 8.. Spark & Flame Sensing Electrodes 1.. Gas Testing and Certification and CE Mark 8.3. Burner 1.3. Spare parts 8.4. Combustion Chamber & Heat Exchanger 1.4.

  • Page 4: Important Information

    (Scotland), The Building Regulations (Northern by Gledhill Water Storage Ltd. It meets the requirements of Statutory Instrument Ireland) – as appropriate ‘The Boiler (Efficiency) Regulations 1993 No 3083’ and is deemed to meet the •...

  • Page 5: Warnings

    IMPOrTANT INFOrMATION 1.6. WArNINGS 1.9 PrOTEcTION AGAINST FrEEZING (a) Gas Leak or Fault (a) The boiler has a built in frost protection If a gas leak or fault exists or is suspected, turn the boiler mains electricity programme as long as the electricity and supply off and turn off the gas supply at the meter.

  • Page 6: Pluming From Flue Terminal

    Free of charge replacement for any faulty components are available from Gledhill Ltd during the in-warranty period (normally 1 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.

  • Page 7: Technical Information

    2.1 DEScrIPTION Figure 2.1 The Gledhill GB35C is a fully automatic, wall mounted gas fired, high efficiency condensing combination boiler (Figure .1). It is a room sealed fan assisted appliance and suitable for sealed central heating system and mains pressure domestic hot water only.

  • Page 8: Operation

    TEcHNIcAL INFOrMATION 2.2 OPErATION The main components of the boiler are shown in figures .a and .b. The status of the boiler and the central heating and hot water demands and the corresponding boiler functions are indicated on the 4 x 7 segment display as described in section ..(e).
  • Page 9 TEcHNIcAL INFOrMATION central heating mode (Figure 2.3) Domestic hot water mode (Figure 2.4) The demand for central heating is generated when both the programmer and Hot water has priority. A hot water demand at any the room thermostat are calling for heat. The demand for central heating ceases hot water terminal fitting will override any central if either the programmer or the room thermostat stops calling for heat.

  • Page 10: Technical Data

    TEcHNIcAL INFOrMATION Frost protection mode The boiler has a built in frost protection function. This function can be deactivated by removing the jumper from pins 1 & 9 on connector J3 on the controller PCB (see section 4). When the boiler is in the frost protection mode, its status is shown on the front panel display. If the boiler temperature drops below 10ºC, the pump is switched on and the diverter valve is moved to the central heating mode.

  • Page 11: Principal Dimensions And Fixings

    CONNECTIONS TEcHNIcAL INFOrMATION A Condensate drain 21/22mm plastic overflow pipe B CH Flow 22mm Copper tail C DHW out 15mm Copper tail D Gas supply 22mm Copper tail CW inlet 15mm Copper tail CH Return 22mm Copper tail G PRV discharge 15mm Copper tail 2.4 PrINcIPAL DIMENSIONS AND FIXINGS (FIGurES 2.6 AND 2.7) H Manual air vent...

  • Page 12: User Controls

    uSEr cONTrOLS The user controls consist of a central heating programmer, boiler ‘on-off’ switch and a 4 digit display as shown in figure 3.1. The boiler ‘on-off’ switch should be left in the ON position which is indicated by a flame symbol for normal operation, otherwise the built in boiler frost protection will not function.

  • Page 13: Lighting The Boiler

    uSEr cONTrOLS 3.2 LIGHTING THE BOILEr 3.3 TO TurN THE BOILEr OFF Switch the appliance on/off switch to on position. The dot D1 will begin to flash The boiler is fully automatic in operation. However to indicate that the controller is active and the  – 4 digits will show the system if necessary, the boiler can be switched off pressure in bar (e.g.

  • Page 14: System Design And Planning Information

    This boiler is for use on G0 natural gas only. The boiler is certified to the current issue of EN483, EN66 and EN 677 for performance and safety. It is important that no alteration is made to the boiler, without the written permission of Gledhill Ltd.

  • Page 15: Central Heating Circuit & System

    System bypass The Gledhill GB35C combination boiler is suitable for fully pumped sealed systems The boiler is fitted with an integral bypass valve for only. The sealed heating system is shown schematically in figure 4.1. The sealed the central heating circuit as shown in figure 4..
  • Page 16 SYSTEM DESIGN AND PLANNING INFOrMATION (e) System filling and topping procedure The appliance is supplied with connections points on the mains cold water If an alternative filling method is used for filling and inlet and central heating return isolating taps as shown in figure 4.3 to which topping up the water loss from the system then it must the filling loop kit supplied can be temporarily fitted.
  • Page 17 SYSTEM DESIGN AND PLANNING INFOrMATION central heating circuit expansion vessel The seven litre appliance expansion vessel (see figure .a) is supplied pre-charged to 1.0 bar. Therefore the minimum cold fill pressure should be 1.0bar. The vessel is suitable for the correct operation of central heating system capacities up to 70 litres. For greater system capacities an additional expansion vessel must be fitted (as shown in Figure 4.1).

  • Page 18: Domestic Hot Water Circuit

    If scale should ever become a problem the plate heat exchanger is easily isolated and quickly replaced with a service exchange unit which can be obtained at Check nominal cost from Gledhill. Valve Pressure Regulator To Hot Taps Stop Tap...

  • Page 19: Site Requirements

    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 ‘ gas Installation in timber Frame Housing’ . If in doubt, ask local gas utility company or Gledhill Water Storage Ltd.
  • Page 20 SYSTEM DESIGN AND PLANNING INFOrMATION Gas Supply The Local Gas Supplier should be consulted at the installation planning stage in order to establish the availability of an adequate supply of gas. An existing service pipe MUST NOT be used without prior consultations with the gas supplier. A gas meter can only be connected by the Local Gas Supplier or by his Contractor.
  • Page 21 SYSTEM DESIGN AND PLANNING INFOrMATION Notes: (a) The 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. (b) Failure to install the condensate discharge pipework correctly will affect the reliable operation of the boiler. Figure 4.11 (a) connection to an internal soil and vent pipe (b) Termination to drain or gully...

  • Page 22: Flue Location And Ventilation

    Flue Position and Length The flue installation procedures, location of flue terminals, flue kit options etc are described in detail in the ‘Gledhill High Efficiency Condensing Combination Boiler Flue design & Installation Manual’ which is also supplied with the boiler and should be read along with these instructions prior to installation.
  • Page 23 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 figure 4.14 and is available from Gledhill Water Storage Ltd quoting part number GF199.

  • Page 24: Boiler Installation

    BOILEr INSTALLATION 5.1 uNPAcKING OF BOILEr Boiler fixing Important Note: With regard to the Manual Handling Important Note: With regard to the Manual Handling Operations, the following Operations, the following lift operation exceeds the lift operation exceeds the recommended weight for a one man lift. recommended weight for a one man lift.

  • Page 25: Electrical Wiring

    ELEcTrIcAL WIrING 6.1 GENErAL The boiler must be permanently connected to a 30V~, 50Hz supply and it MUST BE EARTHED. In GB: 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. In IE: Reference should be made to the current addition of the ETCI rules.
  • Page 26 ELEcTrIcAL WIrING 6.2 EXTErNAL cONTrOLS AND MAINS SuPPLY The Gledhill GB35C combination boiler is fitted with the wiring terminals Figure 6.2 - Permanent Mains Supply inside the control panel as shown in figures 6.1 and 6.. The access to these...

  • Page 27: Commissioning

    cOMMISSIONING 7.1 GENErAL Commissioning should be carried out by a competent person in accordance with the current issue of BS6798 / The Building Regulations. 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 heating system and the boiler.

  • Page 28: Commissioning The Boiler 8

    cOMMISSIONING 7.2 cOMMISSIONING THE BOILEr Ensure the boiler DHW inlet valve is in the open position. Open the mains water supply to the boiler and fill the DHW system. Check for soundness. b) Open all hot water taps and purge the DHW system. After purging the system close all hot water taps.

  • Page 29: Checking Boiler Functions 9

    cOMMISSIONING 7.4 cHEcKING THE BOILEr FuNcTIONS This appliance is factory set and sealed. No adjustments are necessary. Access to sealed inner casing panel is not required. Domestic hot water Fully open a hot water tap. The boiler will sense the hot water demand and the burner will light, This will be indicated on the display as follows: - bar ‘a’...

  • Page 30: Completion

    cOMMISSIONING 7.5 cOMPLETION Instruct the user in the operation of the boiler and the system including the integral central heating programmer and the room thermostat. The explanation should include the sequence of operation. b) The central heating flow temperature and the domestic hot water outlet temperature are factory set.

  • Page 31: Annual Servicing

    (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 For access refer to section 9.1 BY FAcTOrY SET AND SEALED PArTS SuPPLIED BY GLEDHILL LTD. General Remove the yellow cap from the For reasons of safety and economy, it is recommended that the boiler is serviced annually.

  • Page 32: Changing Parts

    cHANGING PArTS cHANGING 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.

  • Page 33: Spark And Flame Sensing Electrodes

    cHANGING PArTS 9.2 SPArK & FLAME SENSING ELEcTrODES For access refer to section 9.1 General. Remove the spark plug style connector from the electrode (and push fit spade connector from the earth lead in the case of the spark electrode). Remove the two retaining screws with a Torx T0 driver, carefully withdraw the electrode from the combustion chamber.

  • Page 34: Burner Sub Assembly

    These settings must not be adjusted. When required the whole assembly must only be replaced by a factory set and sealed replacement supplied by Gledhill Ltd. After replacing the gas valve the combustion cO2 must always be checked at the point provided on the flue. (See commissioning section of the manual for details).

  • Page 35: Heat Exchanger

    cHANGING PArTS HEAT EXcHANGEr For access refer to section 9.1 General and 9.4 Burner Sub-Assembly. After removing the burner sub assembly drain the unit and remover the friction fit connection on the condense pipe from the bottom of the heat exchanger by pulling downwards.

  • Page 36: Heat Exchanger Insulation

    rEPLAcEMENT OF PArTS HEAT EXcHANGEr INSuLATION For access refer to section 9.1 General and 9.4 Burner Sub-Assembly. After breaking down the assembly as described in the above sections and removing the burner remove the spark electrode by removing the  retaining screws using a pozi type screw driver and lift off the insulation from the back of the combustion chamber cover.

  • Page 37: Expansion Vessel

    rEPLAcEMENT OF PArTS EXPANSION vESSEL For access refer to section 9.1 General and for draining procedure section 9.5 Heat Exchanger. After ensuring the appliance is drained down release the flexible connecting pipe from the hydraulic monoblock assembly by pulling the spring clip forward and pulling the pipe upwards out of the monoblock and up through the seal separating the boiler and hydraulic monoblock compartments.

  • Page 38: Controller Pcb

    9.11 cONTrOLLEr PcB For access refer to section 9.1 General. Remove the clear plastic cover from the inside of the electrical/ lower fascia panel by removing the 4 retaining screws using a pozi type screwdriver. Remove all the wiring plugs/spade connectors from the PCB after noting the  spade connector locations. NOTE: There is a need on all, other than the spade connectors, to release the retaining clip before carefully removing the various plug in electrical connectors.

  • Page 39: Boiler Pressure And Return Temperature Sensor

    9.14 BOILEr PrESSurE AND rETurN TEMPErATurE SENSOr As the original DHW Flow Rate and Temperature Sensor – section 9.13 9.15 PuMP For access refer to Section 9.1 General and for draining procedures Section 9.5 Heat Exchanger. After ensuring the appliance is drained down remove the electrical plug by squeezing the clip on the back of the plug and pulling out to the left.

  • Page 40: Hydraulic Monoblock

    9.18 HYDrAuLIc MONOBLOcK 9.22 cENTrAL HEATING cLOcK If it should ever prove necessary the whole of the hydraulic monoblock can be For access refer to Section 9.1 General. Remove the removed and replaced. For access refer to Section 9.1 General and for draining clear plastic cover and release the two holding screws down procedures Section 9.5 Heat Exchanger.

  • Page 41: Fault Finding

    FAuLT FINDING 10.1 INITIAL cHEcK Check that gas, water and electrical supplies are available at the boiler. The electricity supply should be 30V~ 50Hz. The preferred minimum gas pressure is 0mbar. The boiler pressure should be pressurised to 0.5bar minimum when the boiler and the CH system are cold and no more than .5 bar when the system is hot. Carry out electrical system checks.
  • Page 42 10.2.2 Level-1 (Interrogation Mode) Display Functions The level_1 is intended for use by the service engineers and is used to display When the controller is in Level-1 mode, the following the boiler circuit temperatures, set points and errors. The information flow information can be displayed as described below: - diagram for level_1 is shown below in figure 10.3.
  • Page 43 current boiler temperatures When the controller display is in level_1, the temperature display mode is selected by scrolling the mode by pressing button S until ‘S’ flashes on digit  of the display. The sensor number is selected by pressing button S3. The temperature sensors used in the boiler are listed in table 10.1. The sensor number is displayed by alternatively flashing ‘S’...
  • Page 44 iv.) Fan speeds When the controller display is in level_1, the current fan speed interrogation mode is selected by scrolling the mode by pressing button S until ‘F’ flashes on digit  of the display. The required fan speed set point is selected by pressing button S3. The hot water flow rate information that can be displayed is shown in table 10.4.
  • Page 45 vii.) Warning errors The warning errors will not stop the appliance working. If a warning error occurs, the controller will use fault tolerant algorithm to keep the appliance working although full service may not be available. The warning errors are listed in table 10.5. Table 10.5 Error codes LOcKING ErrOrS ‘c’...
  • Page 46 SPArE PArTS 10.2.3 Level-2 Display Functions The level_ is intended for use by the service engineers only and it is used to change the pre-set values e.g. central heating flow temperature. The level- menu is accessed by simultaneously pressing and holding the push buttons S and S3 for at least 10s. The dot ‘D4’ will be lit when level- is menu is selected.
  • Page 47 ii.) changing temperature settings The standard appliance is supplied with the central heating flow temperature, central heating circuit temperature difference and the domestic hot water outlet temperature settings factory set at the default values shown in Table 10.. However, in the unlikely event it is required these can be changed within the pre-set limits when the controller is in level-.

  • Page 48: Computer Software

    If further analysis is required the appliance functions, detailed fault diagnostics The appliance wiring diagram is shown in figure 10.4. and the design parameters can be accessed/changed by Gledhill Engineers Ensure that wiring details are followed when a PCB, using specialist software/equipment.
  • Page 49 Page 49...
  • Page 50 Page 50...

  • Page 51: Bench Mark Commissioning Check List

    BENCHMARK No. GAS BOILER COMMISSIONING CHECKLIST C O L L E C T I V E M A R K BOILER SERIAL No. NOTIFICATION No. CONTROLS To comply with the Building Regulations, each section must have a tick in one or other of the boxes TIME &...
  • Page 52 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.

  • Page 53: Terms And Conditions

    Page 53...
  • Page 54 (c) Integrated Boiler and Storage Vessel Products and Stand Alone Boilers which becomes defective within two years after the In the case of the GulfStream range of products and the Gledhill boiler range of products, Gledhill guarantees date of the delivery by us and is returned to us at the the heat exchanger (boiler) for material and construction faults for two years.
  • Page 55 Gledhill will replace, free of charge, any plate heat exchanger fitted in recovering any such goods the property in which the appliance as original equipment in which scale formation occurs that materially reduces the effectiveness has remained in us under paragraph (2) above.

Table of Contents