IDEAL Harrier GTE 5, Installation And Servicing

Page 1: ...re parts that you can 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 Boilers Harri...

Page 2: ...es unless covered by these Installation and Servicing Instructions or as otherwise recommended by Caradon Ideal Limited in writing If in doubt please enquire Any direct connection of a control device...

Page 3: ...aintenance fuel flexibility and low emissions Suitable for oil or gas operation the Harrier GTE range is supplied in a choice of 5 standard models rated in outputs from 105kW 358 000 Btu h to 330kW 1...

Page 4: ...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 Direc...

Page 5: ...mately 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...

Page 6: ...flue connections and access to the flue sample point drain connection flue and smokehood cleanout doors and any safety or control devices Sides One side may be 100mm the other side must be 200mm plus...

Page 7: ...acent communicating room can in certain conditions adversely affect the safe operation of the boiler Where such a fan is already fitted or if it is intended to fit an extractor fan after installation...

Page 8: ...ituation 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 o...

Page 9: ...e 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 val...

Page 10: ...nd 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...

Page 11: ...crewdriver 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 th...

Page 12: ...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 2 Assemble the front and rear components into the ends of the...

Page 13: ...ection 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 m...

Page 14: ...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 r...

Page 15: ...N 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 For latest prices and delivery to your door visit MyTub L...

Page 16: ...el 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 a...

Page 17: ...lue 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...

Page 18: ...s 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 LO...

Page 19: ...nto 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...

Page 20: ...ain 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...

Page 21: ...8 Connect the pressure system water 9 Open the fill valve 10 Pressurise the boiler Maintain pressure for at least 10 minutes Any drop in pressure indicates a leakage in the boiler body 11 After succes...

Page 22: ...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...

Page 23: ...r edge clips to the crossbars 2 Secure the crossbars to the front and rear section lugs using the M12 bolts washers shakeproof washers and nuts Note the direction of the crossbar to ensure the edge cl...

Page 24: ...the panel bottom onto the base frame 3 Lift the panel to its vertical position 4 Secure the top edge to the front crossbar support using M8 bolts and shakeproof washers by screwing into the edge clip...

Page 25: ...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 1 2...

Page 26: ...panel 2 Route the burner leads through the other opening in the top front panel 3 Lower the control panel onto the location buttons nearer the front and slide the control panel forwards 3 har7018 1 3...

Page 27: ...right hand opening in the top front panel 2 Route the burner leads through the other openings in the top front panel 3 Lower the control panel onto the location buttons farthest away from the front a...

Page 28: ...n buttons and slide the panel downwards har7024 41 ASSEMBLING THE REAR TOP PANEL har7025 1 2 2 1 1 Engage the location buttons on the top panel into the keyhole slots in the side panel and slide the p...

Page 29: ...connection harness The control panel incorporates a boiler thermostat controller a thermometer and a safety thermostat The boiler thermostats one controls the maximum boiler operating temperature The...

Page 30: ...rews on the rear of the control panel and open the panel 2 Pass the connecting cables to the control panel through the two cut outs in the rear panel of the boiler and route them to the front via the...

Page 31: ...t via the cable channel s See Frame 35 5 Pass the cables into the control panel through the rectangular openings in the front top panel 6 Secure the cables to the base of the control panel with the ca...

Page 32: ...pplied har7053 Remove white link wire 50 FITTING OPTIONAL FEATURES FD168 Deluxe Control Panel Hour Run Meters IC8 One or two optional hour run meters stage 1 and 2 may be fitted on the front of the co...

Page 33: ...TS Safety thermostat VA Alarm indicator VA TS Safety thermostat alarm indicator VB1 Stage 1 operating indicator VB2 Stage 2 operating indicator ZB2 Stage 2 burner switch ZEH Summer Winter switch ZG M...

Page 34: ...r stage 1 of two stage burners 4 pin plug for stage 2 of the burner Terminal block for connecting to the control panel Note If the electrical characteristics of the burner exceed the following values...

Page 35: ...l Box Terminal No L1 7 Permanent Live supply from the safety thermostat Burner main supply g y Earth connection Earth connection N 6 Neutral taken after On Off Switch Neutral terminal T1 T2 5 4 Volt f...

Page 36: ...r two stage burners set 2nd stage 5 C below 1st stage setting Built in stops may be reset See Frame 56 Factory set at 75 C 4 Boiler Thermometer Indicates boiler flow water temperature 5 Flue Gas Therm...

Page 37: ...tch TESTSTB When held in the pressed momentary use position it tests the safety thermostat Note If two stage burner control fitted operation will continue on 1st stage after 2nd stage cut off AUTO aut...

Page 38: ...ate Table 1 11 Refer to the burner instructions for specific operating features 12 Set the boiler thermostats 3 or Deluxe model 6 to appropriate settings ensuring the second stage is 5 C lower than th...

Page 39: ...connect 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 Rem...

Page 40: ...s Check the gas rate and measure the combustion CO CO2 content Complete the boiler log book Carry out functional checks as appropriate 66 SERVICING SCHEDULE To ensure the continued safe and efficient...

Page 41: ...41 Harrier GTE Installation Servicing NOTES For latest prices and delivery to your door visit MyTub Ltd 0845 303 8383 www mytub co uk info mytub co uk...

Page 42: ...42 Harrier GTE Installation Servicing NOTES For latest prices and delivery to your door visit MyTub Ltd 0845 303 8383 www mytub co uk info mytub co uk...

Page 43: ...43 Harrier GTE Installation Servicing NOTES For latest prices and delivery to your door visit MyTub Ltd 0845 303 8383 www mytub co uk info mytub co uk...

Page 44: ...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 in...