Gulfstream GS A-Class 12/OV, Design, Installation & Servicing Instructions

Page 1: ...ry Storage Appliance for Hot Water Supply and Central Heating Model Ref Sedbuk Band Maximum Space Heating Load kW Gas Council No Heating System Type GSA CLASS 12 OV A 10 0 Open vented heating system GSA CLASS 12 SS A 10 0 Sealed heating system GSA CLASS 20 OV A 18 0 Open vented heating system GSA CLASS 20 SS A 18 0 Sealed heating system GSA CLASS 30 OV B 26 0 Open vented heating system GSA CLASS 3...

Page 2: ...ractices 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 3 Gas Consumer Council The Gas Consumer Council GCC is an independent organisation which protects the interest of all gas users If you need advice you will find the telephone number in your local telephone directory under Gas 4 Equipment selection This information is provided to assist generally in...

Page 3: ...ALLATION AND WIRING 18 4 1 FITTING THE APPLIANCE 18 4 2 ELECTRICAL WIRING 20 5 COMMISSIONING 22 5 1 INITIAL SYSTEM FILLING 22 5 2 PRELIMINARY ELECTRICAL AND GAS SYSTEM CHECKS 22 5 3 CLEANSING AND WATER TREATMENT 23 5 4 FLUE SYSTEM 23 5 5 CONTROL PANEL DISPLAY AND DIAGNOSTICS 24 5 6 INITIAL LIGHTING 27 5 7 CENTRAL HEATING SYSTEM 28 5 8 DOMESTIC HOT WATER SYSTEM 28 5 9 HANDOVER TO THE USER 28 6 ROUT...

Page 4: ...ance This then does not require a fused spur in the cupboard If scale should become a problem the plate heat exchanger is easily isolated and replaced with a service exchange unit The OV models figure 1 1 are suitable for open vented heating systems only and the SS models figure 1 2 are suitable for sealed heating systems only 1 1 OPERATION The appliance control works on the principle of hot water p...

Page 5: ...rises a number of push fit socketed concentric and single pipe components and is designed to allow air to be taken from the ventilated roof space and the flue gases to be discharged to atmosphere through a suitable ridge tile terminal 1 2 2 Gable terminal flue kit This unbalanced flue system comprises a number of push fit socketed concentric and single pipe components and is designed to allow air to be...

Page 6: ...ponents and it is designed to allow air and flue gases to be discharged to atmosphere through a suitable concentric roof terminal Pitched and flat roof options are both available 1 3 OPTIONAL EQUIPMENT a Flexible hose connection kit For further details see Installation Wiring section of this manual b Grundfos UPR 15 60 modulating pump for larger space heating systems INTRODUCTION Gas Air Gas Valve F...

Page 7: ...iring section of this manual All fuses must be ASTA approved to BS 1362 This appliance MUST BE EARTHED b All external wiring to the boiler must be in accordance with the latest I E E Wiring Regulation and any local regulations which may apply c 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 isol...

Page 8: ...flue system used 3 Assumes that the appliance is installed on a plinth and the feed and expansion cistern is installed in the same cupboard Figure 2 1 Clearances and cupboard dimensions e If the boiler is to be fitted in a timber framed building it should be fitted in accordance with the British Gas publication Guide for Gas Installations in Timber Frame Housing Reference IGE UP 7 1998 If in doubt ad...

Page 9: ...at input kW 11 10 10 00 11 10 10 00 11 10 10 00 Maximum gas rate m3 h Minimum gas rate m3 h 1 27 1 06 2 11 1 06 3 17 1 06 Flue gases maximum flow rate gm s 5 8 9 4 14 0 NOx mg kWh CO mg kWh Burner offset pressure Pa 18 to 20 18 to 20 18 to 20 Electrical Supply via double pole 45 A isolator 230 50hz 45A fused 230 50hz 45A fused 230 50hz 45A fused Power consumption 230V 50Hz W Minimum in standby mode...

Page 10: ...urner cycling and if the demand is below this level the burner will cycle to match the heat demand GulfStreamA CLASS has hot water priority controls and therefore full boiler output is available for space heating i e no allowance is necessary for domestic hot water load when selecting the appliance All GulfStreamA CLASS models are fitted with Grundfos UPR 15 50 modulating pumps as standard The net ...

Page 11: ...ee area not less than the minimum specified in table 3 1 3 2 HOT AND COLD WATER SYSTEM a All recommendations with regard to pipe work systems in this manual are generally based on the use of BS EN Standard copper pipework and fittings b However the plastic pipework system can be used in place of copper internally as long as the chosen system is recommended by the manufacturer for use in cold and hot...

Page 12: ... work correctly a recommended dynamic pressure of between 2 3 bar must be available to the appliance at all times e As a general guideline although a 15mm service may be sufficient for smaller dwellings with one bathroom a 22mm service 25mm MDPE is preferred and should be the minimum for larger dwellings f If the incoming mains pressure exceeds 5 bar at any time in a 24 hour cycle then a pressure r...

Page 13: ... to ensure that the water remains cold and of drinking water quality 3 2 4 Taps and Shower Fittings a Ensure that all terminal fittings are suitable for mains pressure Use aerated taps whenever possible to prevent splashing b Any shower mixing valve used must be suitable for mains fed hot and cold supplies However all mains pressure water systems are subject to dynamic changes particularly when oth...

Page 14: ...programmed by a Gledhill ATSM d Frost protection The appliance has its own built in frost protection which will prevent the appliance temperature dropping below about 5o C However if it is necessary to protect other parts of the system installed in unheated spaces e g garage outhouse and ventilated roof space a frost thermostat s must be fitted and wired as shown in section 4 e User controls The Gu...

Page 15: ...the expansion vessel size must also be recalculated c Expansion vessel The expansion vessel must accommodate the change in volume of system water heated from 10oC to 110oC see BS 5449 1990 clause 16 2 When calculating the system water content the capacity of the hot water store 100 litres must be included The expansion vessel requirement are shown in table 3 2 Note Afterfirstfillingthesystemtoapress...

Page 16: ...e 3 5 b F E cistern The cistern supplied with the unit can be fitted up to 10m above the base of the appliance i e the maximum static pressure in the appliance must not exceed 1 0 bar The water level in the F E cistern should be at least 250mm above the highest point on the system including the radiators c Overflowpipe The overflow warning pipe should be in 20mm internal diameter pipe of suitable mat...

Page 17: ...parate flue system design and 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 Note This appliance must only be installed using one of the above approved flue kits available only from Gledhill Water Storage Ltd and should be ordered with the appliance SYSTEM DESIGN Fall 1 2 4 3 5 Fall Figure 3 6 ...

Page 18: ...re flexible cable for connecting to the fixed wiring in the dwelling The fixed wiring to the appliance must incorporate a double pole isolator with at least 3mm contact separation at all poles This 45A double pole isolator must be within 2m of the appliance and the appliance mains cable must be wired to this isolator 4 1 2 Access to the Appliance a Remove front panel by unscrewing the two screws on t...

Page 19: ...ve a bore diameter no smaller than 20mm d The external pipework should be kept to minimum and have a bore diameter no smaller than 32mm e The pipe should not have any upward pipe runs and must fall at least 2 5o 1 20 throughout its length towards the discharge point f It is strongly recommended that the condensate pipe should be run internally to the house soil or vent stack or to a waste pipe g A...

Page 20: ...nsurethattheelectricitysupplyisswitched off b The appliance is supplied with 2m long 10mm2 twin E flex Uncoil this and connect it to the local fixed isolator figures 1 1 1 2 and 4 5 c DO NOT SWITCH ON the electricity supply to the appliance at this stage Figure 4 4A Appliance wiring panel with factory fitted Programmer Table 4 4 Wiring specification and general guide for all models Rating 230V 50Hz No...

Page 21: ... programmable room thermostat to the appliance terminals as shown in figure 4 7 c A link between terminals SL h2 and SL h1 must be inserted Appliance terminal Programmable room thermostat terminal L P L supply in N N supply in E E supply in SL h2 Space heating switched live SL HTG out SL W Hot water switched live SL HW out 4 2 5 Remote programmer and room thermostat A two channel remote programmer ...

Page 22: ...2 1 J1 Main PCB Gas PCB 2 4 1 3 J29 2 4 1 3 J29 SOHT SOHT E Switch L N J5 6 N J28 2 RS calli ng J28 7 CH c alling J28 8 H W c alling 6 5 4 3 2 1 6 5 4 3 2 1 Honeywell Diverter valve Overheat control sensor Honeywell diverter valve Port B Hot water Port A Heating Blue Brown 2 3 energised Port A Closed Blue Black 2 6 energised Port B Closed L N Gas valve fan Heat exchanger N N N SL w SL h2 L P SL h1...

Page 23: ...pply into the F E cistern COMMISSIONING 5 1 2 Sealed System a The sealed system model is fitted with an automatic filling device CA Valve and the system is filled directly from the mains supply to a nominal operating pressure of 1 0 bar when cold b Before filling check the air pressure in the expansion vessel is 1 0 bar and if necessary adjust it to 1 0bar or the recommended system design pressure c ...

Page 24: ...r leaks Rectify if necessary d Add Fernox Superfloc Cleansing Agent to ensure that all flux residues and installation debris are removed from the system e Heat the system to full operating temperature check for water leaks and rectify if necessary Flush the system again until it is clean f Refill the system and add Fernox MB1 Protector to the system ensuring that the system is fully vented Table 5 1 ...

Page 25: ... switched off or faulty Led 2 yellow OFF Gas boiler in standby mode i e burner is off FLASHING Gas boiler is in ignition phase ON Flame has been sensed and the gas boiler i e burner is on Led 3 Red OFF Gas boiler is in standby mode i e healthy FLASHING Boiler requires resetting e g lockout fault has occurred See below ON Electric backup boiler has been selected See below Push Button 1 Used to rese...

Page 26: ...ns on main PCB COMMISSIONING b Temperature mode In this mode the current temperature read by the selected sensor is displayed The button B1 is used to select this mode and the button B2 is used to select the appropriate sensor The temperature is indicated by alternatively flashing the sensor number and its temperature reading or the error code For example if sensor S1 is selected and the temperatur...

Page 27: ... unique ID tag as part of the appliance wiring harness see section 5 1 The controller reads this tag and compares it with the model selected on the controller and the procedure for setting the appliance code in the controller is described below The appliance selection menu A0 A9 A10 A30 on the controller is hidden It is only possible to get to the appliance selection using the reset button Left ha...

Page 28: ...T_OVERHEAT_2_OPEN 44 Sensor error No T_OVERHEAT_1_SHORTED 45 Sensor error No T_TANK_BOTTOM_SHORTED 46 Sensor error Yes SPARE_BLOCK_ERROR_47 47 Not used T_FLUE_SHORTED 48 Sensor error Yes SPARE_BLOCK_ERROR_49 49 Not used T_TANK_MIDDLE_SHORTED 50 Sensor error Yes SPARE_BLOCK_ERROR_51 51 Not used Yes T_OVERHEAT_2_SHORTED 52 Sensor error No FLAME ERROR 2 53 Burner error Yes When the T_TANK_MIDDLE sens...

Page 29: ...tres minute After about 2 3 seconds the plate heat exchanger pump will start This is indicated by on main PCB display by bar D2 1 b Record the hot water outlet temperature in the Benchmark logbook Close this tap and open the hot bath tap at maximum flow rate and record the flow COMMISSIONING rate and the hot water temperature in the Benchmark logbook c Close the hot water tap s and after few seconds...

Page 30: ...o remove or replace components follow the procedure under Component Exchange Carefully clean the assembly i e remove nay dirt with soft brush and check for signs of wear or deterioration of supply leads burner igniter and sensor assemblies The burner must show no sign of oxidation or cracking Check and if necessary reset the ignition spark gap to 4 5 0 5mm and the flame sensor position figure 6 2 6 ...

Page 31: ...spares co Tel 0161 620 6677 Page 31 GULFSTREAM A CLASS Figure 6 2 Spark Flame sensing electrodes ROUTINE ANNUAL SERVICING Figure 6 3 Condensate trap Flame Sensing Electrode Flame Ignition Electrode Burner 4 5 0 5mm A C C A C B ...

Page 32: ...ls operation 7 3 BURNER REMOVAL a Remove the main sub assembly as stated above Section 7 1 a b Disconnect the burner from the burner adaptor casing by removing the 4 hexagon nuts on top of the casting using an 8mm AF spanner socket c If necessary exchange the burner and reassemble in reverse order d REPLACE the fan sealing gasket if the existing shows any signs of deterioration e Check boiler cont...

Page 33: ...gs 8 at the edge of the PCB b Gently ease the PCB off its supports 8 c Replace if necessary and re assemble in reverse order d Ensure A parameter for appliance type is correctly set see table 5 2 e Check boiler controls operation 7 14 COLD WATER SENSOR a Isolate and drain down as necessary the hot cold water system b Remove the electrical connector from the thermistor c Unscrew using a 15mm AF spa...

Page 34: ...AV Unscrew the hexagonal bottom part of the valve incorporating a non return valve using a 22mm AF spanner c Replace the total valve using PTFE tape on the threads to make watertight d UNDERTAKE WATER SOUNDNESS TEST e Check boiler controls operation 7 24 BYPASS VALVE a Isolate the boiler from the heating system b With the SP model drop the system pressure using the safety relief valve and then dra...

Page 35: ...ses then drain down the boiler to below the level of the 3 way valve g Remove the actuator following the instructions above and then remove the cartridge using the special tool provided h Replace if necessary the cartridge and reassemble in reverse order i UNDERTAKE WATER SOUNDNESS CHECK j Check boiler controls operation 7 30 ELECTRICAL CONTACTOR Figure 6 5 a Release the wires from the terminals o...

Page 36: ...tor 2 Pole N O 25 Amp 2 XB014 MCB Single Pole 25 Amp 2 XB026 MCB Single Pole 6 Amp 1 XB025 Plate Heat Exchanger 1 GT017 PHE Sensor incoming cold supply 1 GT198 DHW Sensor 1 GT198 Store Sensor 1 GT198 Heating Return Sensor 1 GT198 Grundfos 15 50 Pump with 1 connections 2 GT089 1 x 22mm Straight Pump Valve 3 GT133 1 x 22mm Angle Pump Valve 1 GT135 CA Backflow Prevention Valve 1 XB390 Pressure Reducin...

Page 37: ... for Taps Mixers WATER SAVINGS OPTIONS FOR SHOWERS 4 FIXING OPTIONS FOR TAPS MIXERS 1 MK Range Combined Regulators Aera tor for screwing onto Taps Mixers with internal orexternalthreadsontheirnoses Anti Vandal models also available 2 MR05 T Range Internal Regulators Push fit into Tap or Mixer seats Produced in three sizes 12 5mm BS1010 12mm 10mm Flangeless models also available for Taps with Low Li...

Page 38: ...nent label should be fixed to the system in a prominent location Where a combi boiler and or a hot water storage vessel is installed in areas where the mains water can exceed 200ppm Total Hardness as defined by BS 7593 1993 Table 2 a scale reduction device should be installed in accordance with the boiler manufacturer s instructions The levels of water hardness may be measured using a water hardne...

Page 39: ...Supplied By www heating spares co Tel 0161 620 6677 Page 39 GULFSTREAM A CLASS ...

Page 40: ...Supplied By www heating spares co Tel 0161 620 6677 Page 40 ...

Page 41: ...Supplied By www heating spares co Tel 0161 620 6677 Page 41 GULFSTREAM A CLASS ...

Page 42: ...Supplied By www heating spares co Tel 0161 620 6677 ...

Page 43: ...Supplied By www heating spares co Tel 0161 620 6677 ...

Page 44: ...Supplied By www heating spares co Tel 0161 620 6677 ...