gledhill PulsaCoil 145 User guide

Design, Installation
& Servicing
Instructions
Model Numbers
PulsaCoil 145
PulsaCoil 185
PulsaCoil 215
PulsaCoil 235
All models comply with the water heater manufacturers
specification for thermal stores
A mains pressure hot water supply
system incorporating an off peak
electric thermal store
ISSUE 9:06-08

Page 2
Section Page
DESIGN
Introduction 3
Technical Data 5
System Details 9
INSTALLATION
Site Requirements 13
Installation 14
Commissioning 19
SERVICING
Annual Service 20
Changing Components 20
Short Parts List 21
Fault Finding 22
ADDENDIX
Addendix A 25
Addendix B 26
Addendix C 28
Addendix D 29
Terms & Conditions 30
ISSUE 9:06-08
The code of practice for the installation,
commissioning & servicing of central heating systems
The Gledhill PulsaCoil range is a WBS
listed product and complies with the WMA
Specification for hot water only thermal
storage products. The principle was
developed originally in conjunction with
British Gas. This product is manufactured
under an ISO 9001:2000 Quality System
audited by BSI.
TheGledhillGroup’sfirstpriorityis togivea
high quality service to our customers.
Quality is built into every Gledhill product
and we hope you get satisfactory service
from Gledhill.
If not please let us know.
Building Regulations and Benchmark Commissioning
TheBuildingRegulations(England &Wales) requirethattheinstallation of a heating
appliance be notified to the relevant Local Authority Building Control Department.
From 1st April 2005 this can be achieved via a Competent Person Self Certification
Scheme as an option to notifying the Local Authority directly. Similar arrangements
will follow for Scotland and will apply in Northern Ireland from 1st January 06.
CORGI operates a Self Certification Scheme for gas heating appliances.
Thesearrangementsrepresentachangefromthesituationwherebycompliancewith
theBuildingRegulationswasacceptediftheBenchmarkLogbookwascompletedand
this was then left on site with the customer).
Withtheintroductionofaselfcertificationscheme,theBenchmarkLogbookisbeing
replacedbyasimilardocumentintheformofacommissioningchecklistandaservice
interval record is included with all gas appliance manuals. However, the relevant
Benchmark Logbook is still being included with all Thermal Storage products and
unvented cylinders.
Gledhill fully supports the Benchmark aims to improve the standards of installation
andcommissioningofcentralheatingsystemsintheUKandtoencouragetheregular
servicing of all central heating systems to ensure safety and efficiency.
Building Regulations require that the heating installation should comply with the
manufacturer’s instructions. It is therefore important that the commissioning check
listiscompletedbythecompetentinstaller. Thischecklistonlyappliestoinstallations
in dwellings or some related structures.

Page 3
INTRODUCTION
DESIGN
Any water distribution system/installation must comply with the relevant
recommendations of the current version of the Regulations and British Standards
listed below:-
Building Regulations
RequirementsforElectricalInstallations
Water Regulations
Manual Handling Operations Regulations
British Standards
BS6700 and BS7671.
A suitably competent trades person must install the PulsaCoil and carry out any
subsequent maintenance/repairs. In fact the appliance front cover is secured by
2 screws and this should only be removed by a competent trades person.The
manufacturer’s notes must not be taken as overriding statutory obligations.
ThePulsaCoilA-Class isnotcoveredbysectionG3ofthecurrentBuildingRegulations
and is therefore not notifiable to Building Control.
The PulsaCoil A-Class is not intended for use by persons (including children) with
reducedphysical,sensory ormentalcapabilities,or lack ofexperienceorknowledge,
unlesstheyhavebeengivensupervisionorinstructionconcerninguseoftheappliance
by a person responsible for their safety.
Children should be supervised to ensure that they do not play with the appliance.
The information in this manual is provided to assist generally in the selection of
equipment. The responsibility for the selection and specification of the equipment
must however remain that of the customer and any Designers or Consultants
concerned with the design and installation.
Please Note: We do not therefore accept any responsibility for matters of design,
selection or specificationorforthe effectiveness ofaninstallationcontainingone of
our products unless we have been specifically requested to do so.
All goods are sold subject to our Conditions of Sale,which are set out at the rear of
this manual.
Intheinterest ofcontinuouslyimproving thePulsaCoil range,GledhillWaterStorage
Ltdreservetherighttomodifytheproductwithoutnotice,andinthesecircumstances
thisdocument,whichisaccurateatthetimeofprinting,shouldbedisregarded. Itwill
however be updated as soon as possible after the change has occurred.

Page 4
DESIGN
INTRODUCTION
The PulsaCoilA-Classshownschematicallyaboveisdesignedtoprovideanimproved
method of supplying mains pressure hot water when used with a suitable off peak
electric supply/tariff.
An important feature of the concept is that hot water can be supplied directly from
themainsatconventionalflowrateswithouttheneedfortemperatureandpressure
reliefsafety valvesorexpansionvessels. Thisisachievedbypassingthemainswater
throughaplateheatexchanger. Theoutlettemperatureofthedomestichotwateris
maintainedbyaprintedcircuitcontrolboard,whichcontrolsthespeedofthepump
circulating the primary water from the store through the plate heat exchanger.
The Building Regulations L1A: New dwellings/L1B: Existing dwellings and the
requirementssetoutintheDomesticHeatingComplianceGuidespecifythat“where
the mains water hardness exceeds 200ppm provision should be made to treat the
feedwatertowaterheatersandthehotwatercircuitofcombinationboilerstoreduce
the rate of accumulation of lime scale”.
Tocomplywiththisrequirementthehardnessofthemainswatershouldbecheckedby
theinstallerandifnecessarytheoptionalfactoryfittedin-linescaleinhibitorshouldbe
specified at the time of order for hardness levels between 200 and 300 ppm (mg/l).
Wherethewaterisveryhardie300ppm(mg/l)andabovethe optionalpolyphosphate
type,inhibitorshouldbespecifiedatthetimeoforder. However,thiswillneedtobe
fitted by the installer at a suitable point in the cold water supply to the appliance.
THEPRINTEDCIRCUITBOARDINCORPORATES
THE FACILITY TO AUTOMATICALLY RUN
THE D.H.W. PRIMARY PUMP FOR ABOUT
3 SECONDS EVERY 30 HOURS TO HELP
PREVENT IT STICKING. FOR THIS REASON
WE WOULD RECOMMEND THAT ONCE THE
APPLIANCE IS INSTALLED IT SHOULD BE
COMMISSIONEDANDTHEELECTRICITYLEFT
ON TO THE APPLIANCE.
Because this product does not require a safety
discharge from a temperature and pressure
relief valve, any installations will be easy to
incorporateintothebuildingandwillnotsuffer
fromthe problemsassociatedwithusingPVCu
soilstackstotakethedischargefromunvented
cylinders.
Theheatlossesfromthermalstoresshouldnot
be directly compared with heat losses from
unventedorventedcylindersbecausetheyare
treated differently in SAP. The SAP calculator
takes account of the type of store and various
correction factors are included to reflect the
different ways that the hot water and heating
operates.
Figure 1.1
Schematic Hydraulic Arrangement
1. Bottom (Off-Peak) immersion heater
(1H_1)
2. Top (On-Peak) immersion heater (IH_2)
3. Overheat sensor pocket (Sensor S1/S2)
4. Top/middle sensor pocket (Sensor S6 for
IH_2)
5. Bottom sensor pocket (Sensor S5 for
IH_1)
6. Cold water inlet sensor, S3
7. DHW outlet sensor, S4
8. Grundfos UPR 15-50 pump
9. Filter & flow regulator
10. Plate heat exchanger
11. Pump isolating valve
12. Non-Return valve
13. Pre-expansion chamber
14. Open vent
15. Cold Feed
16. CW inlet
17. HW outlet
18. Drain
19. Return from PHE to store
20. Flow from store to PHE
Cistern can be provided
with a ballvalve and
overflow connector as an
optional extra if required.
Appliance
case
Top up cistern
7, S4
6, S3
PULSACOIL
A-CLASS
4, S6
5, S5
19 18
12
16
10
17
11
11
8
9
20
14 15
3, S1/S2
2
1
13

Page 5
Technical Specification PulsaCoil A-Class
Model PCA145 PCA185 PCA215 PCA235
Height (mm) 1042 1142 1300 1440
Width (mm) 530 530 530 550
Depth (mm) 595 595 595 595
Min cupboard height (mm) 1800 1900 2050 2200
Min cupboard width (mm) 550 550 550 570
Min cupboard depth (mm) 600 600 600 600
Weight (empty) (kg) 40 42 44 48
Weight (full) (kg) 187 206 230 258
Volume of water heated by on-peak heater (litres) 65 65 70 75
Model Selection Guide PulsaCoil A-Class
DwellingType
Bedroom 1-2 2-3 2-3 2-4
Bathroom 1 or 1 1 2
En-suite shower rooms 1121
StandardEconomy-7tariff PCA145 PCA185 PCA215 PCA235
10hr Heatwise tariff PCA145 PCA145 PCA185 PCA215
Notes:-
1. Plastic top up cistern will be supplied separately.
2. Theflowratesarebasedona35°Ctemperatureriseandassumethatrecommended
pressures and adequate flow are available at the appliance.The actual flow rate
from the appliance is automatically regulated to a maximum of 28 litres/min.
3. Unit is supplied on a 100mm high installation base.
4. The domestic hot water outlet temperature is automatically regulated to
approximately 52°C at the bath flow rate of 18 litres/min recommended by BS
6700. The temperature is not user adjustable.
Table 1.2
Table 1.1
TECHNICAL DATA
DESIGN

Page 6
Standard Equipment
The standard configuration of the PulsaCoil
A-Class is shown opposite.The Printed Circuit
Control Board (A.C.B.), mounted inside the
appliance, controls the operation of the
completesystem. Thisispre-wiredtoaterminal
stripwhereallelectricalconnectionsterminate.
It is supplied with the following factory fitted
equipment:-
1. 3kW Off-Peak immersion heater
2. 3kW On-Peak boost immersion heater
3. Printed Circuit Board
4. Plate heat exchanger
5. Domestic hot water primary (plate heat
exchanger) pump
6. Isolating terminal connectors for dry fire
protection
7. DHW temperature sensor
8. Incoming cold water sensor
9. Strainer and flow regulator
10. Screwed connection for a drain tap
11. Top up cistern complete with cold feed/
open vent pipework assembly is supplied
separately
12. Overheat thermostat
13. Middle store control sensor
14. Bottom store control sensor
15. Operation/warning light
16. Boost/reset button
17. On/Off switch
Note : Both immersion heaters are low watts
density type with incaloy 825 sheaths and are
speciallymanufacturedtosuitThermalStores. It
isrecommendedthatanyreplacementsshould
be obtained from Gledhill Water Storage.
Optional Extra Equipment
• Scaleinhibitorformainswaterserviceswith
hardness levels above 200 ppm (mg/l)
• Hotandcoldwater manifolds for usewith
plastic pipework.
• Ballvalve/overflow connector for top up
cistern.
Figure 1.2
8
9
4
7
5
15
16
17
14
13
6
12
3
11
2
1
10
DESIGN
TECHNICAL DATA

Page 7
Note: TheAppliancedimensionsabovedonot
allow for the100mm high installation base.
The following table of minimum cupboard
dimensions only allow the minimum space
required for the appliance (including the F & E
cistern). Any extra space required for shelving
etc in the case of airing cupboards etc must
be added.
Note: Theabovedimensions are based on the
Appliance and theTop up cistern (fitted with a
ballvalve) being in the same cupboard. If the
manualfillmethodischosentheheightscan
be reduced by 125mm.
If pipework needs to rise vertically adjacent
to the appliance the width/depth will need
increasing to accommodate this.
Appliance Dimensions
Model Height
AWidth BDepth C
PCA145 1042 530 595
PCA185 1142 530 595
PCA215 1300 530 595
PCA235 1440 550 595
Minimum Cupboard Dimensions
Model Height
DWidth EDepth F
PCA145 1800 550 600
PCA185 1900 550 600
PCA215 2050 550 600
PCA235 2200 570 600
B
E
C
PulsaCoil A-Class
Top up
cistern
Top up
cistern
300 *350A100
D
F
Maintenance
access
Figure 1.3
280
420
*Min maintenance
access to comply with
the Water Regulations
(ballvalve model only)
The minimum
clear opening in
front of the
appliance to be
at least the
same depth as
the appliance.
The cupboard door
opening will need
to take into
account the various
sizes of appliances.
TECHNICAL DATA
DESIGN

Page 8
Connection Details/Dimensions ForTop Of Unit
Figure 1.4
595
530
53
120
385 - Cold Feed/Expansion
323 - Open Vent
Connection Details/Dimensions For Bottom Of Unit
595
530
550
455 - Mains Cold Water Inlet
490 - Hot Water Outlet
Plan Of Appliance Connections
The PulsaCoil A-Class units are supplied on
an installation base to allow the pipe runs to
connect to the appliance from any direction.
It is easier if all pipes protrude vertically in the
cut out area shown. Compression or push fit
connections can be used. All pipe positions
are approximate and subject to a tolerance of
+/- 10mm in any direction. Space will also be
required for a 15mm cold water supply and a
22mm warning / overflow pipe (if the optional
extra ball valve and overflow connector have
been specified. If a warning/overflow pipe
is NOT provided the F&E Cistern should be
filled from a temporary hose connection
incorporating a double check valve.This can
befromatemporaryhoseconnectionsupplied
from a cold water tap or a permanent cold
branchprovidedadjacenttotheTopupCistern.
The temporary connection must be removed
once the appliance is filled.
Note: All dimensions are shown in mm and
are to the centre line of the pipework.
DESIGN
TECHNICAL DATA

Page 9
SYSTEM DETAILS
DESIGN
Hot and ColdWater System
General
A schematic layout of the hot and cold water services in a typical small dwelling is
shownbelow. PulsaCoilA-Classwilloperateatmainspressuresaslowas1barandas
highas5bar although therecommendedrangeis 2-3bardynamicatthe appliance.
If the manifolds (available as an optional extra) are being used the inlet pressure to
themanifoldmust beaminimumof2 bar. Itisalsoimportant tocheckthatall other
equipmentandcomponentsinthehotandcoldwatersystemarecapableofaccepting
the mains pressure available to the property. If the mains pressure can rise above 5
barorthemaximumworkingpressureofanyitemofequipmentorcomponenttobe
fitted in the system,a pressure limiting (reducing) valve set to 3 bar will be required.
If you encounter a situation where the water pressure is adequate but flow rates are
poor please contact our technical helpline for details of an effective solution.
Note :Each Pulsacoil A-Class is fitted with a strainer and flow regulator on the cold
mainssupplyconnection. Ifthesupplypressureis less than 2barorifthemanifolds
(available as an optional extra) are being used or if all taps are provided with flow
regulators the flow regulator on the cold inlet should be removed.
Nocheckvalve or similar deviceshouldbefittedon the cold watersupplybranchto
the PulsaCoil A-Class.
The Building Regulations L1A: New dwellings/L1B: Existing dwellings and the
requirementssetoutintheDomesticHeatingComplianceGuidespecifythat“where
themainswaterhardnessexceeds200ppmprovisionshouldbemadetotreatthefeed
watertowaterheatersandthehotwatercircuitofcombinationboilerstoreducethe
rate of accumulation of lime scale”.
Tocomplywiththisrequirementthehardnessofthemainswatershouldbecheckedby
theinstallerandifnecessarytheoptionalfactoryfittedin-linescaleinhibitorshouldbe
specified at the time of order for hardness levels between 200 and 300 ppm (mg/l).
Wherethewateris veryhardie300ppm (mg/l)
and above the optional polyphosphate type,
inhibitor should be specified at the time of
order. However, this will need to be fitted by
theinstalleratasuitablepointinthecoldwater
supply to the appliance.
The hot water flow rate from the PulsaCoil A-
Class is directly related to the adequacy of the
cold water supply to the dwelling. This must
be capable of providing for those services,
which could be required to be supplied
simultaneously, and this maximum demand
shouldbecalculatedusingproceduresdefined
in BS 6700.
If a water meter is fitted in the service pipe,
it should have a nominal rating to match the
maximum hot and cold water peak demands
calculated in accordance with BS 6700.This
could be up to 60ltr/min in some properties.
Note: The diagram below shows the top up
cistern with ballvalve and warning/overflow
pipewhichcanbesuppliedasanoptionalextra
if required. However, the standard preferred
arrangement is for the cistern to be manually
filled from a temporary hose connection fitted
with a double check valve.
The cistern must not be fitted more than 10
metres above the PulsaCoil A-Class appliance
itself.
Warning/
overflow
pipe
MCWS
Safety/open vent
Shower
Expansion/
cold feed
Second
dwelling
Pressure limiting valve
NOT REQUIRED at
pressures below 5 bar
unless any components
have a lower
maximum working
pressure
Double check valve
NOT REQUIRED unless
pipe supplies more
than one dwelling
‘a’ - flow regulator recommended for
better balance of hot and cold
water supplies
MCWS
supply
pipe
Sink
H C
a a
SV
a a a a
Bath
H C
Hand basin
H C
WC - fitted
with BS1212
ballvalve
C
Figure 1.5
Typical hot and cold water distribution
PULSACOIL
A-CLASS
Check valve
NOT REQUIRED unless
chemical water
treatment unit is fitted
a
Top up cistern

Page 10
DESIGN
TECHNICAL DATA
Hot and ColdWater System
Pipe Sizing / Materials
To achieve even distribution of the available supply of hot and cold water, it is
importantinanymainspressuresystem,thatthepipinginadwellingshouldbesized
in accordance with BS 6700.This is particularly important in a large property with
more than one bathroom.
However,thefollowingruleofthumbguidelinesshouldbeadequateformostsmaller
property types as long as water pressures are within the recommended range.
1. A 15mm copper or equivalent external service may be sufficient for a small 1
bathroom dwelling (depending upon the flow rate available),but the minimum
recommended size for new dwellings is 22mm (25mm MDPE).
2. The internal cold feed from the main incoming stop tap to the PulsaCoil A-Class
should be run in 22mm pipe. The cold main and hot draw-off should also be run
in 22mm as far as the branch to the bath tap.
3. The final branches to the hand basins and sinks should be in 10mm and to the
baths and showers in 15mm (1 metre minimum).
4. We would recommend that best results for a balanced system are achieved
by fitting appropriate flow regulators to each hot and cold outlet. This is
particularly relevant where the water pressures areabove therecommended
water pressure range. Details of suitable flow regulators are provided in
Appendix A.
Note: If manifolds (available as an optional extra) are being used suitable flow
regulators are automatically provided in the manifold and do not need to be
provided at each outlet.See Appendix B for further details.
Alltherecommendationswithregardtopipeworksystemsinthismanualaregenerally
based on the use of BS/EN Standard copper pipework and fittings.
However,wearehappythatplasticpipeworksystemscanbeusedin placeofcopper
internally as long as the chosen system is recommended for use on domestic hot
andcoldwatersystems bythe manufacturerandisinstalledfully inaccordance with
their recommendations.
Thisisparticularlyimportantinrelationtouseofpushfitconnectionswhenusingthe
optional flexible hose kits - see installation section of this manual.
It is also essential that if an alternative pipework material/system is chosen the
manufacturerconfirmsthatthedesigncriteriaofthenewsystemisatleastequivalent
to the use of BS/EN Standard copper pipework and fittings.
Taps/Shower Fittings
Aerated taps are recommended to prevent splashing.
Any type of shower mixing valve can be used as long as both the hot and cold
supplies are mains fed. However all mains pressure systems are subject to
dynamicchangesparticularlywhenotherhotandcoldtaps/showersareopened
and closed,which will cause changes in the water temperature at mixed water
outlets such as showers. For this reason and because these are now no more
expensivethanamanualshowerwestronglyrecommendtheuseofthermostatic
showers with this appliance.
The shower head provided must also be suitable for mains pressure supplies.
However,if it is proposed to use a‘whole body’or similar shower with a number of
high flow/pressure outlets please discuss with the Gledhill technical department.
The hot water supply to a shower-mixing
valveshould be fedwhereverpracticaldirectly
from the PulsaCoil A-CLASS or be the first draw-
off point on the hot circuit. The cold supply
to a shower-mixing valve should wherever
practical be fed directly from the rising mains
via an independent branch. The shower must
incorporateorbefittedwiththenecessarycheck
valvestoprovideback-syphonageprotectionin
accordance with theWater Regulations.
Thesupplyofhotandcoldmainswaterdirectly
toabidet ispermittedprovidedthatit isofthe
over-rimflushingtypeandthatatype‘A’airgap
is incorporated.
Hot and ColdWater System
Ifthelengthofthehotwaterdrawoffpipework
is excessive and the delivery time will be more
than 60 seconds before hot water is available
atthetap,youmaywishtoconsiderusingtrace
heating to the hot water pipework such as the
RaychemHWATsystem. PleaseconsultGledhill
Technical Department for further details.
Note: A conventional pumped secondary
circulation system is NOT suitable for use with
this appliance.
It is important that the cold water pipework
is adequately separated/protected from any
heating/hot water pipework to ensure that
the water remains cold and of drinking water
quality.

Page 11
SYSTEM DETAILS
DESIGN
Electrical Installation
TheSchematicarrangementofthewiringwithin
the PulsaCoil A-Class is shown above.
The whole of the electrical installation shall be
designedandinstalledby a competentperson
fully in accordance with the latest edition of
the Requirements for Electrical installations
BS 7671.
ThePulsaCoilA-Classapplianceisprovidedwith
twosideentry3kWimmersion heatersand has
beendesignedtogenerallyoperatewithanoff
peak supply.
Thelowerimmersionheaterheatsthewholeof
the contents and is normally connected to the
off peak supply.
The upper immersion heater is positioned at a
levelonthePulsaCoilA-Classtoheatthetop65
-75 litresof thestore- seeTechnicalDataTable
onpage5. Thisisconnectedtotheunrestricted
on peak supply and is switched manually by
thehouseholder usingthebuttonprovidedon
the front of the appliance. When pressed the
on-peakboostwillremain active untilthenext
time the off-peak becomes available (unless
switched off again manually).
The size of the appliance and the need to use
the on peak boost facility is reduced if a better
offpeaktariffcanbe agreed withtheelectrical
supply company - see Model Selection Guide
on page 5.
WiringThe PulsaCoil With A Split Consumer
UnitI.e.SeparateOnAnd Off PeakSupplies.
Historically this has been the typical supply
method and no special wiring arrangements
are required.
C2
C1
DHW
Pump
L
N
E
L
N
E
ON PEAK
230V, 50Hz
15A
OFF PEAK
230V, 50Hz
15A
Immersion
(Off Peak)
Immersion
(On Peak)
C1 and C2 : Contactors
PulsaCoil A-Class SchematicWiring Diagram
DHW Outlet Sensor
PHE Inlet Sensor
Control for Off-Peak I.H.
Control for On-Peak I.H.
Store Overheat Sensor
ON
OFF
ON
OFF
ON ON ON ON ON ON
OFF OFF
OFF
OFF
OFF OFF
B16
Off Peak
Element
ON
OFF
20 Amp
MCB
B16
MCB
On Peak
Element
20 Amp
Double Pole
Isolator
Double Pole
Isolator
METER
Twin Tariff Restricted Off Peak Connections
Twin Tariff Consumer Only
RESTRICTED
OFF PEAK
SUPPLY
24 HOUR
DOMESTIC
SUPPLY
Control
Supply
ON PEAK 3KW
OFF PEAK 3KW
Installer
Terminals
Installer
Terminals
Rate1
Rate 2
Boost
Control

Page 12
DESIGN
SYSTEM DETAILS
ON
OFF
ON ON ON ON
ON
OFF OFF
ON
OFF
ON
OFF
ON
OFF
OFF
OFF
OFF
B16
Off Peak
Element
20 Amp
MCB
B16
MCB
On Peak
Element
20 Amp
Double Pole
Isolator
Double Pole
Isolator
METER
Twin Tariff Un-Restricted Off Peak Connections
24 HOUR
DOMESTIC
SUPPLY
Control
Supply
ON PEAK 3KW
OFF PEAK 3KW
Installer
Terminals
Installer
Terminals
Rate1
Rate 2
Boost
Control
Off Peak During
00:00 - 07:00 E7
Immersion Heater
Timeswitch
3KW
Timer Programmed to Synchronized with
Off Peak Availabilty EG. 00:00 - 07:00 E7
ON
OFF
ON ON ON ON
ON
OFF OFF
ON
OFF
ON
OFF
ON
OFF
OFF
OFF
OFF
B16
Off Peak
Element
20 Amp
MCB
B16
MCB
On Peak
Element
20 Amp
Double Pole
Isolator
Double Pole
Isolator
METER
SingleTariff Domestic Supply No Off Peak Connections
24 HOUR
DOMESTIC
SUPPLY
Control
Supply
ON PEAK 3KW
OFF PEAK 3KW
Installer
Terminals
Installer
Terminals
Rate1
Boost
Control
WiringThePulsacoilA-ClassWithCombined
On And Off Peak Supplies
Withthisarrangementthedwellinghasasingle
supply to the consumer unit from the meter
and the whole dwelling goes off-peak or on-
peak when the tariff changes at the meter. In
this case a single channel clock will need to be
fittedintheoffpeaksupplytothePulsaCoil.The
off-peaktimeclockwillneedtobesynchronised
with the tariff times set on the meter and be
rated for at least 3kW at 230V.
Although the PulsaCoil A-Class appliance is
primarilydesignedtooperatewith an off peak
supply it will also operate quite successfully
if it is only supplied with an on peak supply.
However, this will substantially increase the
running costs of the appliance and should
only be considered if an off peak supply is not
available.
Wiring The Pulsacoil A-Class When Only An
On Peak Supply Is Available
Withthisarrangementthedwellinghasnooff-
peaktariffavailable. Becausetheappliancewill
continuouslysensethe presenceof asupplyat
the bottom immersion heater (normally off-
peak)thecontrollerwillalwaysusethebottom
immersion heater to charge the store and
boost will not be available unless the bottom
immersion heater fails.
To allow the appliance to operate successfully
with on peak only supplies,two separate 16A
230V 50Hz supplies MUST be provided with
one wired into the on peak connections in the
normal way and the other wired into the off
peak connections.
In all cases the two switches/isolators must be
clearly labelled for the householders use.

Page 13
SITE REQUIREMENTS
INSTALLATION
The appliance is designed to be installed in an airing/cylinder cupboard and the
relevant minimum dimensions are provided in the Technical Data section of this
manual.
Becauseoftheeaseofinstallationwerecommendthatthecupboardconstructionis
completed and painted before installation of the appliance.The cupboard door can
be fitted after installation.
Iftheunitneedsto be stored priortoinstallationitshould be stored uprightinadry
environment and on a level base/floor.
Installationandmaintenanceaccessisneededtothefrontoftheapplianceandabove
the Top up cistern. See the Technical Data section of this manual for further details.
The minimum dimensions contained in the Technical Data section of this manual
allowforthepassage/connectionofpipestotheappliancefromanydirectionaslong
astheappliance isinstalledonthe installationbaseprovided.If theinstallationbase
isnotused extraspacemay beneededtoallow connectiontothe pipeworkandthe
whole of the base area should be continuously supported on a material which will
not easily deteriorate if exposed to moisture.
Thefloorofthe cupboardneedstobe level andevenandcapable of supportingthe
weight of the appliance when full.Details of the weight when full is provided in the
Technical Data section of this manual.
The appliance is designed to operate as quietly as practicable. However, some
noise(frompumpsetc)isinevitablewhenhotwater is being used. This will be most
noticeable if the cupboards are located adjacent to bedrooms, on bulkheads, or at
the mid span of a suspended floor. Some noise may also be experienced from the
immersion heaters as the store approaches its design temperature.
Cupboard temperatures will normally be slightly higher than in a conventional
systemandthedesignofthe cupboard and door will need totakethisintoaccount.
No ventilation is normally required to the cupboard.
TheseparateTopupcisternwillneedtobelocatedontopoftheapplianceorathigh
level in the cupboard housing the PulsaCoil A-Class.The dimensions and clearances
are provided in the Technical Data section of this manual.The location will need to
provide a suitable route for the cold feed expansion pipe as well as the open safety
ventpipe.Thelocationwillalsoneedtoprovideasuitablerouteanddischargeposition
for the warning/overflow pipe and the ballvalve supply from the mains cold water
system (if provided) if these have been ordered as an optional extra.
Note: The standard appliance is supplied with a cistern without a ballvalve/
overflow for filling manually.
An electrical supply must be available which is correctly earthed, polarized and in
accordancewiththelatesteditionoftheIEErequirementsforelectricalInstallations
BS 7671.
The electrical mains supply needs to be 230V/50Hz.
The sizes/types of electrical supplies must be as detailed in System Details section
of this manual.A means for disconnection from the supply mains having a contact
separation in all poles that provides full disconnection under over voltage category
IIIconditionsmust beincorporatedinthe fixedwiring inaccordancewiththewiring
rules.This shall be located within 1m of the appliance and only serve the appliance.
The hot and cold water ‘first fix’ pipework should be terminated 50mm above the
finishedfloorlevelinaccordancewiththedimensionsprovidedintheTechnicalData
section of this manual.

Page 14
INSTALLATION
INSTALLATION
Br
Br
Br
Br
Y
Br
G
Wh
Wh
Wh
Wh
Wh
S4
S5
S6
S3
S1 & S2
Bl Br
NL
2341
ON
SPD1/2A
SCALE INHIBITOR
PART No.
XB142
COM
312 4
ISSUE No : 6
APPROVED
DATE : JUNE 2007 DO NOT SCALE FROM THIS DRAWING. COPYRIGHT OF THIS DRAWING
IS RESERVED. IT IS NOTTO BE REPRODUCED COPIED OR DISCLOSED
TOA THIRD PARTY EITHER WHOLLY OR IN PART WITHOUT OUR
WRITTEN CONSENT.
© GLEDHILL WATER STORAGE LTD.
DRN. SIGN. DATE. DATEAPP'D.CH'KD.DATE 08-06-07 08-06-0708-06-07S. McGachie S. Gataora
S. McGachie SIGN.
ON
IH
L
ON
PEAK
L
ON
PEAK
N
ON
PEAK
PE
ON
IH
N
OFF
IH
L
OFF
PEAK
L
OFF
PEAK
N
OFF
PEAK
PE
OFF
IH
N
ON
PEAK
F1
OFF
PEAK
F2
A1
A2
11
12
14
RELAY R1
01
200 - 240Vac 50Hz
28
6
4
RELAY R2
01
200 - 240Vac 50Hz
28
6
4
On Peak Supply
1.5mm Flex
Off Peak Supply
1.5mm Flex
22
LNE LNE
ON PEAK
RELAY
R3
OFF PEAK

Page 15
INSTALLATION
INSTALLATION
LNEM
B
Bl
Bl
Br
Br
Bl
Bl
Bl
Bl
RR
R
R
BB
R
G/Y
G/Y
Br Br
Br
Br
Br
Br Br
V
V
Y
B
Y
B
Or
Or
R
R
ROr R
Or
Or
Or
B
B
Y
Y
ID_RESISTOR
FRONT PANEL
Red LED
Push Button
'A' Class Pulsacoil ver 6.ai
J33
J32
J34
J28
J29
J5
J3
J30
J31
J9
DHW
Pump
(ON PEAK SIGNAL)
(OFF PEAK SIGNAL)
(OFF PEAK IMMERSIONHEATER)
(ON PEAK IMMERSION HEATER)
* All wire sizes 0.5mm² unless otherwise stated
1A
1B
1
01
Off - On Green Neon Rocker
8765
A
B
C
D
E
DRG. NAMEDRG. SIZE
JOB NAMETITLE
A3
GLEDHILL WATER STORAGE LTD.
SYCAMORE TRADING ESTATE
SQUIRES GATE LANE
BLACKPOOL
LANCASHIRE
FY4 3RL
'A' CLASS PULSACOILAPPLIANCE
ELECTRICAL SCHEMATIC DRAWING 'A' CLASS PULSACOILAPPLIANCE
On Peak
Immersion
3kW
Off Peak
Immersion
3kW
TOP BOTTOM

Page 16
HANDLING
When lifting the unit work with someone of similar build and height if possible.
Choose one person to call the signals.
Lift from the hips at the same time, then raise the unit to the desired level.
Move smoothly in unison.
Larger units may require a team lift.
A specific manual handling assessment is shown in Appendix D
at the rear of this manual.
Preparation/placing The Appliance In
Position.
The ‘first fix’ pipework positions should be
checked using the template provided with
each appliance. If these have been followed
installation is very simple and much quicker
than any other system.
The appliance is supplied shrink wrapped on a
timber installation base. Carrying handles are
also provided in the back of the casing.
The feed and expansion cistern complete with
ballvalve, cold feed/expansion and overflow/
warningpipefittingsareprovidedinaseparate
box.
The appliance should be handled carefully to
avoiddamageandthe recommendedmethod
is shown above.
Note:Althoughtheaboveguidanceisprovided
any manual handling/lifting operations will
need to comply with the requirements of the
ManualHandlingOperationsRegulationsissued
by the H.S.E.
Theappliancecanbemovedusingasacktruck
ontherearfacealthoughcareshouldbetaken
and the route should be even.
In apartment buildings containing a number
of storeys we would recommend that the
appliancesaremovedverticallyinamechanical
lift.
If it is proposed to use a crane expert advice
should be obtained regarding the need for
slings, lifting beams etc.
Beforeinstallationthesiterequirementsshould
be checked and confirmed as acceptable.
The plastic cover and protective wrapping
shouldberemovedfromtheapplianceand the
installation base (provided) placed in position.
Theappliancecanthenbeliftedintopositionin
the cupboard on top of the base and the front
panelremovedbyunscrewingthe2screwsand
liftingthedoorupandout,readyforconnection
of the pipework and electrical supplies.
The feed and expansion cistern support shall
be installed ensuring that the base is fully
supported, theworkingheadoftheappliance
is not exceeded and the recommended access
isprovidedformaintenance-seetheTechnical
Data section of this manual for details.
INSTALLATION
INSTALLATION

Page 17
Pipework Connections
The position of the pipework connections is
shownopposite.Theexactlocationdimensions
are listed in the Technical Data section of this
manual.
All the connections are also labelled on the
appliance. It is essential that the pipework is
connected to the correct connection.
Connections A and B are plain ended copper
pipe.
Connection C and D compression fittings.
Connection E is RC½ (½ in BSPT internal)
A - 22mm Safety open vent
B - 15mm Cold feed/expansion
C - 22mm Incoming mains cold water
D - 22mm Domestic hot water
E - ½”Drain tap connection
Note: The safety open vent and cold feed/
expansion must be connected to thetopup
cisternusingthepipeworkassemblyprovided.
Do not alter or connect any pressure-relief
device to the vent pipe of this water heater.
Allfactorymadejointsshouldbechecked after
installation in case they have been loosened
during transit.
The fittings for the top up cistern should be
installed following the instructions provided
and the cistern fitted on its supports/top of
the appliance.
The cold feed/expansion and safety open vent
shouldbeinstalledbetweentheapplianceand
the top up cistern.
Figure 1.6
C
D
BA
E
INSTALLATION
INSTALLATION

Page 18
Cold feed / open vent
pipework
(as supplied)
Interconnecting
Pipework
(By Installer)
Figure 1.7
PulsaCoil
Electrical Connection - Standard Appliance
The PulsaCoil A-Class is pre-wired internally,
strictlyinaccordancewiththeIEERequirements
forElectricalInstallationsBS7671. Theexternal
wiring/connections should be carried out by a
competent person to the same standard. The
arrangementoftheinternalwiringisshownon
the previous page.
All the terminals are suitably labelled.
Note:Donotattempttheelectricalworkunless
you are competent to carry it out to the above
standards.
Before commencing check that the power
source is in accordance with the Site
Requirements section of this manual and
ensurethatitisisolatedasshownintheSystem
Details section.
Run the external wiring from the adjacent
isolatorthroughtheserviceslotprovidedinthe
base of the appliance.
Make the connections as shown below.
Clamp the cables in the grips provided and
ensure all cables are routed to avoid hot
surfaces.
Note:Theappliancepipeworkshouldbebonded
to earth to comply with the IEE Requirements
for Electrical Installations BS 7671.
Beforeswitchingontheelectricalsupplycheck
all the factory made terminal connections to
ensure they have not become loose during
transit.
Combined Feed And Open Vent Pipe
Itisnormally envisagedthat thetopup cisternwillbe locatedinthe samecupboard
as the PulsaCoil A-Class appliance itself to maintain a dry roof space.
The cold feed/open vent pipework assembly (as supplied) should be used to install
the top up cistern directly on top of the appliance.
If it is necessary to locate the cistern in the roof space (or on a higher floor) the cold
feed/openventpipeworkassembly(assupplied)shouldbeusedtoconnecttothetop
up cistern and pipework site run by the installler to connect this to the appliance.
Obviously, any pipework in the roof space and the feed and expansion cistern will
need to be adequately insulated to protect against frost damage.
Combined Feed And Open Pipe Arrangements Must Not Be Used.
Novalvesshouldbefittedinthesafetyopenventwhichmustbeaminimumof22mm
copper pipe or equivalent throughout its length.
The mains cold water supply to the ballvalve (if provided) shall be provided with a
suitable servicing valve.
The overflow/warning pipe (if provided) shall have a continuous fall, be fitted to
dischargeclearofthebuildingandbesitedsothatanyoverflowcanbeeasilyobserved.
It shall also be installed in a size and material suitable for use with heating feed and
expansion cisterns in accordance with BS 5449 (e.g 22mm copper) and should not
have any other connections to it.
Note:If a warning/overflow pipe is NOT provided the top up cistern should be
filled from a temporary hose connection supplied from any cold water tap or
from a permanent cold branch provided adjacent to the top up cistern. The
temporary hose must be fitted with a double check valve and removed once
the appliance is filled.
The store may fill more slowly than the feed tank. It is important to check the
water level again in the cistern after commissioning.
ON
IH
L
ON
PEAK
L
ON
PEAK
N
ON
PEAK
PE
ON
IH
N
OFF
IH
L
OFF
PEAK
L
OFF
PEAK
N
OFF
PEAK
PE
OFF
IH
N
On Peak Supply
1.5mm Flex
2
Off Peak Supply
1.5mm Flex
2
LNE LNE
ON PEAK OFF PEAK
INSTALLATION
INSTALLATION

Page 19
COMMISSIONING
INSTALLATION
Opentheincomingstopvalveandfillthedomesticmainscoldandhotwatersystems
including the PulsaCoil A-Class appliance.
Check the water level in the top up cistern and if a ballvalve is fitted adjust if
necessary.
Check the whole of the domestic hot and cold distribution systems for leaks. Fully
flush and if necessary chlorinate the hot and cold water system in accordance with
the recommendations in the Water Regulations and BS 6700.
Pleasenotethatthewholeofthedomestichotandcoldwatersystemsincludingthe
appliancemustbeadequatelyflushedafterchlorination. Failuretodothiscancause
damagetotheplate heat exchanger/immersionheatersetc. Ifthereare any doubts
regardingthisorthequalityofthewaterbeingusedtofillthePulsaCoilappliancean
inhibitorsuchasFernoxMBIorSentinelX100shouldbeaddedtotheappliancewhen
filling in line with the manufacturers instruction for these products.
Check that the top up tank is filled up to the water level shown on the label. If it is a
manual fill model, this is most important.
Ifaballvalveisprovided,turndowntheservicingvalveoncethesystemisfinally
filledtothepointwherethewarning/overflowpipewillcopewiththedischarge
arising from a ballvalve failure.
If an overflow is not provided ensure the temporary filling hose is isolated and
removed from its connection to the cold water supply.
It is essential that all systems function properly for optimum performance.
Toachievethistheflowratefromeachtapshouldbecheckedandasuitablenumber
of taps run simultaneously to check the impact of this on the flow rate at individual
taps.
We recommend that flow regulators are provided for each tap/terminal fitting
to ensure that the available flow is shared evenly - See Appendix A for further
details.
Commissioning the PulsaCoil Control System
OncethePulsaCoilA-Classisfilledwith water,checktheon/offswitch onthefrontis
intheoff position. The electricalsuppliescanthen beswitchedonand the switches
on the two isolating terminal connectors can be pushed home.
WARNING - Pushing home these switches will complete the electrical circuit to the
immersion heaters. DO NOT PUSH HOME THESE SWITCHES AND SWITCH ON THE
ELECTRICITY SUPPLY UNTIL YOU HAVE CHECKED THAT THERE IS WATER IN THE F
& E CISTERN. Failure to do this can result in dry firing and premature failure of the
immersion heaters, which will invalidate the warranty.
Puttheon/offswitchonthefrontcontrolpanel
to the on position to activate the appliance
controlboard.Theswitchwillglowgreenwhen
in the on position.
If an off peak supply is not available the on-
peak boost immersion heater will need to be
switched on by pressing the black button. The
red light will change to permanently on.
It can be checked that the boost immersion
heater is drawing current by use of a clamp
meter on the live supply when boost is active
or by interrogating the printed circuit control
boardinaccordancewiththeinstructionsinthe
fault finding section of this manual.
The sensor control set points are shown on
page25andcanbecheckedonthe2digitACB
display.
The boost immersion heater can be switched
off by pressing again the black button.
If an off peak supply is available at the time
theapplianceis switchedontheappliance will
automaticallyswitchontheoffpeakimmersion
heater. Its operation can be checked in the
same way as described above for the on peak
immersion heater. When the off peak supply
is available the on peak immersion heater
operation can still be checked as described
above by switching off the off peak supply.
Note:Iftheonandoffpeaksupplieshavebeen
connectedwrongly(“crossed”)attheappliance
itwillnotoperate properly (it maychargeifoff
peakisavailablebutwillnotcarryoutanyother
operations)
If the appliances has been connected with the
polarity incorrect it will not operate at all.
See the fault finding section of the manual for
further details.
Run a tap and using a digital thermometer
check that the temperature of the hot water is
about52°C.Thistemperatureisfactorysetandis
independentofthestoretemperatureassuming
the store is above 55°C and typical hot water
flow rates of 6-25l/min are being drawn.
This product is covered by the ‘Benchmark’
scheme and a separate commissioning/
service log book is included with this
product. This must be completed during
commissioning and left with the product
to meet the Warranty conditions offered by
Gledhill.
OFF
ON
FLASHING
Normal
On-Peak boost active
Fault attention required
PUSH BUTTON To activate On-Peak boost
ON/OFF SWITCH Control circuit power
supply

Page 20
SERVICING
ANNUAL SERVICE/CHANGING COMPONENTS
Important Do’s and Don’ts
1. DO check the incoming mains water pressure. The preferred range of mains
pressure is 2 -3 bar.
2. DOcheckthe flowrateoftheincomingcold watermainis adequatetomeetthe
maximum hot and cold water simultaneous demands.
3. DOcheckthatallconnectionsareinaccordancewiththelabellingonthethermal
store.
4. DO NOT push home the 2 switches on the isolating terminal connectors and
switch on the electricity supply until you have checked that the appliance is full
of water i.e.there is water in the top up cistern.
5. DO check the water level is correctly set in the top up cistern when cold and if
fitted that there is no overflow when the appliance is up to temperature.
6. DO check that the sensors switch the immersion heaters off at the correct set
point i.e.approx 70°C.
7. DO insulate any exposed hot water pipework in the PulsaCoil cupboard.
8. If the ballvalve in the F & E cistern is permanently connected to the mains cold
watersupply DOplumb theoverflow/warning pipeina20mminternaldiameter
pipe and ensure it discharges in a conspicuous external position. Use a material
which is suitable for use with heating F & E cisterns in accordance with BS 5449
(such as copper).
9. DO ensure the green light‘on/off’ switch glows.
10. OncetheapplianceisfilledandcommissionedDOleavetheelectricity switched
on to the appliance to ensure the automatic pump run facility can operate to
prevent the pump sticking.
11. DO ensure that the functioning and control of the system is explained to the
occupant.
12. DON’Tplaceanyclothingorothercombustiblematerialsagainstorontopofthis
appliance.
Theseinstructionsshouldbeplacedalongwiththecomponentmanufacturers
instructions inthe pocketprovidedon therearofthefrontpanel. The front
panel should then be refitted.
Annual Servicing
No annual servicing of the PulsaCoil A-Class is
necessary.
However, if required, the operation of the
controls and a hot water performance test can
becarriedouttoprovetheapplianceisworking
satisfactorily and within its specification.
If it is decided to carry out the above tests the
water level in the top cistern should also be
checked and if necessary topped up.
Changing Components
Free of charge replacements for any faulty
componentsare availablefromGledhillduring
the in-warranty period on return of the faulty
part (normally 12 months).
After this, spares can be obtained direct from
Gledhill using the ‘Speed Spares’ service, or
throughanyofthelargerplumbersmerchants/
specialist heating spares suppliers.
Help and advice is also available from the
Technical Helpline on 08449 310000.
However,allcomponentsarereadilyaccessible
and can be changed quickly and easily by the
installer using common plumbing/electrical
practice.
Note: AllmaintenanceworkonthePulsaCoil
appliancemustbecarriedoutbyacompetent
trades person.
Note:
The pump is a Grundfos UPR 15-50 4 wire
pattern and any replacement must be the
same model.