gledhill GC2000/120/E-OV Design, Installation & Servicing Instructions

A combined primary storage unit (cpsu) for domestic hot water supply and central heating appliance category 1 2h types c13:c53:c33 destination gb: ie, nox class 5

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GULFSTREAM 2000
GULFSTREAM 2000
A Combined Primary Storage Unit (CPSU) for
Domestic Hot Water Supply and
Appliance Category 1
Destination GB : IE, Nox CLASS 5
Intended for use with a governed meter only
DESIGN, INSTALLATION AND
SERVICING INSTRUCTIONS
PLEASE LEAVE THESE INSTRUCTIONS IN THE POCKET PROVIDED ON
Supplied By www.heating spares.co Tel. 0161 620 6677
Central Heating
2H
THE BACK OF THE FRONT PANEL
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FOR USE WITH NATURAL GAS ONLY (G20) SUPPLY PRESSURE 20mbar
These instructions are to be followed and specification of the appliance must not be
modifed unless recommended by Gledhill Water Storage Limited.
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, in accordance with the above regulations. Failure to install
appliances correctly could lead to prosecution.''
IMPORTANT - 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.
In the interest of continuously improving the GulfStream
Storage Ltd reserve 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.
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range. Gledhill Water

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Summary of Contents for gledhill GC2000/120/E-OV

  • Page 1 FOR USE WITH NATURAL GAS ONLY (G20) SUPPLY PRESSURE 20mbar These instructions are to be followed and specification of the appliance must not be modifed unless recommended by Gledhill Water Storage Limited. 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, in accordance with the above regulations.
  • Page 2: Table Of Contents

    Fault Finding ������������� � ��������� �� ������� ������� ������� Servicing As part of the industry wide “Benchmark” Initiative all Gledhill GulfStream boilers now include a Benchmark Installation, Commissioning and Service Record Component Exchange Logbook. Please read this carefully and complete all sections relevant to the appliance installation.
  • Page 3 IMPORTANT NOTICE Any installation must be in accordance with the relevant requirements of the current issue of Gas Safety (Installation and Use) Regulations, Local Building Regulations, the Building Standards (Scotland) Consolidations, I.E.E. Wiring Regulations, Local Water Company Byelaws and Health & Safety Document No. 635 - The Electricity at Work Regulations 1989.
  • Page 4: Description

    DESCRIPTION INTRODUCTION GulfStream 2000 (figures 1 and 2) is a room sealed, gas fired, fan flued condensing Combined Primary Storage Unit for supplying wet central heating and mains pressure hot water for dwellings with a design heat loss of up to 25kW. The principle is to separate the heat generator (i.e.
  • Page 5: Clearances & Cupboard Sizes

    DESCRIPTION CLEARANCES AND CUPBOARD SIZES ����� ���� ��������� ��� Sizes - All models overall - ��������� ������ � � � ������� 1300mm 595mm 595mm ����� ���� Ensure compliance with the following: ��������� ��� Clearances required for installation and servicing: ��������� Top 450mm Base nil - appliance is plinth mounted Rear (5-150)mm depending on flue application...
  • Page 6: Boiler

    DESCRIPTION 1⁄2 " / l ( f e i l l a ) l l C º C º t i l 5. Roof Terminal Flue Kit - The balanced BOILER roof terminal flue system comprises a number of push fit socketted concentric The GulfStream is a room sealed fanned flued condensing boiler with a range of components and is designed to allow air flueing options.The boiler incorporates the latest in gas appliance technology.
  • Page 7 DESCRIPTION ��������� ������ ������� ����� ��� ��������� ������� �������� ������� ������ ����� ��� ����� ���� ��� ����� ���� ��������� ������� ������� ���� ���� ���������������� �������� ����� � ���� �������� ��� ���� ���������� ���� ����� ��� ������ �� ��������� ��� ��� ����� �����...
  • Page 8 DESCRIPTION Figure 5 GulfStream 2000/120/E-OV and 2000/130/E-OV (suitable for open vented systems only) Page 8 Supplied By www.heating spares.co Tel. 0161 620 6677...
  • Page 9: Gas Supply/Electrical Supply

    DESCRIPTION GAS SUPPLY ���������� ���� ������ ��� ������ ��� ����� 1. The Local Gas Supplier should be consulted at the installation planning stage in order to establish the availability of an adequate ��� � ��� ������� ������ ������ supply of gas. ����...
  • Page 10: Appliance Location

    DESCRIPTION APPLIANCE LOCATION HOT WATER PERFORMANCE The following limitations MUST be observed when siting the boiler: The hot water performance of the appliances is shown in Figure 8. The flow rates and 1. The appliance is room sealed and can be located in any room/compartment corresponding maximum water volumes drawn in a domestic property.
  • Page 11: System Design

    SYSTEM DESIGN 1. VENTILATION 2.3 Cold and hot water distribution The appliance is room sealed and it is not a mandatory requirement to provide network ventilation to the appliance cupboard. However, in many cases the appliance cupboard is also used as an airing cupboard 1.
  • Page 12 60 seconds before hot water is available at the tap,you may wish to consider using trace heating to the hot water pipework such as the Raychem HWAT system. Please consult Gledhill technical department for further details. Page 12 Supplied By www.heating spares.co Tel. 0161 620 6677...
  • Page 13: Space Heating System

    SYSTEM DESIGN 3. SPACE HEATING SYSTEM 3.1 General All GulfStream models are available for both sealed and open vented heating systems The design heat losses for the property will need to be calculated. We would recommend that the method for heat loss calculations, radiator and boiler sizing contained in BS 5449: 1990 is used and compared to the maximum central heating load listed in Technical Data on...
  • Page 14 SYSTEM DESIGN 3.2 Heating System Design 3.2.1 General The installation must comply with the requirement of BS 6798 and BS 5449. Maximum water temperature is 82 ± 2°C. The appliance is supplied with the flow and return connections terminating in 22mm copper pipe or 22mm compression fittings.
  • Page 15 SYSTEM DESIGN In normal circumstances a pressure of 1.0 bar is suitable for most domestic properties. Warning/overflow 220m min. The minimum system pressure should be not pipe maintenance less than the static head, (the height of the access highest point in the system above the expansion vessel plus a margin of 0.5 bar).
  • Page 16 SYSTEM DESIGN 3.3 Heating System Controls ������� ��� �� ������ ��������� ��������� �������� � � � Both the open vented and the sealed system ������� ������ ��������� ��� ����� ���� ���� � models are fitted with the ‘Switch’ electric � �...
  • Page 17: Flue System Design

    FLUE SYSTEM DESIGN 1. GENERAL REQUIREMENTS A full range of flue options are available for the GulfStream 2000 and details can be found in the following separate Design & Installation Manuals. 1. Ridge Terminal Flue Kit 2. Gable Terminal Flue Kit 3.
  • Page 18: Installation And Wiring

    INSTALLATION & WIRING 1. HANDLING/STORING THE APPLIANCE 1.1 The appliance should be handled carefully to avoid damage and the recommended method is shown opposite. Team Lifts. When lifting the unit work with someone of similar build and height if possible. Choose one person to call the signals.
  • Page 19 INSTALLATION & WIRING Note that if a condensate neutraliser is fitted Written approval has already been obtained for: it must be installed and maintained strictly in Hepworth - Hep O BiTite accordance with the manufacturers instructions. John Guest - Speedfit However, if the installation instructions for Yorkshire - Tectite the boiler and neutraliser are contradictory...
  • Page 20 INSTALLATION & WIRING Figure 18 Figure 19 Figure 20 Page 20 Supplied By www.heating spares.co Tel. 0161 620 6677...
  • Page 21: Electrical Wiring

    INSTALLATION & WIRING 3. ELECTRICAL WIRING 3.1 General Requirements NOTE:THIS APPLIANCE MUST BE EARTHED. Flat Twin & Earth PVC Cable to Consumer Unit Flat Twin & Earth Refer to Figures 20, 21 and 22 as applicable. PVC Cable Thread the power supply cable through the larger of the cable restraining glands Room positioned at the top rear RHS of the casing.
  • Page 22 INSTALLATION & WIRING 3.2 External controls • Room Thermostat Remove link ‘L1’ joining ‘red’ and ‘black’ terminal block in the appliance wiring panel. From the room thermostat connect switched live to black terminal. From the appliance ‘red’ terminal take a ‘live’ to ‘live’ connection on the room thermostat.
  • Page 23: Commissioning

    COMMISSIONING 1. GENERAL It is essential that all systems function properly for optimum performance. To Ensure that the sealed system is pressurised achieve this the primary system should be commissioned in accordance with to 1.0 bar. good practice and generally in accordance with the requirements of BS 6798, BS 5449 and BS 7593.
  • Page 24: Initial Lighting

    COMMISSIONING 5. INITIAL LIGHTING Check that the electricity supply is ISOLATED and the selection knob (fascia panel) is The control system is now initialised. The set to ‘Normal Gas Operation’ . Ensure that the boiler and system are full of water by operation of the controls can now be checking the vent points on the boiler and the system charge pressure.
  • Page 25 COMMISSIONING 7. Instruction to Users. 3. Switch off space heating on clock/programmer or room thermostat • Explain the system to the occupant. • Horizontal LED bar 1 ‘HT’ will switch off. • Instruct how to operate and control the • Green LED 3 on the A.C.B.
  • Page 26: Gas Rate & Gas Pressure

    COMMISSIONING 7. PROCEDURE FOR CHECKING AND ADJUSTING GAS RATE AND BURNER PRESSURE (OFFSET) ������ To check and if necessary adjust the burner ���������� ������� ����� pressure (offset), CO and CO levels, the ������ following equipment will be required: A portable gas analyser - CO range 12% maximum - CO range 500ppm.
  • Page 27: Final Adjustments

    COMMISSIONING 8. FINAL ADJUSTMENTS IMPORTANT: Test nipple B is connected via a permanent sensing line to a nipple located in 1. Re-light the appliance and allow the the elbow below the air pipe inlet and it senses air inlet suction which is the thermal store to heat to maximum.
  • Page 28: User Instructions

    USER INSTRUCTIONS User’s Instructions are provided on the front of this appliance and also a separate MANUAL OVERIDE (located between 3 & 4 p.m., user booklet is also packed with the appliance. on the inner dial) Upper position: permanently ‘ON’ Your GulfStream 2000 has been designed to operate at its most efficient when Centre position: time controlled ‘ON’...
  • Page 29: Fault Finding

    FAULT FINDING 1. FAULT FINDING NO HEATING - HOT WATER OK APPLIANCE CONTROL BOARD 1. Check that jumpers on pcb are in correct locations and the pcb has been The correct operation of the board can be booted correctly. checked by carrying out the following proce- dure: 2.
  • Page 30 FAULT FINDING Page 30 Supplied By www.heating spares.co Tel. 0161 620 6677...
  • Page 31 FAULT FINDING Page 31 Supplied By www.heating spares.co Tel. 0161 620 6677...
  • Page 32 FAULT FINDING Figure 29 Page 32 Supplied By www.heating spares.co Tel. 0161 620 6677...
  • Page 33 FAULT FINDING Figure 30 Page 33 Supplied By www.heating spares.co Tel. 0161 620 6677...
  • Page 34 FAULT FINDING Page 34 Supplied By www.heating spares.co Tel. 0161 620 6677...
  • Page 35 FAULT FINDING Page 35 Supplied By www.heating spares.co Tel. 0161 620 6677...
  • Page 36 FAULT FINDING Page 36 Supplied By www.heating spares.co Tel. 0161 620 6677...
  • Page 37 FAULT FINDING Page 37 Supplied By www.heating spares.co Tel. 0161 620 6677...
  • Page 38: Servicing

    SERVICING If the assembly is clean (apart from acceptable To ensure safe, efficient operation of the appliance, it is necessary to carry out dust) it will not be necessary normally to dis- routine servicing at regular intervals. The frequency of servicing will depend on the assemble it further, unless careful inspections particular installation conditions and use to which the appliance is put.
  • Page 39 SERVICING 4. CLEANING THE CONDENSATE TRAP This procedure must be carried out after the appliance has been switched off and made safe. Remove the trap by undoing nuts ‘A’ and ‘B’ . Clean the trap by removing plug ‘C’ taking precautions regarding water in the trap.
  • Page 40: Component Exchange

    COMPONENT EXCHANGE IGNITION ELECTRODES AND IMPORTANT: Before commencing a service or changing a component, ISOLATE the mains electrical supply TURN OFF the gas supply at the service cock. SENSOR REMOVAL To assist with a component identification and associated wiring refer to Figures Both components are removed in the same 4, 5, 18, 19, 20, 31 and 32.
  • Page 41 COMPONENT EXCHANGE BOILER OVERHEAT THERMOSTAT - REMOVAL RESET BUTTON Remove screw on cover (counter clockwise) at the front of the thermostat. Remove Disconnect single nut fixing from reset button the central fixing nut. Remove (pull off ) the leads from the back. and push it through hole in panel.
  • Page 42 COMPONENT EXCHANGE ELECTRIC BOILER OVERHEAT DHW SENSOR - REMOVAL THERMOSTAT - REMOVAL Identify the appropriate cable connections at the main PCB. Disconnect the sensor cables. Cut any cable ties necessary to strip out the cable back to the Remove electric boiler safety cover as described sensor head.
  • Page 43: Spare Parts List

    SPARE PARTS LIST l i c l l a i t s 1⁄2 t a l i l p 1⁄2 c i t r i a 1⁄2 l i o C ° l i o r i f 1⁄2 f e i °...
  • Page 44 SPARE PARTS LIST l i f n i l r i a l n i p i l r i a l n i f l e e l i C ° t a l Page 44 Supplied By www.heating spares.co Tel. 0161 620 6677...
  • Page 45: Terms & Conditions

    APPENDIX A GULFSTREAM 2000 - SP MODELS ONLY Design/Installation details for the CA type backflow prevention valve assembly and anti-vacuum valve C A VALVE ASSEMBLY The above components are supplied loose with the SP models only and will need to be installed on site adjacent to the appliance in accordance with the following instructions ;...
  • Page 46 APPENDIX A GULFSTREAM 2000 - SP MODELS ONLY The CA backflow prevention valve assembly is supplied complete with a tundish for connection to the discharge pipe. � � ������ �� ������� ��� �� � ����� ���������� ������ �� ��������� ���� ��� The construction of the valve is such that the ����...
  • Page 47 APPENDIX B WATER SAVINGS WATER RELATED COSTS CAN BE REDUCED BY GOOD PLUMBING PRACTICE. ���� � ������ � � � � � ��� �� � �� ���� ���� ���� � ��� �� ��� ����������� ������ ���� ��������� � � ������� 4 FIXING OPTIONS FOR TAPS &...
  • Page 48 Gledhill (Water Storage) AMD. AUGUST 2000 1. We only do business upon the Conditions which appear below and no other. Unless we so agree (2) Domestic Mains Fed Products If the copper storage vessel itself or any integral pipework in writing these Conditions shall apply in full to any supply of goods by us to the exclusion of any as part of the storage vessel assembly proves to be defective Conditions or terms sought to be imposed by any purchaser.
  • Page 49 The Purchaser warrants to repair and make good any damage (f ) nothing in these Conditions shall confer on the purchaser any rights or remedies to which the purchaser caused by the affixation of the goods to or their removal would not otherwise be legally entitled.
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  • Page 51 Supplied By www.heating spares.co Tel. 0161 620 6677...
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This manual is also suitable for:

Gulfstream 2000Gc2000/120/eGc2000/130/e-ovGc2000/130/e

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