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IDEAL Viceroy GT 8, Installation And Servicing, Page: 19 / 40

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IDEAL Viceroy GT 8 Installation And Servicing Download Page 19

19

Viceroy GT - 

Installation & Servicing

INSTALLATION

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GT11 - GT14

GT8 - GT10

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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.

25 ASSEMBLING THE FLOW AND RETURN TAIL PIPES

1.

Fit eight M16 studs into the flow and return flange
faces on the rear section.

2.

Fix the flow and return flanged tail pipes using
four M16 nuts for each flange with a gasket as
shown.

Note.

A. The flow tail pipe outlet must face upwards to

accommodate the flow switch.

B. The return flange for models GT11-14

incorporates a distributor tube and must be
fitted the correct way as shown.

3.

Screw the flow switch into the flow tail pipe using
suitable compound ensuring the arrow on the
casing corresponds to the direction of water flow.

Note.

The flow switch may be fitted after conducting the
hydraulic test described in Frame 26 in order that
the tapping may temporarily be used for venting.

3. Secure the flue outlet onto the rear section with six M12 nuts

and washers.

4. Fit two M12 bolts and nuts on the smokehood for the

cleaning doors (see detail).

5. Secure the cleaning doors using four M12 and two washers

(L12) and two washers (M12).

INST

ALLA

TION

Summary of Contents for 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 use reconditioned or copy parts that have not been clearly authorised by Ideal Boilers Viceroy GT GT 8 GT 9 GT 10 GT 11 GT 12 GT 13 GT 14 ...

Page 2: ...1 12 13 14 Maximum kW 390 450 540 600 670 720 780 Heat Output Btu hx103 1330 1535 1842 2047 2286 2457 2661 Minimum kW 300 390 450 540 600 670 720 Heat Output Btu hx103 1024 1330 1535 1842 2047 2286 2457 Hydraulic mbar 31 6 49 3 75 9 84 2 104 9 127 9 161 4 Resistance at 11k in w g 12 6 19 7 30 3 33 7 42 0 51 2 64 6 Hydraulic mbar 9 6 14 9 23 0 25 5 31 7 38 7 48 8 Resistance at 20k in w g 3 8 6 0 9 ...

Page 3: ...oilers offering high efficiency operation ease of maintenance fuel flexibility and low emissions Suitable for oil or gas operation the Viceroy GT range is supplied in a choice of 7 standard models rated in outputs from 300kW 1 024 000 Btu h to 780kW 2 661 000 Btu h and has a maximum operating pressure of 6 bar All models may have high low operation Designed with a large combustion chamber 3 pass h...

Page 4: ...04 Test 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 1 EN50082 1 and EN55014 90 396 EEC Gas Appliance Directive Relevant standards are EN303 1 EN303 2 and EN304 92 42 EEC Boiler Efficiency Directive IGE UP 1 Soundness testing and purging of industri...

Page 5: ...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 system water is to be achieved The same tank is used to fill the system with water and it is through the cold feed pipe that system water expands into the tank when the boiler passes heat into the system C...

Page 6: ...r 573 mm vic7071 Boiler GT 8 GT 9 GT 10 GT 11 GT 12 GT 13 GT 14 A outside dia 250 250 250 300 300 300 300 B 3 3 3 4 4 4 4 C 135 175 190 240 250 290 or plain plate D 235 235 235 254 254 254 254 E 1427 1427 1427 1447 1447 1447 1447 L 1505 1665 1825 1985 2145 2305 2465 S 1183 1343 1503 1663 1823 1983 2143 Deluxe F 113 5 113 5 113 5 113 5 113 5 113 5 113 5 Control G 355 355 355 355 355 355 355 Panel H...

Page 7: ...m 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 One side may be 100mm the other side must be 200mm plus the burner projection or 500mm whichever is the greater to allow the burner door to be swung open and maintain access to the rear In multiple boiler installations both ...

Page 8: ... or lockout of the boiler s in the event of failure of air flow in either inlet or extract fans IMPORTANT The use of an extractor 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 intended to fit an extractor fan after installation of the appliance the ad...

Page 9: ...the output of the boiler see table below Working pressure 6 bar maximum Particular reference should be made to BS 6644 Section 2 Subsection 11 and Guidance note PM5 Automatically controlled steam and hot water boilers published by the Health and Safety Executive The information and guidance given below is not intended to override any requirements of either of the above publications or the requirem...

Page 10: ...ut of the overheat thermostat 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 Example of Installation The example below does not cover all the possible cases of use It is only aimed at drawing attention to the basic rules which must be complied with In all event...

Page 11: ...eparator 6 Automatic venting valve 7 Valve 8 Shunt pump required for all models 9 Expansion tank 10 Draining valve 11 Sludge valve 12 Mixing valve 13 Non return valve 14 Heating pump 15 Low water safety pressure sensitive switch 16 Sludge decanting pot particularly recommended for older heating systems 17 Independent calorifier 18 Sealed safety unit calibrated to 7bar with indicator type discharge...

Page 12: ...r model in order to ensure sufficient draught at the outlet 1 at boiler maximum input 2 Boiler flow temperature 80ºC ambient temperature 20ºC 11 DIMENSIONAL INFORMATION REQUIRED FOR THE FLUE CONNECTION 45 1000mm min har5968 However care must be taken to comply with any applicable national or local regulations GT 8 390 0 0 184 0 193 220 250 GT 9 450 0 0 212 0 223 220 250 GT 10 540 0 0 255 0 267 220...

Page 13: ...r in which they are opened for assembly Tools required not supplied 12mm Allen key Cross head screwdriver 13 19 and 24mm spanners Knife Hammer 22mm Box spanner JDTE assembly tool The assembly of any optional devices purchased with the boiler is described in the instructions supplied with the relevant device The list of available optional devices is shown on page 3 Burner Door Opening and Fixings v...

Page 14: ...h if necessary or fold the lower insulation after the casing has been completely assembled Note For pre assembled boilers proceed to Frame 27 15 POSITIONING THE REAR SECTION 1 Determine the required location of the framework depending on the direction in which the burner door will be opened and the length of the burner 2 Place the rear section on the framework and support it with a wooden block At...

Page 15: ...me The arrow marker points to the rear to denote the correct way to fit the section 2 Fit the connections of the special intermediate section onto the nipples in the rear section 3 Ensure that the thermocord fits evenly between the sections in the correct manner to make a good seal 4 Hammer in with the help of a small wooden block 5 For safety reasons insert an upper assembly rod body accessories ...

Page 16: ...assembly rods in the order given in the diagram in the same manner 5 Remove the assembly tool Lg 580 Lg 580 Lg 420 Lg 580 Lg 420 Lg 420 Lg 580 Lg 580 Lg 580 Lg 580 Lg 740 Lg 420 Lg 740 Lg 740 Lg 740 Lg 740 Lg 740 Lg 740 Lg 420 Lg 420 Lg 420 Lg 580 Lg 420 Lg 420 AVANT VORN ARRIERE HINTEN DETAIL 1 AVANT VORN ARRIERE HINTEN DETAIL 2 AVANT VORN ARRIERE HINTEN DETAIL 3 AVANT VORN ARRIERE HINTEN DETAIL ...

Page 17: ...d fix using three M12x30 bolts and washers 4 Fix the burner door guide bracket body accessories pack using two M12x25 bolts and washers L12 21 ASSEMBLING THE BURNER AND FLUE CLEANOUT DOORS 1 Position the burner door in place and secure with four M12 nuts and washers 2 Locate the hinge and secure with the hinge pin 3 Remove the three M12x30 bolts and washers on the side the burner door is to be hin...

Page 18: ... 0010 1x8229 0022 3x8229 0010 Middle 8229 0011 2x8229 0011 then then 8229 0023 2x8229 0011 1x8229 0023 3x8229 0011 Lower 8229 0012 2x8229 0012 then then 8229 0024 2x8229 0012 1x8229 0024 3x8229 0012 1 2 4 3 and Note The part number of the baffles is marked on the casting 3 Close the cleaning doors and secure with three M12 locknuts and washers 23 FITTING THE THERMOSTAT SENSOR POCKET AND PLUGGING T...

Page 19: ...t as shown Note A The flow tail pipe outlet must face upwards to accommodate the flow switch B The return flange for models GT11 14 incorporates a distributor tube and must be fitted the correct way as shown 3 Screw the flow switch into the flow tail pipe using suitable compound ensuring the arrow on the casing corresponds to the direction of water flow Note The flow switch may be fitted after con...

Page 20: ... inlet valve 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 30 minutes Any drop in pressure indicates a leakage in the boiler body 11 After successfully conducting the test release the pressure and drain After assembling the boiler body the installer must carry out a water tightness test ...

Page 21: ...ing each strap to the lower casing support at each side of the boiler Note The table below indicates the quantity of insulation panels supplied for each boiler and the appropriate position according to their width 3 Fit the rear insulation Note This will be held in place by the rear panels when fitted later Frame 35 1 vic7102 HM 8x25 vic7117 Note For pre assembled boilers loosen the base frame sec...

Page 22: ... lock washer at each support 2 Fit the cross pieces using two M5x12 bolts and lock washer 3 Fit the front top panel and secure to the wiring ducts using M5x12 bolts and lock washers 30 INSTALLING THE MAINS AND CONTROL WIRING 1 Route the mains supply in at the rear along one of the wiring ducts and up through the opening in the front top panel 2 Route any remote sensor cables similarly in the other...

Page 23: ... sensors into the control panel through the appropriate opening ready to make the connections 3 4 REAR FRONT vic7081 32 INSTALLING THE CONTROL PANEL FD168 Deluxe 1 Route the sensors through the left or right hand opening in the front top panel 2 Route the burner leads through the other openings in the front top panel 3 Lower the control panel onto the location buttons farther away from the front a...

Page 24: ...e panels length 520 in the lower casing supports then hook onto the wiring ducts 2 Fix at the sides onto the lower casing supports using M5x12 bolts and lock washers and at the front top panel using self tapping screws and lock washers 3 Fit the remaining side panels in the order given in the table below Position each panel in the lower casing supports then hook onto the wiring duct 3 4 2 Boiler S...

Page 25: ...diate top cover length 480 onto the wiring duct using four M5x12 bolts and lock washers 3 Fix the remaining top covers onto the wiring duct using two M5x12 bolts and lock washers 37 ASSEMBLING THE LOWER FRONT PANELS 1 Fit the lower front panel onto the crosspiece two self tapping screws and lock washers 2 Fit the lower crosspiece assembly by securing onto the side panels using two self tapping scr...

Page 26: ... panel buttons 2 Hook the front casing support two slots into the side panel slots vic7082 39 NAMEPLATE 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 The boiler thermostats one controls the maximum boiler operating temperature The other controls the high low operation if a two stage burne...

Page 27: ...in 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 panel of the boiler and route them to the front via the cable channels See Frame 30 3 Pass the cables into the control panel through the rectangular openings in the front top panel 4 Secure the cables t...

Page 28: ... cut outs in the rear panel of the boiler and route them to the front via the wiring ducts See Frame 30 5 Pass the cables into the control panel through the rectangular openings in the front top panel 6 Secure the cables to the base of the control panel with the cable clamps 7 Connect the mains to terminals 1 2 and 3 of the connecting strip as shown See also Frame 46 N L V A A L I 2 3 0 V 5 0 H z ...

Page 29: ... CH Pump not supplied 3x 0 75 mm 2 min Shunt Pump not supplied har7053 Remove white link wire 47 FITTING OPTIONAL FEATURES FD168 Deluxe Control Panel Hours Run Meters IC8 One or two optional hours run meters stage 1 and 2 may be fitted on the front of the control panel Proceed as follows 1 Cut the cover with a cutter along the edges of the coloured rectangle 2 Pull out the two wires standing by in...

Page 30: ...age 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 ZB2 Stage 2 burner switch ZEH Summer Winter switch ZG Main switch ZT Test switch 1 1a 1 2 2a 2 1 2 6 9 11 6 3 12 9 8 5 8 1 8 9 11 12 4 2 1 3 4 5 2 1 7 8 9 6 7 N L1 T1 T2 S3 1 2 B4 T6 T7 T8 B5 6 14 10 1...

Page 31: ...ther 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 characteristics of the burner exceed the following values start up current 16 A or P 450 W or 1 2 cont hp motor or I 2A cos ϕ 0 7 The burner controls circuit must use a relay Burner Wire Connector No From Co...

Page 32: ...lues start up current 16 A or P 450 W or 1 2 cont hp motor or I 2A cos ϕ 0 7 The burner controls circuit must use a relay 51 FUEL OIL OR GAS CONNECTIONS Refer to the instructions supplied with the burner Burner Wire Connector No From Connection to the Burner Control Box Terminal No L1 2 Permanent Live supply from the safety thermostat Burner main supply g y Earth connection Earth connection N 1 Ne...

Page 33: ...ºC For ON OFF burners use 1st stage thermostat only For two stage burners set 2nd stage 5ºC below 1st stage setting Built in stops may be reset See Frame 53 Factory set at 75ºC 4 Boiler Thermometer Indicates boiler flow water temperature 5 Flue Gas Thermometer Optional Location if fitted 6 Circuit Breaker 6 amp Manual reset 7 Safety Thermostat Set at 110ºC Manual reset 53 BOILER THERMOSTAT Maximum...

Page 34: ...ump 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 continue on 1st stage after 2nd stage cut off AUTO automatic position Used for normal operation of the boiler Manual Position May also be used for normal operation 4 Burner Alarm Indicator Indicates b...

Page 35: ...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 settings ensuring the second stage is 5ºC lower than the first stage if a 2 stage burner is fitted 57 GENERAL CHECKS Make the following checks for correct operation 1 The correct operations of ANY seco...

Page 36: ... combustion chamber four nuts and flue way three nuts doors by removing the nuts 6 Remove the flue way baffles 7 Thoroughly clean the flue ways and baffles 8 Release and allow to swing down the rear cleanout covers by undoing the two upper nuts and loosening the two lower nuts Dispose of the debris soot that may have accumulated 9 Replace the rear cleanout covers after first inspecting and if nece...

Page 37: ...ystem 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 63 SERVICING SCHEDULE To ensure the continued safe and efficient operation of the appliance it is recommended that it is checked at regular intervals and serviced as necessary The frequency of servicing will depen...

Page 38: ...38 Viceroy GT Installation Servicing NOTES ...

Page 39: ...39 Viceroy GT Installation Servicing NOTES ...

Page 40: ...uing 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 class training courses for domestic commercial and industrial heating installers engineers and system specifiers For details of courses please ring 01482 498 432 Ideal Commercial Technical Helpline 0...

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