Commissioning; General; Initial System Filling; Cleansing & Water Treatment - gledhill GC2000/120/E-OV Design, Installation & Servicing Instructions

1. GENERAL

It is essential that all systems function properly for optimum performance. To
achieve this the primary system should be commissioned in accordance with
good practice and generally in accordance with the requirements of BS 6798,
BS 5449 and BS 7593.
Full details of the requirements are given in PAS 33:1999 under Section 10

Commissioning.

2. INITIAL SYSTEM FILLING

Experience with sealed systems shows that make up may be needed during the
first six weeks of operation.
If draining down is necessary, first release any internal pressure by opening the
pressure relief valve, then after ensuring all system and boiler vents are open,
open the drain valve.
Open the CH flow and CH return valves.
Check and adjust the expansion vessel air pressure if necessary to the initial
charge pressure (1.0 bar).
The approved method of filling the sealed heating system/appliance is described
in section 3.2, page 14.
Fill the open vented system in the normal way through the feed and expansion
cistern. If the system fails to fill easily release the air vent on the cold feed connection
on top of the appliance until all the air is released. When the system is full check
the water level in the F & E cistern is correct and regulate the servicing valve
so that in a fault condition the warning/overflow pipe can carry the maximum
water supply rate.
Vent the system via the appliance's automatic air vents and the radiator valves
and system air vents in accordance with normal practice.
Open the cold water inlet cock and allow water to flow through the appliance to the
domestic hot water taps. Ensure all air is vented and there are no leaks.
3. CLEANSING AND WATER TREATMENT
The water system must be thoroughly flushed out, initially with cold water and
ensuring that all valves are fully open.
The correct use of a cleaning agent and addition of the correct strength of a
suitable corrosion inhibitor is essential for the efficient and long life of the
GulfStream 2000 appliance. For this reason we have extensively tested and
would recommend the use of the following Fernox products only for use with
the GulfStream 2000 appliance.
Refil the system and pressurise it to normal working pressure and examine for water
leaks. Rectify if necessary and then add Fernox Superfloc Cleaning Agent to ensure
that all flux residues and installation debris are removed from the system.
Heat the system to full operating temperature and check for water leaks and rectify
if necessary. Flush the system again until the system is clean.
Refil the system and add Fernox MBI Protector to the system ensuring that the
system is fully vented.
Ensure that the water level in the F & E cistern is at correct level in open vented
system models designated by '-OV' .
Supplied By www.heating spares.co Tel. 0161 620 6677
COMMISSIONING
Ensure that the sealed system is pressurised
to 1.0 bar.
When determining the quantities of cleanser
and corrosion inhibitor agent required, be sure
to allow for the increased volume of water in
the primary circuit (70 litres) due to the thermal
store.
It is important when chemically cleansing and
treating the system that this is carried out
fully in accordance with the instructions of the
manufacturer of the product being used.
WARNING: The aluminium waterways of the
GulfStream 2000 boiler require the ph level of
the water to be maintained between 7 and 8 to
ensure long life. This level will automatically be
provided by the Fernox MBI corrosion inhibitor
if the correct concentration is used. However,
dependent on the quality of the water being
used, failure to dose/maintain the correct
concentration will result in premature corrosion
of the boiler.
With an open vented system, once the system
is finally filled, turn down the servicing valve to
the ballvalve in the F & E cistern to the point
where the warning/overflow pipe will cope with
the discharge arising from a ballvalve failure.
POWERFLUSHING/CLEANING OF THE
HEATING SYSTEM
If it is proposed to 'powerflush' the heating
system we would recommend that the
GulfStream appliance is isolated from the
heating system being cleaned. Failure to do this
could seriously damage the appliance.
When carrying out the work always comply
fully with the manufacturers instructions for the
powerflushing equipment being used.
If in any doubt please consult our Technical
Helpline.
4. FLUE AND AIR PIPES
The flue/air pipe systems should have been
designed and installed in accordance with the
requirements under 'Flue System Design' in this
literature.
Concentrate particularly on the integrity of the
joints and the sealing of terminal(s) and pipes,
as applicable. Check that horizontal lengths
of flue pipe fall back to the boiler with no low
points to trap condensate. This is an important
procedure as incorrectly installed flue systems
can lead to potentially dangerous situations.
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