IDEAL GTE 5, Installation And Servicing

Page 1: ...When replacing any part on this appliance use only spare parts that you can be assured conform to the safety and performance specification that we require Do not use reconditioned or copy parts that h...

Page 2: ...onomisers etc are directly connected to these appliances unless covered by these Installation and Servicing Instructions or as otherwise recommended by Caradon Ideal Limited in writing If in doubt ple...

Page 3: ...t boilers offering high efficiency operation ease of maintenance fuel flexibility and low emissions Suitable for oil or gas operation the Harrier GTE range is supplied in a choice of 5 standard models...

Page 4: ...est code for 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...

Page 5: ...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 s...

Page 6: ...re as shown Rear 1000mm or adequate space to make the flue connections and access to the flue sample point drain connection flue and smokehood cleanout doors and any safety or control devices Sides On...

Page 7: ...actor fan in the same room as the boiler or in an adjacent 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...

Page 8: ...ng 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 c...

Page 9: ...Heating 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 v...

Page 10: ...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 e...

Page 11: ...r 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 optiona...

Page 12: ...into the slots in the side components 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 2 Assem...

Page 13: ...h 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...

Page 14: ...to 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...

Page 15: ...15 Harrier GTE 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 stu...

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...

Page 18: ...or models GTE 7 GTE 8 and GTE 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 ha...

Page 19: ...ug 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 sect...

Page 20: ...d 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 ta...

Page 21: ...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 10 minutes Any drop in pressure...

Page 22: ...the sides and tuck underneath 2 Models GTE 8 and GTE 9 After fitting the front insulation similarly place the rear section 3 Secure the two sections together using the clips provided 4 All Models Pla...

Page 23: ...1 31 INSTALLING THE CASING CROSSBAR SUPPORTS 1 Fit four 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 No...

Page 24: ...ont edges can be identified by the projection 2 Engage 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...

Page 25: ...corner with four 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...

Page 26: ...rough the left or right hand opening in the top front 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 fro...

Page 27: ...L FD168 Deluxe 1 Route the sensors through the left or 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 on...

Page 28: ...LING THE FRONT PANEL 1 Push the panel onto the location 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 in...

Page 29: ...carton contains 1 control panel complete with burner connection harness The control panel incorporates a boiler thermostat controller a thermometer and a safety thermostat The boiler thermostats one...

Page 30: ...n access to the connection strip unscrew the three screws 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 pan...

Page 31: ...n the rear panel of the boiler and route them to the front 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 Secur...

Page 32: ...H Pump not supplied 3x 0 75 mm 2 min Shunt Pump not supplied har7053 Remove white link wire 50 FITTING OPTIONAL FEATURES FD168 Deluxe Control Panel Hour Run Meters IC8 One or two optional hour run met...

Page 33: ...ge 1 boiler thermostat TCH2 Stage 2 boiler thermostat TS Safety thermostat VA Alarm indicator VA TS Safety thermostat alarm indicator VB1 Stage 1 operating indicator VB2 Stage 2 operating indicator ZB...

Page 34: ...other end VIS5146 7 pin plug for one stage burners or 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 chara...

Page 35: ...ire 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 connection Earth connection N 6 Neutral taken...

Page 36: ...C For ON OFF burners use 1st stage thermostat only For 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 In...

Page 37: ...mp Summer stops the heating pump 3 Three Position Switch TESTSTB When held in the pressed momentary use position it tests the safety thermostat Note If two stage burner control fitted operation will c...

Page 38: ...r 20 minutes and for gas fired boilers check the gas rate Table 1 11 Refer to the burner instructions for specific operating features 12 Set the boiler thermostats 3 or Deluxe model 6 to appropriate s...

Page 39: ...solate the mains supply to the boiler and burner 4 Disconnect 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 baff...

Page 40: ...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 66 SERVICIN...

Page 41: ...41 Harrier GTE Installation Servicing NOTES...

Page 42: ...42 Harrier GTE Installation Servicing NOTES...

Page 43: ...43 Harrier GTE Installation Servicing NOTES...

Page 44: ...ing 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...