ideal commercial HARRIER GTS 5, Installation And Servicing

Page 1: ...an be assured conform to the safety and performance specification that we require Do not use reconditioned or copy parts that have not been clearly authorised by Ideal For the very latest copy of literature for specification and maintenance practices visit our website www idealcommercialboilers com where you can download the relevant information in PDF format ...

Page 2: ...onomisers etc are directly connected to these appliances unless covered by these Installation and Servicing Instructions or as otherwise recommended by Ideal Boilers in writing If in doubt please enquire Any direct connection of a control device not approved by Ideal Boilers could invalidate the certification and the normal appliance warranty It could also infringe the Gas Safety Regulations and t...

Page 3: ...GTS boilers are a range of cast iron sectional pressure jet boilers offering high efficiency operation ease of maintenance fuel flexibility and low emissions Suitable for oil or gas operation the Harrier GTS range is supplied in a choice of 5 standard models rated in outputs from 105kW 358 000 Btu h to 330kW 1 126 000 Btu h and has a maximum operating pressure of 6 bar All models may have high low...

Page 4: ...or heating boilers for atomizing oil burners 73 23 EEC Low voltage directive Relevant standard is EN60335 1 89 336 EEC Electromagnetic Compatibility Directive Relevant standards are EN50081 1 EN50082 1 and EN55014 90 396 EEC Gas Appliance Directive Relevant standards are EN303 1 EN303 2 and EN304 92 42 EEC Boiler Efficiency Directive IGE UP 1 Soundness testing and purging of industrial and commerc...

Page 5: ...r body or even premature boiler failure Corrosion and the formation of black iron oxide sludge will ultimately result in premature radiator failure Open vented systems are not completely sealed from the atmosphere if proper venting and expansion of system water is to be achieved The same tank is used to fill the system with water and it is through the cold feed pipe that system water expands into ...

Page 6: ...smokehood cleanout doors and any safety or control devices Sides One side may be 100mm the other side must be 200mm plus the burner projection or 500mm whichever is the greater to allow the burner door to be swung open and maintain access to the rear In multiple boiler installations both sides may be 100mm except at one end consideration must also be given to the burner door hinge position and con...

Page 7: ...advice of the gas supplier should be obtained The temperature within a boiler room shall not exceed 25o C within 100 mm of the floor 32o C at mid height and 40o C within 100 mm of the ceiling Filling shall be performed with a low flow rate from a low point in the boiler room in order to ensure that all the air in the boiler is bled from the high point of the system Always stop the pump before fill...

Page 8: ...g down the boiler plant if a potentially hazardous situation should arise Examples of such situations are low water level and operating pressure or excessive pressure within the system Depending on circumstances controls will need to be either manual or automatic reset In the event of a shutdown both visual and audible alarms may be necessary Open vent safety pipe 750mm Cold feed expansion pipe H ...

Page 9: ...ting return 3 3 bar safety valve and pressure gauge 4 Flow switch if necessary 5 Air separator 6 Automatic venting valve 7 Valve 8 Shunt pump required for all models 9 Expansion tank 10 Draining valve 11 Sludge valve 12 Mixing valve 13 Non return valve 14 Heating pump 15 Low water safety pressure sensitive switch 16 Sludge decanting pot particularly recommended for older heating systems 17 Indepen...

Page 10: ...sign of flues for GAS fired appliances are quoted in BS 6644 and IGE UP 10 whilst BS 5410 Pt 1 similarly applies to OIL fired boilers The table below contains the minimum dimensions of the flue required for each boiler model in order to ensure sufficient draught at the outlet 1 at boiler maximum input 2 Boiler flow temperature 80o C ambient temperature 20o C 11 DIMENSIONAL INFORMATION REQUIRED FOR...

Page 11: ...ackages which make up the boiler The packages are listed in the order in which they are opened for assembly Tools required not supplied Phillips head screwdriver Wide flat screwdriver 13 and 17mm spanners hammer Silicone glue JDTE assembly tool Simplified assembly tool The assembly of any optional devices purchased with the boiler is described in the instructions supplied with the relevant device ...

Page 12: ...s into the slots in the side components 2 Assemble the front and rear components into the ends of the 15 FITTING THE BASE FRAME INSULATION 1 Locate the insulation between the sides and end with the black fabric on the underside 2 2 fal5982 1 1 2 2 har5983 side components and secure with the 4 bolts INSTALLATION ...

Page 13: ...rough the rear section 4 Pass the rods through the rear section and secure both ends with the 4 washers and M12 nuts This may be conducted after preparing the section Frame 17 and fitting thermocord Frame 18 if preferred 17 PREPARING THE REAR SECTION This may be conducted before Frame 16 with the section laid flat on the floor 1 Clean the nipple ports and nipples with cleaning fluid 2 Coat the nip...

Page 14: ...nto the groove 3 Cut it to the correct length 4 Repeat for intermediate sections 19 ASSEMBLING THE INTERMEDIATE SECTIONS 1 Place the first intermediate section onto the base frame 2 Fit the connections of the intermediate section onto the nipples in the rear section 3 Ensure that the thermocord fits evenly between the sections in the correct manner to make a good seal 4 Hammer in with the help of ...

Page 15: ...15 Harrier GTS Installation Servicing INSTALLATION 20 ASSEMBLING THE INTERMEDIATE SECTIONS CONT D Proceed likewise for other intermediate sections A 20 cm har5993 1 3 2 4 5 6 8 7 INSTALLATION ...

Page 16: ... any surplus silicone 6 Remove the assembly tool 7 Level the boiler by adjusting its feet 22 PREPARATION FOR FITTING THE FLUE CLEANOUT AND BURNER DOORS FOR RH OPENING 1 Screw in and tighten all the studs in the appropriate tappings as shown for items A and B 2 Position the burner door hinge bracket and secure with two M12 nuts and washers 3 Position the burner door catch and secure with two M12 nu...

Page 17: ... evenly with four M12 nuts and washers 3 Position the flue cleanout door hinge bracket as shown and secure with two M12 nut and washers Note For left hand opening position the hinge bracket on the left 4 Position the flue cleanout door in place and insert the hinge pin Note Do not close and secure the door at this time har5996 1 har5998 4 M12 M12 4x 2x har5997 A A B A A A B B 3 2 2 INSTALLATION ...

Page 18: ...for models GTS 7 GTS 8 and GTS 9 will contain two sizes of baffle Use only the 570 mm long ones and discard the shorter ones 4 In all cases the baffles should be pushed in to be flush with the front har5999 3 2 1 25 POSITIONING THE FLUE BAFFLES IN THE LOWER FLUEWAYS 1 All Models Place one baffle in each of the two lower flue ways 2 In all cases the flue baffles should be pushed in to be flush with...

Page 19: ...2 Screw the threaded bush with the sensor pocket into the upper connection and the plug into the lower connection har7001 1 2 2 27 FITTING THE SMOKEHOOD 1 Screw the four M8 studs into the rear section 2 Put a drop of silicone at about every 100mm of the groove 3 Insert the thermocord into the groove 4 Cut it to the correct length 5 Assemble the smokehood onto the studs and secure with four flanged...

Page 20: ...ed and tapped connections of the sections pipes and drain cock with thread sealing tape or compound not supplied 2 Screw the flow and return pipes and the drain cock into the rear section Ensure the tapping on the flow connection faces upwards to accept the pressure relief valve Note This tapping is not to be used for venting 3 Use plumbline to ensure the flanges are vertical and equally screwed i...

Page 21: ...inlet valve 6 Close the vent valve 7 Disconnect the supply water 8 Connect the pressure system water 9 Open the fill valve 10 Pressurise the boiler Maintain pressure for at least 30 minutes Any drop in pressure indicates a leakage in the boiler body 11 After successfully conducting the test release the pressure and drain After assembling the boiler body the installer must carry out a water tightne...

Page 22: ...n the sides and tuck underneath 2 Models GTS 8 and GTS 9 After fitting the front insulation similarly place the rear section 3 Secure the two sections together using the clips provided 4 All Models Place the rear insulation into position ensuring it fits neatly over the pipe connections and flue cleanout box 5 Secure at the top and sides using the clips provided har7009 4 5 1 har7011 140 90 har700...

Page 23: ...roof washers and nuts Note the direction of the crossbar to ensure the edge clips fit from the front 32 INSTALLING THE MAINS AND SENSOR CABLE TRAYS 1 Slide the trays into the casing crossbar supports 2 Lower the front plate into position on the trays 3 Secure the front plate with screws at each side 4 Slide the assembly towards the rear until the front plate meets the crossbar 5 Secure the trays w...

Page 24: ... bottom onto the base frame 2 Raise the panel to its vertical position and lift over the crossbar supports 3 Secure the top edge to the front crossbar support using M8 bolts and shakeproof washers by screwing into the edge clips 4 Secure to the rear crossbar in the same manner har9085 1 1 2 4 3 INSTALLATION ...

Page 25: ... with two self tapping screws and shakeproof washers Note If a pressure relief valve has already been fitted in the flow connector or if the panel is being replaced on a completed installation the top centre piece of the panel may be removed 35 ASSEMBLING THE FRONT TOP PANEL 1 Engage the notches in the top panel onto the location buttons and slide forwards 2 1 3 har9086 INSTALLATION ...

Page 26: ... left hand opening in the top front panel 2 Route the burner leads through the same opening in the top front panel 3 Lower the control panel onto the location buttons nearer the front and slide the control panel forwards har7019 4 5 5 4 Remove the three screws from the rear of the control panel and remove the top rear cover 5 Secure the control panel to the casing top front panel with two self tap...

Page 27: ...es RH side shown for clarity 2 Insert the sensors into the sensor pocket 3 Loop the sensor leads back over the sensor pocket 4 Secure the leads with the spring clip har9090 1 4 2 3 1 39 ASSEMBLING THE LOWER FRONT PANEL 1 Push the panel onto the location buttons and slide the panel downwards 40 ASSEMBLING THE FRONT PANEL 1 Push the panel onto the location buttons and slide the panel downwards har90...

Page 28: ...ide the panel forwards 2 Secure the panel at the two top rear corners with two self tapping screws and shakeproof washers 1 2 2 1 har9093 42 NAMEPLATE AND LEVELLING 1 Affix the identification plate supplied in the instructions bag on the casing on the left or right hand side in an easily accessible location 2 Check the boiler for level and adjust the feet if necessary INSTALLATION ...

Page 29: ...ions The electrical connection must comply with standards in force The equipment must be powered by a circuit containing a remote double pole switch with opening 3mm WARNING The boiler must be earthed All connections must be made using the terminal blocks provided for this purpose at the back of the boiler control panel Connections cables are brought inside the boiler through cut outs provided in ...

Page 30: ...Alarm Indicator System 1 The unused insulated terminal on the safety thermostat may be used to connect an alarm signal This terminal becomes live if the safety thermostat trips 2 Remove the insulation and connect the live wire from the alarm indicator to the unused terminal using a suitable spade connector and the neutral to terminal 4 12 11 10 9 8 7 6 5 4 VA S3 T8 T7 T6 T 2 T1 L1 N 230V 50Hz L N ...

Page 31: ...nnecting terminals on the other end Note If the electrical characteristics of the burner exceed the following values start up current 16 A or P 450 W or 1 2 cont hp motor or I 2A cos ϕ 0 7 The burner controls circuit must use a relay Burner Wire Connector No From Connection to the Burner Control Box Terminal No L1 7 Permanent Live supply from the safety thermostat Burner main supply g y Earth conn...

Page 32: ...er Thermostats Adjustment range 30 90o C For ON OFF burners use 1st stage thermostat only For two stage burners set 2nd stage 5o C below 1st stage setting 4 Boiler Thermometer 5 Location for Flue Gas Thermometer Optional 6 Timed Circuit Breaker 10A with delayed action and manual reset 7 Safety Thermostat Set at 110o C Manual reset 51 BOILER THERMOSTAT Maximum Setting Adjustment The boiler thermost...

Page 33: ...or specific operating features 10 Set the boiler thermostats 3 to the appropriate settings ensuring the second stage is 5o C lower than the first stage if a 2 stage burner is fitted 54 GENERAL CHECKS Make the following checks for correct operation 1 The correct operations of ANY secondary system controls should be proved Operate each control separately and check that the main burner or circulating...

Page 34: ...isconnect the cable and supply pipe to the burner 5 Open the combustion chamber and flue way doors by removing the 8 nuts 6 Remove the flue way baffles 7 Thoroughly clean the flue ways and baffles 8 Remove the rear cleanout covers by undoing the 4 wingnuts and dispose of the debris soot that may have accumulated 9 Replace the rear cleanout covers after first inspecting and if necessary replacing t...

Page 35: ...h the system hot examine all water connections for soundness Check the gas rate and measure the combustion CO CO2 content Complete the boiler log book Carry out functional checks as appropriate 60 SERVICING SCHEDULE To ensure the continued safe and efficient operation of the appliance it is recommended that it is checked at regular intervals and serviced as necessary The frequency of servicing wil...

Page 36: ...ntinuing improvement in the design and performance of its products The right is therefore reserved to vary specification without notice The Ideal Boilers Technical Training Centre offers a series of first class training courses for domestic commercial and industrial heating installers engineers and system specifiers For details of courses please ring 01482 498 432 Ideal Installer Technical Helplin...