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IDEAL Viceroy GT 8 Installation And Servicing

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installation and
servicing
Viceroy GT
Your Ideal installation and servicing guide
GT 8, GT 9, GT 10, GT 11,
GT 12, GT 13 & GT 14
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
ENGINEERED FOR PEACE OF MIND
use reconditioned or copy parts that have not been clearly authorised by Ideal Boilers.

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Summary of Contents for IDEAL Viceroy GT 8

  • 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 ENGINEERED FOR PEACE OF MIND use reconditioned or copy parts that have not been clearly authorised by Ideal Boilers.

  • Page 2: Hydraulic Resistance

    Installation and Servicing Instructions or as otherwise Oil rates relate to Gas Oil using a calorific value of 45.56 MJ/kg recommended by Caradon Ideal Limited in writing. If in doubt gross or 42.69 MJ/kg nett. please enquire.

  • Page 3: Table Of Contents

    GENERAL CONTENTS Viceroy GT Gas and Fuel Oil Assembly..............13-26 Destination Countries: GB, IE Boiler Clearances............. 7 Burner Connection............13 Commissioning and Testing........33-35 Electrical Connections..........27-29 Electrical Supply............... 5 Flue Installation..............5 Fluing.

  • Page 4: Gas Safety Regulations

    Further guidance is provided in IGE/UP/2 as listed above. General requirements. Assembly and Installation Instructions for Ideal Viceroy GT heating boilers should be read in conjunction with the general technical data tables enclosed and any other technical publication supplied with the burner.

  • Page 5: Electrical Supply

    The system pump MUST be connected to the boiler. treated. Even the water in closed systems will promote corrosion unless treated. For the reason stated, Caradon Ideal The boiler must NOT be used for direct hot water supply. The Limited strongly recommend that when necessary the systems hot water storage cylinder MUST be of the indirect type.
  • Page 6 GENERAL BOILER DIMENSIONS Water flow tapping ∅ B (to be welded) ∅ Sludge removal hole ∅ " (plugged) 1000 ∅ Water return tapping ∅ Drain 2" tapped (to be welded) (plugged) Effective diameter of combustion chamber : - front section : 455 mm - intermediate section : 530 mm...

  • Page 7: Boiler Clearances

    GENERAL BOILER CLEARANCES Recommended minimum clearances are as follows: The minimum dimensions as indicated must be respected to ensure good access around the boiler. Rear 1000mm or adequate space to make the flue connections and access to the flue sample point, drain Note.

  • Page 8: Ventilation

    GENERAL VENTILATION Position ventilation grilles to avoid the risk of accidental obstruction by blockage or flooding. If further guidance on Safe, efficient and trouble-free operation of conventionally ventilation is required then consult BS 6644. flued gas boilers is vitally dependent on the provision of an The supply of air by mechanical means to a space housing the adequate supply of fresh air to the room in which the boiler should be by mechanical inlet with natural or mechanical...

  • Page 9: Filling The System

    GENERAL FILLING THE SYSTEM addition to automatic air vents which bleed the system when it is 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 operating.

  • Page 10: System Design

    If system return temperature remains below 30ºC for most of the heating period some protection from condensation is required. Please contact Caradon Ideal Limited for further information. Viceroy GT - Installation & Servicing...
  • Page 11 110ºC (230ºF) is 2.5m. The example illustrated is intended as a general guide only. Caradon Ideal Limited will be pleased to advise on specific applications. Design and minimum flow rate tables are shown Frame 8.

  • Page 12: Fluing

    INSTALLATION 10 FLUING According to the output, the difference between the temperature of 1000mm min. the flue gas and the ambient temperature can be as low as 160ºC. The installer will have to respect all of the usual precautions (dilution - piping - T for removal of condensation) in order to prevent deterioration of the chimney.

  • Page 13: Assembly

    INSTALLATION 12 BURNER CONNECTION Burner Door Opening and Fixings Gas Supply The gas supply MUST be sized in accordance with British Gas recommendations. The Local Gas Authority should be contacted, at a stage prior to actual installation, for any advice or information Baffle turbul required.
  • Page 14 INSTALLATION 14 PREPARING THE BASE FRAME AND FITTING THE BASE INSULATION 1. Fit the 2 rear attachment brackets (in the body accessories pack) and attach them onto the framework using two M12 x 40 bolts, four washers and two nuts. M 12 Caution: use the corresponding holes according to the indications...

  • Page 15: Assembly

    INSTALLATION 16 PREPARING THE REAR SECTION 1. Clean the nipple ports and nipples with cleaning fluid. 2. Coat them with the lubricant supplied with the sections. 3. Drive in the two nipples gently. vic7090 17 ASSEMBLING THE SPECIAL INTERMEDIATE SECTION Note.
  • Page 16 INSTALLATION 19 FITTING THE ASSEMBLY RODS AND UPPER CASING SUPPORTS 1. Fit the upper assembly rods (body accessories pack) in 3. Fix the upper casing supports (pack IE 13) and the upper the order given in the appropriate diagram. crosspieces (packs IE 10, 11, 12, 14) with the assembly rods.
  • Page 17 INSTALLATION 20 PREPARATION FOR FITTING THE FLUE CLEANOUT AND BURNER DOORS 1. Screw in and tighten the eight M12x50 studs for the cleaning doors and the burner door and the M12x85 studs for the hinges of the flue cleanout doors. (short end into the section) 2.
  • Page 18 2. Important: Interlock the baffles one into another before placing them in the flue way. vic7098 Baffles (by flue way) Viceroy GT 8 Viceroy GT 9-10 Viceroy GT 11-12 Viceroy GT 13-14 pack IE 30 pack IE 31...
  • Page 19 INSTALLATION 24 FITTING THE SMOKEHOOD 1. Fix the flue outlet spigot (body accessories pack) to the smokehood using four M12x40 bolts, nuts and washers. 2. Screw in the two threaded rods (body accessory pack) M12x175 for the flue outlet. vic7099 3.
  • Page 20 INSTALLATION 26 HYDRAULIC TEST After assembling the boiler body, the installer must carry out a water tightness test at a hydraulic pressure of 1.5 times the design pressure for a period of 30 minutes. The test must be done at room temperature. 1.
  • Page 21 INSTALLATION 27 FITTING THE CASING SUPPORTS 1. Fix the lower casing supports to the framework using Note. one M8x25 bolt and lock washer for each support. For pre-assembled boilers loosen the base frame securing bolts. Note. The quantity varies according to the boiler length. vic7117 vic7102 HM 8x25...
  • Page 22 INSTALLATION 29 ASSEMBLING THE WIRING DUCTS AND FRONT TOP PANEL 1. Fit the left and right wiring ducts, respecting the assembly direction and attach each to the casing support using one M5x12 bolt and vic7104 lock washer at each support. 2.
  • Page 23 INSTALLATION 31 INSTALLING THE CONTROL PANEL - FD167 Standard 1. Route the sensors through the left or right hand opening Rear Front in the front top panel. 2. Route the burner leads through the other opening in the front top panel. 3.
  • Page 24 INSTALLATION 33 INSTALLING THE SENSORS AND ROUTING THE BURNER CABLE 1. Route the burner cable inside the front edge return of one side of the casing side panels opposite the burner hinges. (RH side shown for clarity. See Frame 34.) 2.
  • Page 25 3. Fix the remaining top covers onto the wiring duct using two M5x12 bolts and lock washers. Boiler Front Top Intermediate Rear Pack Panel Top Panel Top Panel Viceroy GT 8 480(IE10) IE12 Viceroy GT 9 480(IE10) 480 480 IE13+IE14 Viceroy GT 10 480(IE10) 480 480 IE11+IE13...
  • Page 26 INSTALLATION 38 ASSEMBLING THE FRONT PANELS 1. Hook the left and right lower front panels on the side 3. Position the upper front cover lower edge behind the front panel buttons. casing support and hook it over the front top cover. 2.

  • Page 27: Electrical Connections

    INSTALLATION 41 ELECTRICAL CONNECTIONS WARNING. The boiler must be earthed. WARNING. The electrical connections must be made by a qualified professional. The electrical wiring has been carefully All connections must be made using the terminal blocks checked in the factory and the internal connections of the provided for this purpose at the back of the boiler control panel.
  • Page 28 INSTALLATION 44 WIRING DIAGRAM - FD167 Standard Control Panel Dj6A Burner Connection strip Dj 6 A 6 A circuit-breaker TCH2 TCH1 Live Neutral TCH1 Stage 1 boiler thermostat TCH2 Stage 2 boiler thermostat Safety thermostat Alarm indicator BA 6 BA 7 BA 8 BA 9 BA 10...
  • Page 29 INSTALLATION 46 CONNECTING OPTIONAL FEATURES - FD168 Deluxe Control Panel Circulating Pump The CH circulating pump should be connected across 14 15 terminals 8, 9 and 10. 14 15 Shunt Pump The shunt pump should be connected across terminals 11, 12 and 13.
  • Page 30 INSTALLATION 48 WIRING DIAGRAM - FD168 Deluxe Control Panel DJ6A TCH1 TCH2 N L1 VA-TS har7056 Heating pump TCH1 Stage 1 boiler thermostat Burner TCH2 Stage 2 boiler thermostat Connecting strip Safety thermostat Cascade connection block Alarm indicator Stage 1 hours run meter (optional) VA-TS Safety thermostat alarm indicator Stage 2 hours run meter (optional)
  • Page 31 INSTALLATION 49 BURNER WIRING HARNESS - FD167 Standard Control Panel Burner Cable The control panel is supplied with a burner power supply cable, with one 7 and one 4-pin European plugs on one end and a terminal block with male connecting terminals on the other end.
  • Page 32 INSTALLATION 50 BURNER WIRING HARNESS - FD168 Deluxe Control Panel Burner Cable Burner Connections without Plug-in Connectors The control panel is supplied with a burner power supply In this case, the connectors supplied with the burner cable cable with one 7 and one 4-pin European plugs which must be rewired.
  • Page 33 INSTALLATION 52 COMMISSIONING - FD167 Standard Control Panel IMPORTANT. Domestic hot water circuits (if they exist and Refer to the following instructions and Frame 56 to start up the heating circuits must have been filled and bled, and leak boiler. tightness tests must have been carried out on them, in the instructions delivered with the burner.
  • Page 34 INSTALLATION 54 COMMISSIONING - FD168 Deluxe Control Panel IMPORTANT. Domestic hot water circuits (if they exist and Refer to the following instructions and Frame 56 to start up the heating circuits must have been filled and bled, and leak boiler. tightness tests must have been carried out on them, in the instructions delivered with the burner.

  • Page 35: Initial Lighting

    INSTALLATION 55 COMMISSIONING AND TESTING A. ELECTRICAL INSTALLATION B. FOR GAS INSTALLATION 1. Checks to ensure electrical safety should be carried 1. The whole of the gas installation, including the meter, out by a competent person. should be inspected and tested for soundness and then purged in accordance with the recommendations of the 2.
  • Page 36 INSTALLATION 59 MAINTENANCE WARNING The operations described below shall always be performed with the boiler and the power supply switch off. The boiler front panel has to be removed to access the various devices to be maintained and checked. 1. Unhook the front panels and remove. Cleaning the Casing Material Use a soapy solution and sponge only.

  • Page 37: System Maintenance

    90% of the nominal, no further action need be taken. If not proceed to 4. Caradon Ideal Limited does not accept any liability resulting from the use of unauthorised parts or the repair and servicing 4.
  • Page 38 NOTES Viceroy GT - Installation & Servicing...
  • Page 39 NOTES Viceroy GT - Installation & Servicing...
  • Page 40 Technical Training 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 Boilers, P.O. Box 103, National Ave, Kingston upon Hull, HU5 4JN.

This manual is also suitable for:

Viceroy gt 9Viceroy gt 11Viceroy gt 10Viceroy gt 12Viceroy gt 13Viceroy gt 14

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