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IDEAL GTE 5 Installation And Servicing
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IDEAL GTE 5 Installation And Servicing

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installation and
servicing
Harrier GTE
Your Ideal installation and servicing guide
GTE 5, GTE 6, GTE 7, GTE 8 & GTE 9
9486 2069
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 GTE 5

  • 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 GENERAL CONTENTS Harrier GTE Gas and Fuel Oil Assembly..............11-29 PI No. 49AQ950 Destination Countries: GB, IE Boiler Clearances............. 6 Burner Connection............11 Commissioning and Testing......... 36 & 37 Electrical Connections..........30-32 Electrical Supply............... 5 Flue Installation.
  • Page 4 Further guidance is provided in IGE/UP/2 as listed above. General requirements. Assembly and Installation Instructions for Ideal Harrier 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 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 Dimension Boiler GTE 5 GTE 6 GTE 7 GTE 8 GTE 9 In multiple boiler installations both sides may be m m 1000 1160 1320 1480 1640 100mm except at one end consideration must also...
  • 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 11ºC (20ºF) at the flow rates. maximum rated output. For hydraulic resistance see Performance Data table (page 2). Boiler Size GTE 5 GTE 6 GTE 7 GTE 8 GTE 9 Normal water flow rate 3.04...
  • Page 9 Heating and/ condensation is required. or hot water controls should be interlocked electrically with the burner, to prevent firing when the system does not demand Please contact Caradon Ideal Limited for further information. heat. Example of Installation Typical Sealed System Example...
  • Page 10 Output Draught kg/s Temperature Minimum (1) (2) Recommended Diameter Fuel Oil Natural Gas 13% CO 9.5% CO mbar ºC Ø min GTE 5 105-140 0.060 0.066 GTE 6 140-180 0.076 0.084 GTE 7 180-230 0.097 0.107 GTE 8 230-280 0.118 0.130...
  • Page 11 Phillips head screwdriver which they are opened for assembly. Wide flat screwdriver JDTE assembly tool 13 and 17mm spanners Simplified assembly tool Boiler GTE 5 GTE 6 GTE 7 GTE 8 GTE 9 Boiler body delivered loose - front section...
  • Page 12 INSTALLATION 14 PREPARING THE BASE FRAME 1. Insert the inner cross members into the slots in the side 2. Assemble the front and rear components into the ends of the components. side components and secure with the 4 bolts. 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 GTE - 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 GTE 5 and GTE 6. Place 2 flue baffles in each of the four upper flueways. 2. The baffles should be hooked together as shown. 3. Models GTE 7, GTE 8 and GTE 9.
  • 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 This tapping is not to be used for venting. 3. Use plumbline to ensure the flanges are vertical and equally screwed into the tappings. Tightness sealant (not supplied) Drain cock GTE 5 GTE 6 GTE 7 GTE 8 GTE 9 Plumb...
  • Page 21 INSTALLATION 29 HYDRAULIC TEST After assembling the boiler body, the installer must carry out a water tightness test at a pressure equal to 1.3 times the operating pressure (that is 7.8 bar minimum) for 10 minutes at least. The test must be done at room 1.
  • Page 22 INSTALLATION 30 INSTALLING THE INSULATING MATERIAL 1 4 0 1. Models GTE 5, GTE 6 and GTE 7. Place the insulating material over the boiler, ensuring the lugs protrude through the top, wrap down the sides and tuck underneath. 2. Models GTE 8 and GTE 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.) Harrier GTE - Installation &...
  • Page 24 INSTALLATION 32 ASSEMBLING THE CASING SIDE PANELS 1. Fit the edge protection along the top front edges as shown. Note the front 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.
  • Page 25 INSTALLATION 33 ASSEMBLING THE REAR PANEL 1. Place the panel in position and engage the plastic push clips. 2. Secure the panel at each 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, the top centre piece of the panel may be...
  • Page 26 INSTALLATION 35 INSTALLING THE MAINS AND CONTROL WIRING 1. Route the mains supply in at the rear, along the tray of one of the side panels and up through the opening in the top front panel. 2. Route any remote sensor cables similarly in the other side panel.
  • Page 27 INSTALLATION 37 INSTALLING THE CONTROL PANEL - 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 onto the location buttons farthest away from the front and slide the control panel forwards.
  • Page 28 INSTALLATION 39 ASSEMBLING THE LOWER FRONT PANEL 40 ASSEMBLING THE FRONT PANEL 1. Push the panel onto the location buttons and slide the 1. Push the panel onto the location buttons and slide the panel downwards. panel downwards. 41 ASSEMBLING THE REAR TOP PANEL 1.
  • Page 29 INSTALLATION 42 NAMEPLATE AND LEVELLING 1. Affix the identification plate and CE label (supplied in the instructions bag) on the casing (on the left or right-hand side) in an easily accessible location. 2. Check the boiler for level and adjust the feet if necessary.
  • Page 30 INSTALLATION 44 ELECTRICAL CONNECTIONS WARNING . The electrical connections must be made by a WARNING. The boiler must be earthed. qualified professional. The electrical wiring has been All connections must be made using the terminal blocks carefully checked in the factory and the internal connections provided for this purpose at the back of the boiler control panel.
  • Page 31 INSTALLATION 47 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 32 INSTALLATION 49 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 33 INSTALLATION 51 WIRING DIAGRAM - FD168 Deluxe Control Panel DJ6A TCH1 TCH2 N L1 VA-TS har7056 TCH1 Heating pump Stage 1 boiler thermostat TCH2 Burner Stage 2 boiler thermostat Connecting strip Safety thermostat Cascade connection block Alarm indicator VA-TS Stage 1 hours run meter (optional) Safety thermostat alarm indicator Stage 2 hours run meter (optional) Stage 1 operating indicator...
  • Page 34 INSTALLATION 52 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 35 INSTALLATION 53 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 36 INSTALLATION 55 COMMISSIONING - FD167 Standard Control Panel IMPORTANT. Domestic hot water circuits (if they exist and Refer to the following instructions and Frame 59 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 37 INSTALLATION 57 COMMISSIONING - FD168 Deluxe Control Panel IMPORTANT. Domestic hot water circuits (if they exist and Refer to the following instructions and Frame 59 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 38 INSTALLATION 58 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 39 SERVICING 62 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. Lift off the engaging location buttons Cleaning the Casing Material Use a soapy solution and sponge only.
  • Page 40 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 41 NOTES Harrier GTE - Installation & Servicing...
  • Page 42 NOTES Harrier GTE - Installation & Servicing...
  • Page 43 NOTES Harrier GTE - Installation & Servicing...
  • Page 44 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.

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