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IDEAL Falcon GTE 4 Installation And Servicing Manual

Falcon gte series
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installation and
servicing
Falcon GTE
Your Ideal installation and servicing guide
GTE 4, GTE 5, GTE 6, GTE 7 & GTE 8
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 have not been clearly authorised by Ideal Boilers.
ENGINEERED FOR PEACE OF MIND

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Summary of Contents for IDEAL Falcon GTE 4

  • 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 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 Falcon GTE Gas and Fuel Oil Assembly..............11-22 PI No. 0049AT2527 Destination Countries: GB, IE Boiler Clearances............. 6 Burner Connection............11 Commissioning and Testing......... 26 & 27 Electrical Connections..........22-24 Electrical Supply............... 5 Flue Installation.

  • Page 4: Assembly

    BS 5885 Pt1 Gas burners - with inputs 60kW and above. Assembly and Installation Instructions for Ideal Falcon GTE 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 Even the water in closed systems will promote The system pump MUST be connected to the boiler. corrosion unless treated. For the reason stated, Caradon Ideal Limited strongly recommend that when necessary the systems The boiler must NOT be used for direct hot water supply. The is thoroughly cleaned, prior to the use of stable inhibitor, which hot water storage cylinder MUST be of the indirect type.

  • Page 6: Boiler Clearances

    GENERAL BOILER DIMENSIONS 51 111 heating outlet flue gas spigot heating return 3/4" tapped draining tube Rp : Tapped R : Threaded (1) Adjustable feet: basic height 50mm with 35 to 65mm adjustment range. Boiler GTE 4 GTE 5 GTE 6 GTE 7 GTE 8 1008...
  • Page 7 GENERAL VENTILATION Position ventilation grilles to avoid the risk of accidental Safe, efficient and trouble-free operation of conventionally flued gas boilers is vitally dependent on the provision of an obstruction by blockage or flooding. If further guidance on ventilation is required then consult BS 6644. adequate supply of fresh air to the room in which the appliance is installed.
  • Page 8 GENERAL OPEN VENTED SYSTEM REQUIREMENTS - minimum static head requirements The Falcon GTE boiler has a minimum static head requirement of 5.0 metres (16.5 feet approx.) depending on the particular Open vent characteristics of the system design (see diagram). The information safety pipe provided is based on the following assumptions.
  • Page 9 Notes: Minimum static head requirements with limit thermostat set at 100ºC (212ºF) : 2.5m. The examples illustrated are 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 in this leaflet.
  • Page 10 INSTALLATION FLUING 500 minimum According to the output, the difference between the temperature of the flue gas and the ambient temperature can be as low as 160 C. 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 11: Burner Connection

    INSTALLATION 11 BURNER CONNECTION 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 required. Ø 305 Burner plate Oil Storage Tank cut out O112...
  • Page 12 INSTALLATION 13 PREPARING THE FRONT AND REAR SECTIONS Installing the height convertor and the adjustable feet on the 2. Place the rear section on the floor and fix the height rear section. converter with two M10 x 25 bolts, serrated washers and nuts using a 17mm spanner.
  • Page 13 INSTALLATION 15 FITTING THE SILICON BRAID 16 ASSEMBLING THE INTERMEDIATE SECTIONS 1. Working from point A, insert the silicone braid into the groove of the intermediate and front sections. 1. Place the first intermediate section on the wooden block. 2. Cut it to the correct length. 2.
  • Page 14 INSTALLATION 18 ASSEMBLING THE FLOW, RETURN AND DRAINING PIPES 1. Coat the threaded and tapped connections of the sections, 3. Screw the threaded bush with the sensor pocket into the pipes, plugs and sensor tubes with thread sealing upper connection and the plug into the lower connection. compound (not supplied).
  • Page 15 INSTALLATION 20 DOOR ALIGNMENT 21 ASSEMBLING THE DOOR WITH LEFT-HAND OPENING 1. Adjust the upper hinge to align the door by Assembling the door with left-hand opening a. Loosen screw A b. Adjust screw B so that the door is positioned correctly.
  • Page 16 INSTALLATION 23 FITTING THE SMOKEHOOD 1. Screw the two M8 studs into the rear section. 2. Assemble the flue gas collector hood onto the studs and secure with two flanged nuts. FAL5833 FAL5832 24 INSTALLING THE CONTROL PANEL 1. Place the control panel on the boiler body. 3.
  • Page 17 INSTALLATION 25 INSTALLING THE SENSORS (AND REAR CROSSBAR) 1. Put the sensors in place in the sensor pocket. 2. Slide the spirap along the leads. 3. Loop the leads over and secure with the spring clip. 4. pass the wires under the control panel. 5.
  • Page 18 INSTALLATION 27 FITTING THE SIDE PANEL SUPPORTS 1. Place the two lower side pieces (with the round hole towards the front and the oblong hole towards the back of the boiler). 2. Fix: a. to the front with a screw, serrated washer and nut.
  • Page 19 INSTALLATION 30 SECURING THE BURNER CABLE 1. Assemble the cable clamp on the side panel. 2. Place the burner cable behind the side panel on the burner side, holding it in place with the cable clamp and two 3.5 ∅ x 25 screws. 3.
  • Page 20 INSTALLATION 33 ASSEMBLING THE REAR PANEL 1. Mount the lower and upper rear insulating material, with the top folded in towards the boiler at a 90 angle. 2. Secure the rear plate (8 self tapping screws and serrated washers). FAL5846 34 ASSEMBLING THE REAR PANEL (If pipework already made) 1.
  • Page 21 INSTALLATION 35 FITTING THE TOP PANEL 36 ASSEMBLING THE INSULATED FURNACE DOOR PANEL 1. Assemble the cover by placing it on studs located on the front and rear of the left and righ-hand side panels. 1. Secure with the three black screws with large heads provided.
  • Page 22 INSTALLATION 38 NAMEPLATE Type of boiler Year (1) Affix the identification plate and CE label Week (supplied in the instructions bag) on the X X - X X casing (on the left or right-hand side) in Date of manufacture an easily accessible location. F 67110 NIEDERBRONN Unit serial no.
  • Page 23 INSTALLATION 41 BASIC CONNECTIONS (On/Off Burner Control - All Models) OPTION - ZÜBEHOR OPTION - ZÜBEHOR - OPTION OPTION-ZÜBEHOR OPTION - ZÜBEHOR OPTION - ZÜBEHOR - OPTION COMMANDE A DISTANCE 13 12 11 10 SONDE SONDE SONDE SONDE 230V- 50Hz 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 This terminal block is for COMBI Models only...
  • Page 24 INSTALLATION 43 BASIC CONNECTIONS (High/Low Control - Models GTE 7 & GTE 8 Only) 14 15 230V 50Hz VA - TS 44 WIRING DIAGRAM (High/Low Control - DR31 Control Panel - Models GTE 7 and GTE 8 only) F6,3AT 1a 1 S3 B4 T6 T7 T8 B5 N L1...
  • Page 25 INSTALLATION 45 WIRING HARNESS (On-Off Burner Control) The burner control circuit is fitted with a cable with a 7-pin In the case of a burner not fitted with sockets, remove the plugs European connecting plug which can be fitted directly to on the burner cable from the boiler and connect the leads to the burners fitted with connector sockets.
  • Page 26 INSTALLATION 48 COMMISSIONING IMPORTANT. Domestic hot water circuits (if they exist and Refer to the following instructions to start up the boiler. heating circuits must have been filled and bled, and leak the instructions delivered with the burner. tightness tests must have been carried out on them, in the instructions delivered with the domestic hot water accordance with the instructions for the domestic hot water calorifier, (if existing).

  • Page 27: Commissioning And Testing

    INSTALLATION 50 COMMISSIONING AND TESTING B. FOR GAS INSTALLATION A. ELECTRICAL INSTALLATION 1. The whole of the gas installation, including the meter, 1. Checks to ensure electrical safety should be carried should be inspected and tested for soundness and then out by a competent person.
  • Page 28 SERVICING 54 MAINTENANCE WARNING The operations described below shall always be performed with the boiler and the power supply switched off. The boiler front panel has to be removed to access the various devices to be maintained and checked. 1. Pull the front panel forward at the top. 2.
  • Page 29 If not proceed to 4. Caradon Ideal Limited does not accept any liability resulting 4. Remove and clean the burner. from the use of unauthorised parts or the repair and servicing of appliances not carried out in accordance with the 5.
  • Page 30 NOTES Falcon GTE - Installation & Servicing...
  • Page 31 NOTES Falcon GTE - Installation & Servicing...
  • Page 32 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:

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