gledhill GC2000/120/E-OV User guide

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GULFSTREAM 2000
PLEASE LEAVE THESE INSTRUCTIONS IN THE POCKET PROVIDED ON
THE BACK OF THE FRONT PANEL
A Combined Primary Storage Unit (CPSU) for
Domestic Hot Water Supply and
Central Heating
Appliance Category 12H Types C13 : C53 : C33
Destination GB : IE, Nox CLASS 5
Intended for use with a governed meter only
GULFSTREAM 2000
DESIGN, INSTALLATION AND
SERVICING INSTRUCTIONS
FOR USE WITH NATURAL GAS ONLY (G20) SUPPLY PRESSURE 20mbar
These instructions are to be followed and specication 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 GulfStream2000 range. Gledhill Water
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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GULFSTREAM2000
ISSUE 4: 01-03
Section Page
Description 4
Introduction 4
Clearances & Cupboard Sizes 5
Boiler 6
Gas Supply/Electrical Supply 9
Appliance Location 10
System Design
Ventilation 11
Hot and Cold Water System 11
Space Heating System 13
Flue System Design
General Requirements 17
Installation and Wiring
Handling/Storing the Appliance 18
Fitting the Appliance 18
Electrical Wiring 21
Commissioning
General 23
Initial System Filling 23
Cleansing & Water Treatment 23
Flue & Air Pipes 23
Initial Lighting 23
Gas Rate & Gas Pressure 26
Procedure for checking and
adjusting gas rate and burner
pressure 26
Final Adjustments 27
External Controls 27
User Instructions 28
Fault Finding 29
Servicing 38
Component Exchange 40
Spare Parts List 43
Terms & Conditions 45
CONTENTS
Gledhill Water Storage Limited
Sycamore Estate
Squires Gate
BLACKPOOL
Lancs
FY4 3RL
As part of the industry wide “Benchmark” Initiative all Gledhill GulfStream boilers
now include a Benchmark Installation, Commissioning and Service Record
Logbook. Please read this carefully and complete all sections relevant to the
appliance installation. The details of the Log book will be required in the event of
any warranty work being required. There is also a section to be completed after
each regular service visit. The completed Log Book and these instructions
should be left in the pocket provided on the back of the front panel.
The boiler should be installed and serviced only by CORGI registered operatives.
All CORGI registered Installers carry a CORGI ID card, and have a registration
number.
Both should be recorded in the Benchmark Log Book. You can call CORGI direct
on 01256 372300.

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      

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GULFSTREAM2000
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. Detailed recommendations are contained in the current
issue of the following British Standards and codes of practice :-
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.
Gas Consumer Council
The Gas Consumer Council (GCC) is an independent organisation which protects
the interest of gas users. If you need advice, you will nd the telephone number in
your local telephone directory under Gas.
General
Details of essential features of cupboard design are given in BS 6798.
This information is provided to assist generally in the selection of equipment.
Responsibility for selection and specication of our equipment must,
however, remain that of our customers and any experts or consultants
concerned with the installation(s).
PLEASE NOTE THAT WE DO NOT THEREFORE ACCEPT ANY RESPONSIBILITY FOR
MATTERS OF DESIGN SELECTION OR SPECIFICATION, FOR THE EFFECTIVENESS OF
AN INSTALLATION OR UNIT CONTAINING ONE OF OUR PRODUCTS.
All goods are sold subject to our Conditions of Sale which are set out in the
Appendix to this Specication.
WARNING
The GulfStream is for use on natural gas only and must not be used on any other
gas.
This appliance must be serviced by a competent person e.g. a Corgi Registered
Installer.
If sealed components are replaced and re-commissioned in the eld then these
must be re-sealed.
A WRAS APPROVED PRODUCT.
British Patent No: Patent Pending

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Page 4
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GULFSTREAM2000
GulfStream 2000 (figures 1 and 2) is a
room sealed, gas red, fan ued 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. the boiler) from the heat
emitters (i.e. the radiators and the domestic
hot water generator) by a thermal store. This
evens out the uctuating demands for heating
and hot water and signicantly improves the
system efciency.
Another important feature of the system is
that because the thermal store acts as a buffer
between the boiler and the heating system,
any variety of space heating control systems
can be used, although the heating system
circulating pump is an integral part of the
appliance. This aspect is discussed further on
in this manual.
An important feature of this design is that
domestic hot water can be supplied directly
from the mains without the need for additional
safety controls in the DHW supply. This is
achieved by passing the mains water through
a high performance plate heat exchanger.
The outlet temperature of the domestic hot
water is maintained by a printed circuit board
which controls the speed of the pump which
circulates primary hot water from the thermal
store through the primary side of the plate
heat exchanger. This is shown in Figures 4-7.
Because of the innovative method of hot water
production no in-line scale reducer is required
on the cold supply to the appliance.
If scale should become a problem the plate
heat exchanger is easily isolated and replaced
with a service exchange unit.
The GulfStream high efciency appliance is
tted with a unique electric emergency backup
system for both heating and hot water.
TECHNICAL DATA
All models are supplied with 9kW electric
boiler for emergency backup for heating and
hot water. They are fused internally at 5A
for gas circuit. A 230V , 50Hz electricity
supply fused at 45A is required direct from the
consumer unit.
The models GC 2000/120/E and 130/E are
suitable for sealed heating system. The models
GC 2000/120/E-OV and 130/E-OV are suitable
for open vented systems only.
INTRODUCTION
DESCRIPTION
Figure 1 Models 2000/120/E 2000/130/E
Figure 2 Models 2000/120/E-OV
2000/130/E-OV

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GULFSTREAM2000
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Sizes - All models overall -
H W D
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 ue application
Left Hand Side 10mm from door frame
Right Hand Side 10mm from door frame
Front 600mm for servicing.
The appliance should be cleaned with a non
abrasive cleaning agent.
Minimum internal cupboard size required:
* H W D*
1850mm 700mm (620-745)mm - SP Model
2300-2500mm 700mm (620-745)mm - OV Model
* Assumes plinth height is 100mm from nished oor level and,
in the case of the OV Model, that the F & E cistern is installed in
the same cupboard as the appliance.
Height of 2300 can only be used if the F & E cistern is installed
length ways on the R.H. side of the cupboard (see opposite) to
allow sufcient access to the boiler.
*Depth required depends on ue application.
Domestic Hot Water Pressure/Flow Characteristics:
Minimum ow to operate 1.5 l/min.
Minimum inlet pressure to obtain nominal ow rate:
1 bar dynamic
Maximum recommended water pressure 5 bar
Specic water rate:
Models GC2000/130/E,/130/E-OV 23.3 l/min
Models GC2000/120/E, /120/E-OV 15.3 l/min
Central Heating Circuit Characteristics:-
a. Sealed System Models
Minimum water pressure 0.5 bar
Maximum water pressure 3.0 bar
Maximum stored water temperature 82 ± 2°C
b. Open Vented System Models
Minimum static head : 300mm - Above the highest point of the system.
Maximum static head : 10m - From the top of the appliance
Maximum stored water temperature : 82 ± 2°C
DESCRIPTION
CLEARANCES AND CUPBOARD SIZES
Figure 3 Minimum Clearances and Cupboard
Dimensions
NOTE: 350mm is required above the F & E
cistern for maintenance access to comply with
the Water Regulations.
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Page 7
GULFSTREAM2000
The GulfStream is a room sealed fanned ued condensing boiler with a range of
ueing options. The boiler incorporates the latest in gas appliance technology.
FEATURES
• Emergency heat back-up --- Both sealed and open vented system models in
the GulfStream 2000 range are supplied with an integral 9kW electric boiler for
emergency heat back-up for heating and hot water.
• Automatic control --- Specially designed electronic controls with electronic
ignition (no pilot), boiler thermostat and indicator light display mounted on
the front facia panel of the appliance. Fitted with all items required for fully
pumped sealed systems.
• Choice of room sealed - multi directional concentric/twin pipe ueing systems
--- Options include:-
1. Ridge Terminal Flue Kit - The un-balanced ridge terminal ue system comprises
a number of push t socketted concentric and single pipe components and is
designed to allow air to be taken from the roof space and the ue gases to be
discharged to atmosphere through a suitable ridge tile terminal.
2. Gable Terminal Flue Kit - The un-balanced ue kit system comprises a number
of push t socketted concentric and single pipe components and is designed to
allow air to be taken from the roof space and the ue gases to be discharged to
atmosphere through a suitable concentric gable wall terminal.
3. Balanced Flue Terminal Kit - The standard balanced ue kit comprises a number
of push fit socketted concentric components and is designed to allow the
appliance to be tted internally on an outside wall with the air inlet and ue gas
outlet discharged direct to atmosphere through a suitable concentric gable wall
terminal. The arrangement is suitable for rear, left or right hand discharge.
4. Twin Pipe Horizontal Flue Kit - The balanced twin pipe ue system comprises
a number of push t socketted concentric and single pipe components. It
is designed to allow the installation of ues within ceiling voids, or ducts, in
apartments with the fresh air and ue exhaust being provided from a concentric
wall terminal built into the external wall.
DESCRIPTION
BOILER 5. Roof Terminal Flue Kit - The balanced
roof terminal flue system comprises a
number of push t socketted concentric
components and is designed to allow air
and the flue gases to be discharged to
atmosphere through a suitable concentric
roof terminal. Pitched and Flat Roof options
are both available.
• The air intake and ue discharge pipes are
connected to sockets positioned top - rear
of the GulfStream. From this point they
may be run in any direction sanctioned
within this literature.
• Latest pre-mix burner technology gives
low Nitrogen Oxide values --- meets all
proposed EC requirements and helps
reduce acid gas emissions and
environmental damage. NOx - 17ppm.
• Combustion efficiency is higher and
volumes of CO and NOx are lower
compared with traditional atmospheric
burners running at the same heat input.
• The nominal maximum NOx emission
from the appliance is 30mg/kWh. This
is well within the EC requirement of
70mg/kWh maximum for inclusion as a
Class 5 appliance.
• High efciency, low weight, low thermal
capacity aluminium heat exchanger.
OPTIONAL EQUIPMENT
• Grasslin digital clock
• Flexible connection kit. For further details
see Installation & Wiring - 2. Fitting The
Appliance.
• Grundfos 15/60 pump - for space heating
only.
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GULFSTREAM2000
Figure 4 GulfStream 2000/120/E and 2000/130/E
(suitable for sealed systems only)
DESCRIPTION
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GULFSTREAM2000
DESCRIPTION
Figure 5
GulfStream 2000/120/E-OV and 2000/130/E-OV
(suitable for open vented systems only)

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GULFSTREAM2000
1. The mains supply required is 230V
50Hz. All GulfStream 2000 models are fused
internally. Minimum external fuse rating
and the mains supply cable specication
will vary according to model type. Refer to
‘’Electrical Wiring’’ for complete details. All
fuses must be ASTA approved to BS 1362.
THE APPLIANCE MUST BE EARTHED.
2. All external wiring to the boiler must be
in accordance with the latest I.E.E. Wiring
Regulations, and any local regulations which
apply.
3. There must be only one common isolator for
the boiler and its control system, and it must
provide complete electrical isolation via a
fused double pole isolator with a contact
separation of at least 3mm in both poles.
4. In the event of an electrical fault after
installation of the appliance, preliminary
electrical systems checks must be carried
out i.e. Earth Continuity, Short Circuit,
Polarity, and Resistance to Earth.
DESCRIPTION
Figure 6 Schematic Diagram
Figure 7 Appliance Hydraulic and Control System
ELECTRICAL SUPPLY
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.
2. An existing service pipe MUST NOT be used
without prior consultation with the Gas
Supplier.
3. A gas meter can only be connected by the
Local Gas Supplier or by his Contractor.
4. An existing meter should be of sufcient size
to carry the maximum boiler input plus the
demand of any other installed appliance,
(BS 6891 : 1988). See section Technical Data
for the gas required for each specic model.
Table 1.
5. A minimum of 22mm diameter pipework
to within 1 metre of the appliance gas cock
should be tted.
6. The governor at the meter must give a
constant outlet pressure of 20mbar when
the appliance is running.
7. The gas supply line should be purged.
WARNING: before purging open all doors
and windows, also extinguish any cigarettes,
pipes, and any other naked lights.
8. The complete installation must be tested
CONDENSATE
DRAIN
ELECTRONIC CONTROL
SYSTEM
BOILER OVERHEAT
THERMOSTAT
DRAIN
DHW PLATE
HEAT EXCHANGER
STORE
LIMIT
T'STAT
PRIMARY
CONTROL
SENSOR
TEMP
82 ± 2˚C
THERMAL STORE
CH
PUMP
DHW
SENSOR
PRE-MIX BURNER (MODULATES
1/1 AIR/GAS RATIO)
DHW PUMP
INTEGRAL
CONDENSING
BOILER
P.R. VALVE
DISCHARGE
CH
RETURN
CH
FLOW
DHW
COLD
IN
DHW
HOT
OUT
BOILER
PUMP
EXPANSION
VESSEL
PRESSURE
RELIEF
VALVE
9kW
ELECTRIC BOILER
MODELS2000/120/E
AND/130/E ONLY
INDEPENDENT
POWER SUPPLY
R
Z
PLATE
HEAT EXCHANGE
SENSOR
Not fitted to models suitable for open vented
heating systems
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
  
 


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 
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
   





       
 

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Page 10
Page 11
GULFSTREAM2000
DESCRIPTION
The hot water performance of the appliances
is shown in Figure 8. The flow rates and
corresponding maximum water volumes drawn
off and quoted in Table 1 assume normal
dynamic water pressure and adequate ow to
the property. The mixed ow temperature will
provide a 35°C rise when water is drawn off
at up to 35 l/min as shown, if the maximum
water volume is not exceeded.
For the nominal 35°C temperature rise, the
maximum hourly rate of the 20kW and 30kW
models is 550 litres and 780 litres respectively.
Figure 8 Hot Water Performance
HOT WATER PERFORMANCE
APPLIANCE LOCATION
The following limitations MUST be observed when siting the boiler:
1. The appliance is room sealed and can be located in any room/compartment
in a domestic property. The appliance is essentially quiet but does
incorporate a fan/pumps. The chosen position should bear this in mind
and not be one which is particularly sensitive to noise.
2. The boiler is not suitable for external installation. The position selected for
installation should be within the building, unless otherwise protected by a
suitable enclosure, and MUST allow adequate space for installation, servicing,
and operation of the appliance, and for air circulation around it.
3. This position MUST allow for the ue and air inlet system to be tted in its
correct position.
4. The boiler must be installed on a at surface which is capable of supporting the
weight of the appliance and any ancillary equipment.
5. If the boiler is to be tted in a timber framed building it should be tted in
accordance with the British Gas publication 'Guide for Gas Installations Timber
Frame Housing', Reference IGE/UP/7:1998. If in doubt, advice must be sought
from the Local Gas Supplier.
6. A compartment used to enclose the appliance MUST be designed and
constructed specically for this purpose. An existing cupboard, or compartment,
may be used provided it is modied accordingly. BS 6798 gives details of
the essential features of cupboard/compartment design, including airing
cupboards.
7. It is sensible to put sound deadening material (felt) between the boiler and
the oor to absorb any vibration from the pumps/fan etc.
Models 130/E
and130/E-OV
Models 120/E
and120/E-OV

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Page 10
Page 11
GULFSTREAM2000
2.2 Use in hard water areas
A patented control system prevents domestic water from exceeding 55o C for most
of the operational time of the appliance.
IT IS NOT NECESSARY TO FIT ANY FORM OF SCALE INHIBITING EQUIPMENT IN THE
DOMESTIC COLD SUPPLY TO THE APPLIANCE.
If it ever becomes necessary the plate heat exchanger is easily replaced with a
service exchange unit without complete drain down.
The appliance is room sealed and it is not a mandatory requirement to provide
ventilation to the appliance cupboard.
However, in many cases the appliance cupboard is also used as an airing cupboard
and in these situations some ventilation openings at high and low level will be
helpful in providing air movement.,
2.1 Mains Pressure Domestic Hot Water Supply
1. GulfStream models are designed to be fed directly from the mains. They fulll
the requirements of Water Byelaw 91, and therefore do not require a check
valve to be tted to the supply pipe. The performance of the GulfStream is
directly related to the adequacy of the cold supply to the dwelling. This must be
capable of providing for those services which could be required simultaneously
and the maximum demand should be calculated. GulfStream OV model will
operate at pressures as low as 1 bar which must be available when local demand
is at its maximum, but the preferred range is upwards of 2 bar. 2 bar must be
available at all times for the correct operation of the SP model for the automatic
lling device to function correctly. As a general guideline, although a 15mm
service may be sufcient for the smaller dwelling with one bathroom, a 22mm
service is preferred (25mm MDPE) and should be the minimum for larger
dwellings, and properties above two storeys.
2. If a water meter is tted in the service pipe, it should have a nominal rating to
match the anticipated maximum simultaneous hot and cold water demand,
calculated in accordance with BS 6700. This could be 50 litres per minute
in some properties.
3. If the incoming static mains water pressure exceeds 5 bar at any point in
the 24 hour cycle then a pressure limiting valve set at 3 bar should be tted
downstream of the stop tap where the cold supply enters the property. Units
must be tted strictly in accordance with the requirements of the Local Water
Undertaking who should be consulted prior to installation. In the event of any
difculty please contact ourselves as the manufacturer.
4. Equipment used in the system should be suitable for a working pressure of 5
bar. A non-return valve is not required. Should ancillary equipment, requiring
a non-return valve, be tted to the same mains supply as the GulfStream, then
this valve must not be tted between the inlet of this mains supply to the
house and the GulfStream.
No safety ttings are required on the secondary system.
SYSTEM DESIGN
1. Although a 15mm copper supply may
be adequate for the smaller 1 bathroom
dwelling, a 22mm (25mm MDPE) supply is
preferred where possible to make best use
of this appliance.
2. Internally run in 22mm copper to the
GulfStream and from the GulfStream in
22mm past the hot draw-off to the bath.
3. We would recommend that best results
for a balanced system are achieved by
fitting appropriate flow restrictors to
each hot and cold outlet. These MUST
be tted in cases where the nal branch
pipe sizes are not as recommended in
item 4 or water pressures are above the
recommended water pressure range of
2-3 bar. See Appendix B for details of
suitable ow regulators.
4. Alternatively the tee-offs to the outlets
should be in 10mm except for the bath and
showers which should be 15mm (1 metre
minimum).
5. Alternatively, tee-offs to terminal ttings in
existing property can easily be tted with
ow restrictors to balance the simultaneous
demand.
6. The hot water supply to a shower mixing
valve should be the first draw-off point
on the circuit. The cold water supply to a
shower mixing valve should be fed directly
from the rising main and should be the rst
draw-off point on the cold circuit.
7. Typical cold and hot water distribution
network is shown in Figures 9 and 10.
All the recommendations with regard to
pipework systems in this manual are
generally based on the use of BS/EN
Standard copper pipework and ttings.
2.3 Cold and hot water distribution
network
2. HOT & COLD WATER SYSTEM
1. VENTILATION

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Page 12
Page 13
GULFSTREAM2000
SYSTEM DESIGN
2.4 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 dynamic changes particularly when
other hot and cold taps/showers are opened and
closed. To minimise the impact of this we would
always recommend the use of thermostatic
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
ow/pressure outlets please discuss with the
Gledhill technical department.
The hot water supply to a shower-mixing valve
should be fed wherever practical directly from
the GulfStream 2000 or be the rst 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
incorporate or be fitted with the necessary
check valves to provide back-syphonage
protection in accordance with the Water
Regulations. The supply of hot and cold mains
water directly to a bidet is permitted provided
that it is of the over-rim ushing type and that
a type ‘A’ air gap is incorporated.
2.5 Hot and Cold Water System
If the length of the hot water draw off pipework
is excessive and the delivery time will be more
than 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.
Pressure limiting valve NOT
REQUIRED at pressures
below 5 bar if terminal
fittings have flow regulators
fitted.
Second
dwelling
M.C.W.S
supply pipe.
Sink
Hand
basinBath
GS 2000 Scale inhibitor
NOT REQUIRED
Shower.
H
a a a
a
a a a
CH C H C
Check valve NOT REQUIRED unless
chemical water treatment unit is fitted.
'a' - flow regulator recommended for better
balance of hot and cold water supplies.
Double check valve NOT REQUIRED unless supply
pipe services more than one dwelling.
Gate valve - can be used to isolate in case
of maintanance or to restrict the total flow
rate if flow restriction is not provided
Figure 9 Hot & Cold Water Distribution Network




 




Figure 10
However, we are happy that plastic pipework
systems can be used in place of copper
internally as long as the chosen system is
recommended for use on domestic hot and
cold water systems by the manufacturer and is
installed fully in accordance with their
recommendations.
This is particularly important in relation to
use of push t connections when using the
optional exible hose kits see Installation &
Wiring - 2. Fitting the Appliance.
It is also essential that if an alternative pipework
material/system is chosen the manufacturer
conrms that the design criteria of the new
system is at least equivalent to the use of BS/EN
Standard copper pipework and ttings.

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Page 12
Page 13
GULFSTREAM2000
3. SPACE HEATING SYSTEM
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 4. Allowances for domestic hot
water requirements have been built into the
difference between the nominal heat output
and maximum central heating load figures
shown on page 6:
If large baths or extra bathrooms are required
please seek guidance from Technical Sales
Department.
Note: A room thermostat and/or thermostatic
radiator valves may be used: the former being
wired directly to the boiler terminal strip - refer
to Figures 29 and 30.
All the recommendations with regard to
pipework systems in this manual are generally
based on the use of BS/EN Standard copper
pipework and ttings.
However, we are happy that plastic pipework
systems can be used in place of copper
internally as long as the chosen system is
recommended for use on domestic heating
systems by the manufacturer and is installed
fully in accordance with their recommendations.
We always recommend the use of barrier pipe
for these systems.
It is also essential that if an alternative pipework
material/system is chosen the manufacturer
confirms that the design criteria of the new
system is at least equivalent to the use of BS/EN
Standard copper pipework and ttings.
SYSTEM DESIGN
3.1 General
Figure 11 Pump Head Available for CH System
System load kW based on system T of 11ºC
Pump set at maximum
0
1
2
3
4
5
00.25 0.5 0.75 1 l/sec
011 22 33
mH
2
0
*
* If head available is insufficient fit an additional
system pump (2 pumps in series)

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Page 14
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GULFSTREAM2000
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 ow
and return connections terminating in 22mm copper pipe or 22mm compression
ttings.
The pump head available for the central heating circuit is shown in Figure 11.
The sealed system models incorporate the following components:-
• Heating pump - on the ow from the store.
• Expansion vessel - 12 litres, pre-charged to 1.0 bar.
• Pressure gauge 0 to 4 bar
• Expansion relief valve - set to operate at 3 bar.
At least one ushing valve should be tted at the lowest point in the system to
enable the water system to be drained.
If the appliance is the highest point on the heating system a manual air vent is
provided above the heating pump. However, if any point of the heating system is
higher than the appliance we would recommend that an automatic air vent is tted
at the highest point in the system.
Normal procedures for sizing heating circuit pipes should be used and the pump
head available for the heating system is shown in Figure 11. If all the radiators
are provided with thermostatic valves a suitable by-pass should be provided as
normal on the heating circuit.
3.2.2 Sealed Central Heating System
The sealed heating system/appliance must only be lled by a competent person.
Full details are provided in Appendix A - Design/Installation details for the CA type
backow prevention valve assembly and anti-vacuum valve.
Note: Minimum of 2 bar mains pressure must always be available for correct
operation of CA devices.

Supplied By www.heating spares.co Tel. [phone]
Page 14
Page 15
GULFSTREAM2000
SYSTEM DESIGN
In normal circumstances a pressure of 1.0 bar
is suitable for most domestic properties.
The minimum system pressure should be not
less than the static head, (the height of the
highest point in the system above the expansion
vessel plus a margin of 0.5 bar).
Expansion Vessel
The appliance is supplied with a 12 litre
expansion vessel pre-charged to 1.0 bar.
The expansion vessel has to be suitable to
accommodate the change in volume of the
water in the system when heated between 100C
to 1100C. See BS 5449: 1990 clause 16.2 for
further information.
NOTE: After rst lling the system to a pressure
of 1.0 bar at mains supply temperature (typically
around 15OC in summer), the unit should be
switched on, and the GulfStream2000 should
be heated to its maximum temperature. If the
pressure gauge then indicates 2.6 bar or higher,
an additional expansion vessel may be required
in the system. Expansion vessel requirements
are shown in Table 3.
3.2.3 Open Vented Central Heating System
The ‘-OV’ models the GulfStream 2000 are only
suitable for an open vented system shown
schematically in Figure 12.
The F & E cistern can be tted up to 10m above
the base of the appliance i.e. the maximum
static pressure in the appliance must not exceed
1 bar.
The water level in the F & E cistern should be
at least 250mm above the highest point on the
system including the radiators.
The overflow/warning pipe should be in a
20mm internal diameter pipe of suitable
material for use with a heating F & E cistern, in
accordance with BS 5449 (such as copper). It
should have continuous fall and discharge in a
conspicuous external position.
The cold feed pipe should be in 15mm overall
diameter copper tube or equivalent and the
open vent should be in 22mm copper or
equivalent.
Figure 12 Schematic layout of the open vented heating system
Warning/overflow
pipe
Cold feed
Mains cold
water
Open Vent
GulfStream
- OV models
h. >250mm
220m min.
maintenance
access
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Page 16
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GULFSTREAM2000
Figure 15
3.3 Heating System Controls
Both the open vented and the sealed system
models are fitted with the ‘Switch’ electric
back-up system. This allows the user the
choice of natural gas for normal operation and
back-up electrical energy in an emergency.
The control panel of sealed system models
2000/120/E and 2000/130/E is shown in gure
13.
The control panel of open vented system
models 2000/120/E-OV and 2000/130/E-OV
is shown in gure 14.
A room thermostat and/or thermostatic
radiator valves may also be tted to control
the central heating requirements.
If the appliance is sited in an unheated space
(e.g. a garage, out house, ventilated roof space)
then a frost thermostat must be fitted to
protect the appliance and the heating system.
The details are given in the electrical section
SYSTEM DESIGN
Figure 13 Panel for models 2000/120/E and 2000/130/E
Figure 14 Panel for models 2000/120/E-OV and 2000/130/E-OV
Push pins
outwards
Indicator
Continuous
Timed
Off
TIMER OPERATION
CLOCK FACE
Set to for Continuous Operation
Set to for Timed Operation - then:-
Push pins outwards as shown to cover the required ''on''
period - clock timings shown on Outer Bezel.
Rotate the Outer Bezel in a clockwise direction to set the
correct time against the indicator arrow.
O
U
T
E
R
B
E
Z
E
L
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
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

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

    
  
  
 
 
  
  





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
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 
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

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Page 16
Page 17
GULFSTREAM2000
Fall
1.
2. 4.
3.
5.
Fall
FLUE SYSTEM DESIGN
1. GENERAL REQUIREMENTS
A full range of ue 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. Balanced Flue Terminal Kit
4. Twin Pipe Horizontal Flue Kit
5. Roof Terminal Flue Kit
This appliance must only be installed
using one of the above approved ue kits.
Figure 16

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GULFSTREAM2000
INSTALLATION & WIRING
Figure 17
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.
Lift from the hips at the same time, then raise
the unit to the desired level.
Move smoothly in unison.
1.2 The appliance is supplied shrink wrapped
on a timber installation base. Carrying handles
are also provided in the back of the casing.
1.3 If the unit needs to be stored prior to
installation it should be stored upright in a dry
environment and on a level base/oor.
2. FITTING THE APPLIANCE
2.1 General
The appliance should be mounted on a 100mm
high plinth supplied with the appliance to
facilitate the pipework connections at the front
of the appliance.
When using push fit connectors with the
exible hose kits it is important to check that
they are compatible.
   
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Page 19
GULFSTREAM2000
Written approval has already been obtained for:
Hepworth - Hep2O BiTite
John Guest - Speedt
Yorkshire - Tectite
However, as similar assurances cannot be obtained for Polypipe ttings we cannot
recommend their use.
All the water connections, apart from make-up tank and cold feed, are located at
the bottom front of the appliance. The gas connection, electricity supply cable
entry, along with the make-up tank and cold feed connections, are located at the
top of the appliance (see Figure 17).
2.2 Central heating and domestic hot water
Using 22mm copper pipework connect the appliance to the central heating and
secondary DHW. Stop valves should be tted as close to both appliance connections
as possible. Both CH and DHW appliance connections are clearly labelled.
2.3 Expansion relief valve (sealed system models)
The valve should be installed into a discharge pipe which permits the safe discharge
of steam and hot water such that no hazard to persons or damage to electrical
components is caused.
NOTE:- The valve incorporates plastic components which will be adversely affected
by heat. For this reason we recommend the use of compression ttings for joints
to the valve and adjacent to the valve.
2.4 Drain cock
A ’’ drain cock supplied with the appliance should be tted to the drain connection
on the appliance using an approved jointing compound.
2.5 Gas
Connection is made at the top rear of the casing. The union gas cock is supplied
as a loose item in the tting kit. The male liner, with union nut, should be tted to
the Rc ’’ gas inlet using an approved jointing compound. The gas cock can then
be tted and the gas supply completed. The whole gas installation including the
meter should be inspected and tested for soundness and purged in accordance
with the recommendations of the current issue of BS 6891.
2.6 Condensate drain
• Connect the condensate trap to a suitable plastic drain pipe i.e. PVC, UPVC,
ABS or PP which must have a minimum internal diameter of 15mm inside
the building and 32mm internal diameter outside the building. Any external
pipework should be kept to a minimum length to minimise the risks of
freezing.
• The pipe should not have any upward pipe runs and must fall at least 2.5°
(1:20) throughout its length towards the discharge point.
• It must be safely terminated in a permanent drain. This may be an internal
soil stack or waste pipe, an external gulley hopper or soakaway and may require
the use of a trap or break.
Note that condensate will be slightly acidic providing that the instructions above are
followed no special provision is necessary normally. (Refer to gures 4 and 5).
The position chosen for the discharge must ensure no damage as a result of
condensate release. It should be protected from blockage by debris or frost. Any
local building control authority requirements must be complied with.
INSTALLATION & WIRING
Note that if a condensate neutraliser is tted
it must be installed and maintained strictly in
accordance with the manufacturers instructions.
However, if the installation instructions for
the boiler and neutraliser are contradictory
seek advice from both manufacturers before
installation.
2.7 Access to the appliance
To gain access to all components refer to gures
4, 5, and 18.
First remove the front panel by unscrewing the
two retaining screws at the top front LH and RH
sides. Lift the panel slightly and swing it forward
from the top. Lift the panel to disengage it
from the bottom edge. Remove the top panel
by unscrewing the screws at the LH and RH
sides.
2.8 Feed and expansion cistern
The feed and expansion cistern support shall
be installed ensuring that the base is fully
supported and the working head (10m) of the
appliance is not exceeded.
The adequate access must be provided for
maintenance of the F & E cistern.

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GULFSTREAM2000
INSTALLATION & WIRING
Figure 19
Figure 20
Figure 18