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

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gledhill GC2000/120/E Design, Installation & Servicing Instructions Download Page 40

Supplied By www.heating spares.co  Tel. 0161 620 6677

Page 40

Page 41

GULFSTREAM

2000

IMPORTANT: Before commencing a service or changing a component, ISOLATE the 
mains electrical supply TURN OFF the gas supply at the service cock.

To  assist  with  a  component  identification  and  associated  wiring  refer  to  Figures 
4, 5, 18, 19, 20, 31 and 32.

GAS VALVE - COMBUSTION FAN - BURNER - VENTURI

The components above form part of a sub-assembly, which must be removed before 
one of them can be exchanged.
Remove the assembly by following the procedure detailed under ‘Routine Annual 
Servicing.’

GAS VALVE/VENTURI - REMOVAL

Remove  these  components  as  a  common  assembly  -  then  split  and  replace  as 
necessary.  Unscrew the two torq head screws fixing the assembly to the combustion 
fan housing.
Pull  off  the  assembly.    Disconnect  the  valve  from  the Venturi  by  removing  the 
three torq head screws.
DO  NOT  MISPLACE THE  SYNTHETIC  RUBBER  SEALING WASHER  -  BETWEEN THE 
COMPONENTS. 
The Venturi  is  a  straight  forward  replacement.    If  the  gas  valve  is  to  be  replaced 
remove the male 1⁄2’’ gas connection from the old valve.  Fit it to the replacement 
valve using an approved jointing compound.
BEFORE re-assembling the gas valve/Venturi check the soundness of the cork gasket 
and rubber washer.  Replace if deterioration or damaged.  Check and reset gas rate 
and burner pressure (page 26 section 7).
NOTE:- Exchange of either gas valve or venturi will necessitate re-commissioning 
of the appliance.

COMBUSTION AIR FAN - REMOVAL

Remove the main sub-assembly as stated above.  
Remove the gas valve/Venturi assembly.
Disconnect the fan from the burner/adaptor casting by removing the (4) hexagon 
nuts behind the mounting flange.
If necessary exchange the fan and re-assemble in reverse order.
Replace the fan sealing gasket if the existing shows signs of deterioration.
Check boiler/controls operation.

BURNER - REMOVAL

Remove the main sub-assembly stated above.
Disconnect the burner from the burner/adaptor casing by removing the (4) hexagon 
nuts on top of the casting.
If necessary exchange the burner and reassemble in reverse order.
REPLACE the fan sealing gasket if the existing shows signs of deterioration.  
Check boiler/controls operation.

HONEYWELL SEQUENCE CONTROL BOX - REMOVAL

Disconnect HT - Sensor - and Earth leads from control box.
Remove control box - (fixing screw under edge connector - RHS) by pulling to the 
right.  Remove the edge connector.  DO NOT pull wires from connector.
If necessary exchange box and reassemble in reverse order.  
Check boiler/controls operations.

IGNITION ELECTRODES AND
SENSOR REMOVAL

Both components are removed in the same 
manner.
Disconnect the appropriate leads from the 
sequence control box i.e.
Ignition Electrodes - HT and EARTH
Sensor - SENSOR LEAD
Remove the (2) cross head screws retaining 
the component and carefully lift it up out of 
the combustion chamber.
If necessary exchange the component.
ALWAYS fit a new ceramic sealing gasket. 
Re-assemble in reverse order.
Check boiler/controls operation.

FLAME VIEWING WINDOW - 
REMOVAL

Remove  the  (2)  cross  head  screws  retaining 
the frame.  
Lift off the frame and site glass.
Clean/exchange the site glass as necessary.
ALWAYS fit new ceramic sealing gaskets.
Re-assemble in reverse order.

DRY FIRING THERMOSTAT - 
REMOVAL 

Pull  off  the  leads  on  top  of  the  thermostat.  
Unscrew the body (counter clockwise).
If necessary exchange and re-assemble in
 reverse order. 
Check boiler/controls operation.

STORE OVERHEAT THERMOSTAT 
- REMOVAL 

Remove (pull off) the leads from the back.
Remove the central fixing nut.
Remove  the  split  pin  at  the  thermostat  phial 
pocket and pull out the phial.
Remove the thermostat by passing the capillary 
tube  and  phial  through  the  adjacent  hole  in 
the bulkhead.
Replace as necessary and re-assemble in reverse 
order.  Finally depress thermostat reset button.
Check boiler/controls operation.

COMPONENT EXCHANGE

Summary of Contents for GC2000/120/E

Page 1: ...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 m...

Page 2: ...mponent 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 installa...

Page 3: ...phone number in your local telephone directory under Gas General Details of essential features of cupboard design are given in BS 6798 Thisinformationisprovidedtoassistgenerallyintheselectionofequipment Responsibility for selection and specification 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...

Page 4: ...ly 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 ho...

Page 5: ... 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 tempera...

Page 6: ...ere through a suitable concentric roofterminal PitchedandFlatRoofoptions are both available The air intake and flue 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 ...

Page 7: ...Supplied By www heating spares co Tel 0161 620 6677 Page 7 GULFSTREAM 2000 Figure 4 GulfStream 2000 120 E and 2000 130 E suitable for sealed systems only DESCRIPTION ...

Page 8: ...Supplied By www heating spares co Tel 0161 620 6677 Page 8 DESCRIPTION Figure 5 GulfStream 2000 120 E OV and 2000 130 E OV suitable for open vented systems only ...

Page 9: ...of an adequate supply of gas 2 An existing service pipeMUSTNOT 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 Anexistingmetershouldbeofsufficientsize 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 sp...

Page 10: ...tion 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 flue and air inlet system to be fitted in its correct position 4 The boiler must be installed on a flat surface which ...

Page 11: ... bar at any point in the 24 hour cycle then a pressure limiting valve set at 3 bar should be fitted downstream of the stop tap where the cold supply enters the property Units must be fitted strictly in accordance with the requirements of the Local Water Undertaking who should be consulted prior to installation In the event of any difficulty please contact ourselves as the manufacturer 4 Equipment ...

Page 12: ...awoffpipework 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 Se...

Page 13: ... 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 fittings 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 manuf...

Page 14: ...nable 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 fitted at the highest point in the system Normal procedures for sizing heating circuit pipes should be used and the pump head ava...

Page 15: ...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 disch...

Page 16: ...also be fitted 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 20...

Page 17: ...lue 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 flue kits Figure 16 ...

Page 18: ...nit 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 floor 2 FITTING THE APPLIANCE 2 1 General The appliance should be mounted on a 100mm high...

Page 19: ...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 ...

Page 20: ...Supplied By www heating spares co Tel 0161 620 6677 Page 20 INSTALLATION WIRING Figure 19 Figure 20 Figure 18 ...

Page 21: ... i w n o i t c n u j n o c n i w o l e b s l i a t e d e h t e s u o t r e l l a t s n I l a c i r t c e l E t n e t e p m o c e h t f o y t i l i b i s n o p s e r s d r a d n a t S h s i t i r B t s e t a l 0 1 V 0 3 2 g n i t a R W k 6 V 0 3 2 t n e r r u c l a n i m o N s p m a g n i t a l o s i f o g n i t a r n i M s p m a V 0 3 2 h c t i w s p o o l t l u a f h t r a e d n a p o r d V 2 9 n...

Page 22: ...low terminals take neutral and earth to neutral and earth on the room thermostat respectively 3 3 Frost Protection If a frost thermostat is fitted then it should be wired as shown in Figure 22 The frost thermostat will then override both the programmer and room thermostat and switch on heating and boiler until the frost stat is satisfied NOTE For the frost thermostat to work the appliance must be ...

Page 23: ...dd 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 th...

Page 24: ...the burner visible through the site glass and the burner should remain at low rate for around 30 seconds Also burner on indicator light in yellow will illuminate on front panel The burner should then increase to maximum high rate This is signalled by a noticeable increase in fan speed and burner flame size The remaining system functions can now be checked 2 Once a temperature of 64 C has been reac...

Page 25: ...ck green LED 2 remains lit for this period of time when the boiler switches off i e the thermal store reaches temperature Thecontrolfunctionshavenowbeenchecked Let the boiler heat the store and when the store is satisfied i e green LED s 1 and 2 on the A C B are off the radiator circuit and hot water can be checked and balanced in the normal way 7 Instruction to Users Explain the system to the occ...

Page 26: ...er clockwise direction 3 A minimum dynamic inlet pressure boiler running of 15mbar is necessary at the inlet test nipple 4 Counter clockwise adjustment 1 4 turn max at each attempt of the throttle will increase gas in and out hence CO2 level Throttle adjustment usually results in small if any change in offset reading 5 The final offset reading MUST always be NEGATIVE 6 Counter clockwise adjustment...

Page 27: ...ON THE PRESET CONTROLS OF THE APPLIANCE 9 EXTERNAL CONTROLS Check that any other external controls connected in the system such as time clocks and thermostats control the boiler as required Explain and instruct the occupants on how to use the system CO2 operation at slightly higher level upto 9 8 is satisfactory provided 0 01 CO is not exceeded Proceed as follows 1 Turn off the electrical supply a...

Page 28: ...tton does not require resetting under black cap IF EITHER RESET BUTTON REQUIRES RESETTING PRESS IN ONCE OR TWICE IF THE APPLIANCE DOES NOT UNLOCK WAIT 15 SECONDS AND TRY AGAIN IN CERTAIN CIRCUMSTANCES LOCK OUTS MAY OCCUR IT IS ONLY NECESSARY TO CALL AN ENGINEER IF THIS HAPPENS ON A REGULAR BASIS EMERGENCY SHUTDOWN 1 Turn off the electrical supply to the appliance at the fused isolator switch 2 Tur...

Page 29: ...re is still no hot water then go to fault finding chart 3 NO HEATING AND HOT WATER 1 Check that jumpers on pcb are in correct locations and the pcb has been booted correctly 2 Check that there is gas supply to the appliance 3 Check that there is electrical supply to the appliance and the ON OFF button on the facia panel is switched on 4 Check electrical supply is of the correct polarity 5 If a 2 c...

Page 30: ...Supplied By www heating spares co Tel 0161 620 6677 Page 30 FAULT FINDING ...

Page 31: ...Supplied By www heating spares co Tel 0161 620 6677 Page 31 GULFSTREAM 2000 FAULT FINDING ...

Page 32: ... 11 12 Switch PCB FAN FAN PCB Schematic wiring diagram GufStream2000 with 9kW backup Models 12SP 18SP and 25SP Orange white Purple white Switch OHS manual reset Contactor Coil white On Off switch 9kW heaters Switch control thermostat Contactor 2 x 25A fuses red blue black 1 2 3 4 5 6 7 8 16 15 14 13 12 11 10 9 SL N L E blue blue blue brown brown brown blue blue red red brown brown Green yellow bro...

Page 33: ...0 11 12 Switch PCB FAN FAN PCB Schematic wiring diagram GufStream2000 with 9kW backup Models 12OV 18 OV and 28OV Orange white Purple white Switch OHS manual reset Contactor Coil white On Off switch 9kW heaters Switch control thermostat Contactor 2 x 25A fuses red blue black 1 2 3 4 5 6 7 8 16 15 14 13 12 11 10 9 SL N L E blue brown brown blue blue red red brown brown Green yellow brown red red bro...

Page 34: ...b terminal 13 Y Is there 230V at live terminal of heating pump Y Is heating pump free Y Is heating pump rotating at right speed Ensure heating pump is NOT stuck between speed settings Y Check heating circuit pipe work and radiator valves N Faulty ACB pcb CHANGE N Free heating pump Faulty pump CHANGE N Retest heating functions FAULT FINDING CHART 1 No Space Heating but Hot Water performance is sati...

Page 35: ...Supplied By www heating spares co Tel 0161 620 6677 Page 35 GULFSTREAM 2000 FAULT FINDING ...

Page 36: ...Supplied By www heating spares co Tel 0161 620 6677 Page 36 FAULT FINDING ...

Page 37: ...Supplied By www heating spares co Tel 0161 620 6677 Page 37 GULFSTREAM 2000 FAULT FINDING ...

Page 38: ...will depend on the particular installation conditions and use to which the appliance is put In general once a year should be adequate It is the law that any service work must be carried out by a competent person such as BritishGasorotherCORGIregisteredpersonnel 1 ROUTINEANNUALSERVICING IMPORTANT Before commencing a service or changing a component ISOLATE the mains electric supply TURN OFF the gas ...

Page 39: ... in reverse order and check for leaks 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 equipm...

Page 40: ...ler controls operation BURNER REMOVAL Remove the main sub assembly stated above Disconnect the burner from the burner adaptor casing by removing the 4 hexagon nuts on top of the casting If necessary exchange the burner and reassemble in reverse order REPLACE the fan sealing gasket if the existing shows signs of deterioration Check boiler controls operation HONEYWELL SEQUENCE CONTROL BOX REMOVAL Di...

Page 41: ... cover Check boiler controls operation PRESSURE GAUGE REMOVAL Isolate the appliance from the heating system Turn off supply to auto make up tank if fitted Open the safety valve to release internal boiler pressure Drain down the boiler to below the level of the safety valve Unscrew counter clockwise the capillary at the valve Remove the knurled nut at the back of the gauge and pull the capillary ou...

Page 42: ... UNDERTAKE WATER SOUNDNESS TEST Check boiler controls operation STORE SENSOR 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 sensor head Remove the R cup at the sensor pocket and pull out the sensor Replace if necessary and re assemble in reverse order Replace cable ties Check boiler con...

Page 43: ...l a u n a m C 0 0 1 t a t s o m r e h t t a e h r e v o r e l i o B 1 8 8 1 T G t e s l a u n a m t a t s o m r e h t y t e f a s g n i r i f y r d r e l i o B 1 6 8 1 T G l a e s s a g t s u a h x E 1 1 9 1 T G s w e r c s d n a g n i r O e g n a l F 1 2 1 2 9 1 T G e l p p i n k c a b d e e F 2 3 9 1 T G e v l a v f e i l e r n o i s n a p x e r a B 3 1 5 9 1 T G p m u p 0 5 5 1 s o f d n u r G ...

Page 44: ... S X m m 2 1 x 5 M t l o b d u t S 1 1 0 5 0 S X t e s l a u n a m C 8 9 t a t s o m r e h t t a e h r e v o e r o t S 1 4 6 0 T G 8 7 9 7 9 3 l e s s e v n o i s n a p x e t l 2 1 1 2 6 1 T G e g u a g e r u s s e r P 1 1 6 1 T G n a f t u o h t i w y l b m e s s a r e n r u B 1 3 6 1 T G n a f r o f t e k s a G 1 5 6 1 T G e r o c c i m a r e c t n e m e c a l p s i D 1 6 6 1 T G e v o b a e b u...

Page 45: ...er Byelaws and means the connection to the mains cold water supply can be permanent This will allow any loss of water from the heating system to be automatically replenished as with an open vented system fitted with a feed and expansion cistern Details of the valve assembly and its installation requirements are shown opposite The valve requires a pressure differential to operate correctly and a mi...

Page 46: ...ughout its length The method of sizing the pipe is shown opposite A 22mm minimum diameter discharge pipe is recommended the discharge pipe diameter must be at least one size larger than the cold water inlet NOTE DO NOT open the control isolating valves C V for the CA backflow prevention valve until the heating system is complete ANTI VACUUM VALVE Details of where to fit the anti vacuum valve are s...

Page 47: ... 2 Compression Fitting Range In Line regulators as in Option 4 for Taps Mixers WATER SAVINGS OPTIONS FOR SHOWERS 4 FIXING OPTIONS FOR TAPS MIXERS 1 MK Range Combined Regulators Aerator for screwing onto Taps Mixers with internal or external threads on their noses AntiVandal models also available 2 MR05 T Range Internal Regulators Push fit into Tap or Mixer seats Produced in three sizes 12 5mm BS10...

Page 48: ...losest possible substitute in the case of any obsolete product and will collect and deliver to any address in England Wales and Scotland excluding all Scottish Islands a free of all charge during the first year after delivery by us b thereafter at a charge of one fifth of the then current list price or any copper price supplement and delivery charge during the second year after delivery by us incr...

Page 49: ...to enter at any time any vehicle or premises owned or occupied by the Purchaser or in the possession of the Purchaser for the purposes of repossessing and recovering any such goods the property in which has remained in us under paragraph 2 above We shall not be responsible for and the Purchaser will indemnify us against liability in respect of damage caused to any vehicle or premises in such repos...

Page 50: ...Supplied By www heating spares co Tel 0161 620 6677 ...

Page 51: ...Supplied By www heating spares co Tel 0161 620 6677 ...

Page 52: ...Supplied By www heating spares co Tel 0161 620 6677 ...

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