Gulfstream A-CLASS Series User manual
DESIGN AND INSTALLATION MANUAL
FOR THE ROOF TERMINAL FLUE KIT
FOR PITCHED AND FLAT ROOFS
ROOF TERMINAL FLUE KIT G.C. NO .................
THE GAS SAFETY (INSTALLATION AND USE)
REGULATIONS -
In your own interest and that of safety, it is
law that all gas appliances are installed by
competent persons and in accordance with the
above regulations.
TM
benchmark
The code of practice for the installation,
commissioning & servicing of central heating systems
GulfStream
A - C L A S S
Page 2
Page 3
GULFSTREAM A-CLASS
1.0 INTRODUCTION
These instructions must be read in conjunction
with the Design, Installation and Servicing
instructions for the GulfStreamA-CLASS
Any central heating flue installation must
comply with the relevant recommendations
of the current version of the Gas Safety
(Installation and Use) Regulations, and the
Building Regulations as well as any British and
European Standards such as BS 5440:Part 1.
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.
Please note: We do not therefore accept any
responsibility for matters of design, selection
or specification or for the effectiveness of an
installation containing one 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.
In the interest of continuously improving
the GulfStream range, Gledhill Water Storage
Ltd reserve the right to modify the product
without notice, and in these circumstances
this document, which is accurate at the time of
printing, should be disregarded. It will however
be updated as soon as possible after the change
has occurred.
Note :
See separate manuals for details of the
following flue kits which are also available.
1. Gable Terminal Flue Kit
2. Balanced Terminal Flue Kit
3. Ridge Terminal Flue Kit
4. Twin Pipe Horizontal Flue Kit
The Gledhill Group’s first priority is to give a
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.
ISSUE 1: 08-03
SECTION PAGE
1.0 INTRODUCTION 3
2.0 DESCRIPTION 4
3.0 DESIGN/TECHNICAL 5
4.0 INSTALLATION 8
TERMS & CONDITIONS 10
R00F TERMINAL FLUE KIT
Page 4
Concentric pipes - 0.5m / 1.0m long- with clamp
* Concentric pipe and fittings are normally
supplied in 60/100mm nominal epoxy finish.
FLUE COMPONENTS
Concentric Boiler terminal
conversion box
with fixing screws
Concentric pipe
support bracket
Concentric pipe
87/90° bend
with clamp
Concentric pipe
43° /45° bend
with clamp
Concentric Roof
Terminal
with clamp
Universal pitched
roof flashing
Flat roof flashing
2.0 DESCRIPTION
The balanced roof terminal flue system
comprises a number of the push fit socketted
concentric components (shown opposite), and
is designed to allow air and the flue gases to be
discharged to atmosphere through a suitable
roof terminal.
The system is equally suitable for a pitched
or flat roof and the standard kits available are
shown opposite.
Because the GulfstreamA-CLASS is a condensing
appliance the whole of the flue MUST be
installed with a continuous minimum fall of
3° back to the boiler. (50mm/metre)
It is important that the position and fixing of
the roof terminal is checked and confirmed as
suitable before the flue is installed.
It is also important that the flue terminal is
located as near as practical to the GulfStream
A-CLASSappliance and the route of the flue is
checked and clear of any roof trusses or other
obstructions in the roofspace.
Note: An equivalent 80/125mm concentric flue
system is also available. Please consult Gledhill
Technical Department if this is considered
necessary.
ROOF TERMINAL FLUE KIT
Page 5
GULFSTREAM A-CLASS
3.0 DESIGN/ TECHNICAL
The standard pitched roof terminal flue kit,
(stock code no. AFG006) is based on the
60/100mm concentric flue system components
shown opposite.
The standard kit should cover the majority
of typical installations. However separate
extra components can be ordered using the
individual stock codes shown if required.
The maximum air/flue length which can be
used must not exceed an equivalent length
specified in the table on page 6.
Flues should generally be installed in
accordance with BS 5440 : Part 1.
The roof terminal is the balanced type and
provides air for combustion as well as an outlet
for the flue gases.
R00F TERMINAL FLUE KIT
60/100mm pitched
roof flashing
60/100 concentric
roof terminal
60/100
concentric flue
60/100
concentric flue
Boiler conversion box to suit
60/100 concentric flue
If necessary the flue can
be run using 87/90° bends
with a continuous min. fall
of 50mm/metre
Min. 3° Fall
50mm/metre
60/100 flat
roof flashing
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- l
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- gnihsalffoortalFmm521/08 212FG
- º54/34sdneBeulFepiPcirtnecnoCmm521/08 312FG
- º09/78sdneBeulFepiPcirtnecnoCmm521/08 412FG
- m
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Page 6
5.0m
50mm/metre fall
GS
A-CLASS
3.0m
GS
A-CLASS
Roof
Roof
ROOF TERMINAL FLUE KIT
3.0 DESIGN/TECHNICAL
Two examples of how to calculate the
equivalent flue length for the typical 60mm
diameter flue system installations shown
opposite , using the Table below, is as follows.
1. Concentric flue pipe length
4.0m x 2 = 8.0m
Equivalent length of fittings
2 x 45° bends x 3.0m = 6.0m
Total equivalent flue length
8.0 + 6.0 = 14m
If the flue needs to run along the roof space
before rising, this would be calculated as
follows.
2. Concentric flue pipe length
5.0m x 2 = 10.0m
Equivalent length of fittings
1 x 90° bend x 3.8m = 3.8m
2 x 45° bend x 3.0m = 6.0m
Total equivalent flue length
10.0 + 3.8 + 6.0 = 19.8m
As the equivalent flue length calculated for
the 60/100 system is above the 17m maximum
equivalent flue length allowed, the same
calculation must be carried out for the 80mm
system and if this is below the 60m maximum
equivalent flue length this should be used.
As long as the flue pipework always runs back
to the boiler at a minimum fall of 50mm/metre,
any pipework configuration can be used as
long as the equivalent total air/flue length is
less than the maximum equivalent flue length
shown in the Table below for the size of flue
system being used.
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Page 7
GULFSTREAM A-CLASS
ROOF TERMINAL FLUE KIT ROOF TERMINAL FLUE KIT
3.0 DESIGN / TECHNICAL
The location of the air inlet and flue/exhaust
connections on the appliance are shown
opposite. Each connection is provided with a
push fit socket and is labelled.
Note: It is the installers responsibility to
check that the roof flashing is suitable for
the roof covering/tile being used.
The appliance location itself should have
been chosen to comply with the relevant
requirements of the GulfStreamA-CLASS Design
Installation and Servicing Instructions.
When terminating the flue adjacent to an
opening in a pitched or flat roof these must be
positioned in accordance with the requirements
shown opposite.
The concentric flue pipe used in the appliance
cupboard means that the flue can be safely
touched or clothes/towels etc. can be stored
next to the flue and can pass into the roof space
close to combustible material without any extra
protection/insulation being required.
If the flue is run through a timber wall or
cupboard, the concentric flue will automatically
provide the necessary protection and a further
air gap/insulation is not required.
Recommendations on protection of combustible
material are given in BS 5440 : Part 2 : Clause
20.
FRONT
360 120
480
75
595
595
APPLIANCE TOP PANEL
All dimensions are in mm
230
120
Page 8
GS A-CLASS
Clamp
2 Screws 2 Screws
5mm
5mm
340mm 255mm
Minimum clearance
to internal wall
ROOF TERMINAL FLUE KIT
4.0 INSTALLATION
Make sure the appliance is in the correct
position before commencing installation of
the air/flue pipes.
The flue pipes must be assembled with the
plain end of pipe (or fitting) nearest the
appliance and the socket end furthest from
the appliance.
Always adjust length of pipes by cutting the
plain end. We would strongly recommend that
a pipe cutter is used to cut the internal flue pipe
which will reduce the possibility of any damage
to the twin lip seal when making the joint.
The external flue pipe can be cut using a
hacksaw as long as all burrs inside and outside
are removed.
Keep the outside of the flue pipes clean and
free of oil or grease.
Do not use any sealant or lubricant other than
water.
When cutting the flue pipe it is essential that
the inner flue must be left protuding by exactly
20mm (plain end).
Any generally horizontal run of flue pipe must
have a fall of at least 50mm/metre back to the
boiler and must not be allowed to dip, i.e. fall
below the horizontal or form a low point at
which condensate could accumulate.
4.0 INSTALLATION
Page 9
GULFSTREAM A-CLASS
ROOF TERMINAL FLUE KIT
The roof terminal should be installed as follows
- see sketches opposite;
1. Check the flue terminal for any damage
Flat roof flashing Universal pitched roof
flashing
2. Taking the roofing into account check
the type of weather collar is correct. For a
tiled pitched roof use universal pitched roof
flashing or for a flat roof an aluminium flat roof
flashing.
Note: The universal pitched roof flashing is
adjustable to suit all roof pitches from 25º to
40º.
3. Determine where the flue terminal will be
positioned and plan the route of the flue.
4. Make a hole for the flue terminal. Ensure that
no saw dust or dust gets into the boiler.
5. Fit the weather collar on the roof.
6. Carefully insert the flue terminal through
the roof from the outside. Attention: do not
turn the cap.
7. Put the flue terminal into a vertical position
using an air level. (If desired, cover plates, to be
supplied separately, can be fitted internally).
8. Fix the wall clamp supplied round the flue
terminal and fit it to the roof construction. Do
not tighten the clamp at this stage.
4.0 INSTALLATION
Page 10
The standard flue kit should be installed as
follows ;
1. Push the concentric boiler conversion
box firmly into the sockets provided on the
appliance ensuring the flue and air inlet are not
exchanged. (The connections are labelled and
when installed correctly the flue pipe socket
on the appliance will be directly below the flue
pipe connection on the adaptor), see diagram
opposite. Fix in position on the appliance using
the 4 screws provided.
2. Fit a1000mm length of concentric pipe to
the adaptor using the clamp provided on the
outside joint. Ensure the inner flue joint is
pushed fully home.
3. Repeat the above procedure for any further
pipes/bends etc. until the pipework extends to
the roof terminal, (temporarily support/secure
the pipe if necessary). Measure and cut any
pipes as necessary. Be sure to follow the
earlier instructions when cutting pipes/making
joints.
4. Connect the roof terminal to the pipework.
Ensure the vertical pipework is adequately
supported at the connection to the roof
terminal.
5. Visually inspect and check each joint is
pushed home fully. Ensure the flue also has
a minimum continuous fall back to the boiler
of 50mm/metre.
6. Permanently secure the flue pipes at
approximately 1 metre centres. Ensure a
bracket is provided adjacent to each joint on
horizontal pipes.
7. Check the joint between the roof terminal
and flashing is watertight and secure the roof
wall clamp.
Note : The flue pipe must not rely on the roof
terminal for support.
It is the responsibility of the installer to ensure
that the flue installation through the roof is
weatherproof i.e no rain must ingress into
dwelling roof space.
ROOF TERMINAL FLUE KIT
Page 11
GULFSTREAM A-CLASS
Page 12
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