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ideal commercial HARRIER GTS 5 Installation And Servicing
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ideal commercial HARRIER GTS 5 Installation And Servicing

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INSTALLATION
AND SERVICING
HARRIER GTS
5 - 9
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.
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.
January 2016
UIN 203620 A04
300014485-001-C

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Summary of Contents for ideal commercial HARRIER GTS 5

  • Page 1 INSTALLATION AND SERVICING HARRIER GTS 5 - 9 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. 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 GENERAL Table 1 Performance Data Boiler GTS 5 GTS 6 GTS 7 GTS 8 GTS 9 Number of Sections Maximum Heat Output Btu/hx10 1126 Minimum Heat Output Btu/hx10 Hydraulic mbar 20.3 37.9 55.8 82.7 118.6 Resistance at 11k in w.g. 15.2 22.3 33.1...
  • Page 3 GENERAL CONTENTS Harrier GTS Gas and Fuel Oil Assembly..............11-28 PI No. 1312 BR 4783 Destination Countries: GB, IE Boiler Clearances..............6 Burner Connection............11 Commissioning and Testing........32,33 Electrical Connections............30 Electrical Supply..............5 Flue Installation..............5 Fluing................10 Gas Safety Regulations ...........4 Gas Supply.
  • Page 4 GENERAL SAFETY with atomising oil burners. Current Gas Safety (Installation and Use) Regulations or EN 304 Test code for heating boilers for atomizing oil rules in force. burners. It is law that all gas appliances are installed and serviced by a 73/23 EEC Low voltage directive.
  • Page 5 GENERAL It is the responsibility of the installer to ensure, in practice, that drawn back from the tank into the system together with a quantity products of combustion discharging from the terminal cannot of dissolved oxygen. re-enter the building or any other adjacent building through Even if leakage from the heating and hot water system is ventilators, windows, doors, other sources of natural air infiltration, eliminated there will be evaporation losses from the surface of the...
  • Page 6 GENERAL BOILER DIMENSIONS har9077 Boiler GTS 5 GTS 6 GTS 7 GTS 8 GTS 9 1297 1297 1297 1297 1297 1151 1311 1471 1631 1791 1130 1290 BOILER CLEARANCES The minimum dimensions as indicated must be respected to ensure good access around the boiler. Note.
  • Page 7 GENERAL VENTILATION 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 adequate supply of fresh air to the room in which the appliance The supply of air by mechanical means to a space housing is installed.
  • Page 8 GENERAL OPEN VENTED SYSTEM REQUIREMENTS - minimum static head requirements The Harrier GTS boiler has a minimum static head requirement Open vent safety pipe of 5.0 metres (16.5 feet approx.) depending on the particular 750mm characteristics of the system design (see diagram). The information provided is based on the following assumptions.
  • Page 9 GENERAL SYSTEM DESIGN CONTINUED System Design completely closed to the boiler flow. This will dissipate residual heat. Also a pump overrun of at least 5 minutes is required on Recommendations relating to water system design are plant shutdown to avoid interference trip out of the overheat contained in BS.
  • Page 10 INSTALLATION 10 FLUING 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 INSTALLATION 12 BURNER CONNECTION Burner Door Opening and Fixings Gas Supply The gas supply MUST be sized in accordance with British Gas recommendations. Stud The Local Gas Authority should be contacted, at tappings Burner a stage prior to actual installation, for any advice door or information required.
  • Page 12 INSTALLATION 14 PREPARING THE BASE FRAME 1. Insert the inner cross members into the slots in the side side components and secure with the 4 bolts. components. 2. Assemble the front and rear components into the ends of the 15 FITTING THE BASE FRAME INSULATION 1.
  • Page 13 INSTALLATION 16 POSITIONING THE REAR SECTION 1. Place the rear section in its required position and support with a wooden block. 2. Position the base frame up to the rear section and insert the two lower tie rods. 3. Slide the spacer over the rear end of the threaded tie rod before passing it through the rear section 4.
  • Page 14 INSTALLATION 18 FITTING THE THERMOCORD 2. Working from point A, insert the thermocord into the groove. (This may be conducted before Frame 16 with the sections laid flat on the floor) 3. Cut it to the correct length 1. Put a drop of silicone at about every 200mm of the groove. 4.
  • Page 15 INSTALLATION 20 ASSEMBLING THE INTERMEDIATE SECTIONS CONT'D Proceed likewise for other intermediate sections 20 cm Harrier GTS - Installation & Servicing...
  • Page 16 INSTALLATION 21 ASSEMBLING THE FRONT SECTION AND PULLING UP COMPLETE ASSEMBLY 1. Remove the M12 nuts and washers from the front end of the threaded rods and slide backwards. 2. Complete the assembly with the front section. 3. Insert the assembly tool through the nipples and tighten.
  • Page 17 INSTALLATION 23 ASSEMBLING THE BURNER AND FLUE CLEANOUT DOORS 1. Position the Burner door in place and insert the hinge pin. 2. Close the burner door and secure 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.
  • Page 18 INSTALLATION 24 POSITIONING THE FLUE BAFFLES IN THE UPPER FOUR FLUEWAYS 1. Models GTS 5 and GTS 6. Place 2 flue baffles in each of the four upper flueways. 2. The baffles should be hooked together as shown. 3. Models GTS 7, GTS 8 and GTS 9. Place one flue baffle only in each of the four upper flueways.
  • Page 19 INSTALLATION 26 FITTING THE THERMOSTAT SENSOR POCKET AND PLUGGING THE UNUSED TAPPING 1. Apply some thread sealing tape or compound to the sensor pocket, reducing bush and bottom tapping plug. 2. Screw the threaded bush with the sensor pocket into the upper connection and the plug into the lower connection.
  • Page 20 INSTALLATION 28 ASSEMBLING THE FLOW, RETURN AND DRAIN COCK 1. Coat the threaded 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.
  • Page 21 INSTALLATION 29 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 22 INSTALLATION 30 INSTALLING THE INSULATING MATERIAL 1 4 0 1. Models GTS 5, GTS 6 and GTS 7. Place the insulating material over the boiler, ensuring the lugs protrude through the top, wrap down the sides and tuck underneath. 2. Models GTS 8 and GTS 9. After fitting the front insulation similarly place the rear section.
  • Page 23 INSTALLATION 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. (Note the direction of the crossbar to ensure the edge clips fit from the front.) 32 INSTALLING THE MAINS AND SENSOR CABLE TRAYS 1.
  • Page 24 INSTALLATION 33 ASSEMBLING THE CASING SIDE PANELS 1. Engage the panel 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.
  • Page 25 INSTALLATION 34 ASSEMBLING THE REAR PANEL 1. Place the panel in position 2. Engage the plastic push clips. 3. Secure the panel at each corner 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.
  • Page 26 INSTALLATION 36 INSTALLING THE MAINS AND CONTROL WIRING 1. Route the mains supply in at the rear, along one of the cable trays and up through the opening in the top front panel. 2. Route any remote sensor cables similarly in the other cable tray. 3.
  • Page 27 INSTALLATION 38 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) 2. Insert the sensors into the sensor pocket.
  • Page 28 INSTALLATION 41 ASSEMBLING THE REAR TOP PANEL 1. Engage the location buttons on the side panel into the keyhole slots in the top panel and slide the panel forwards. 2. Secure the panel at the two top rear corners with two self tapping screws and shakeproof washers.
  • Page 29 INSTALLATION 43 CONTROL PANEL (General) Refer to Frame 50 for specific details of panel. Electrical control panel, equipped with temperature control. The boiler thermostats - one controls the maximum boiler operating temperature. The other controls the high/low operation The control panel carton contains: if a 2 stage burner is fitted.
  • Page 30 INSTALLATION 46 CONNECTING OPTIONAL FEATURES Flow Switch / Optional Safety Devices If a flow switch or other safety control is to be included in the system, connect the device(s) in series in the safety circuit, (i.e. between terminal 5 of the connecting strip and burner terminal L1).
  • Page 31 INSTALLATION 48 BURNER WIRING HARNESS 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. Control Panel Connections Burner Connections without Plug-in Connectors Connect the terminal block with the male connecting terminals...
  • Page 32 INSTALLATION 50 COMMISSIONING IMPORTANT. Domestic hot water circuits (if they exist) Refer to the following instructions and Frame 53 to start up the and heating circuits must have been filled and bled, and boiler. leak tightness tests must have been carried out on them, in the instructions delivered with the burner.
  • Page 33 INSTALLATION 52 COMMISSIONING AND TESTING A. ELECTRICAL INSTALLATION B. FOR GAS INSTALLATION 1. Checks to ensure electrical safety should be carried out 1. The whole of the gas installation, including the meter, by a competent person. should be inspected and tested for soundness and then purged in accordance with the recommendations of the 2.
  • Page 34 SERVICING 56 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. Slide the front panel up and pull forwards. Cleaning the Casing Material Use a soapy solution and sponge only.
  • Page 35 SERVICING 58 SYSTEM MAINTENANCE Safety Devices Water Level Check that safety devices, and particularly the heating circuit Check the water level in the installation regularly, and if safety valve, are working correctly at regular intervals, and at least necessary top it up without allowing a sudden inlet of cold when the boiler is cleaned.
  • Page 36 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 is a trademark of Ideal Boilers. Registered Office Ideal Boilers Limited National Avenue, Hull, HU5 4JB.

This manual is also suitable for:

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