Ideal Boilers Harrier GT Guide

Harrier GT
Installation, Assembly and Servicing
Oil, Gas or Dual Fuel Fired Boilers
CAUTION. To avoid the possibility of injury during the installation, servicing or cleaning of this appliance care should be taken
when handling edges of sheet steel components.
Assembly and Installation Instructions for Ideal Harrier Oil, Gas or Dual Fuel Fired heating boilers should be read in
conjunction with the general technical data tables enclosed and any other technical publication supplied with the
burner.

GENERAL
CONTENTS
Assembly.........................................................................5
Chimney Connection .....................................................7
5.1 Flue sizing ..................................................................7
5.2 Dimensional information required..............................7
5.3 Connection.................................................................7
Electrical Connection to the Control Panel.................8
7.1 Deluxe (option) - control panel ..................................9
7.2 Standard control panel ............................................12
General............................................................................3
1.1 The boilers covered by this document ......................3
1.2 Packing ......................................................................3
Hydraulic Connection ....................................................5
4.1 Dimensional information required..............................5
4.2 Installation recommendations....................................6
4.3 Filling the installation .................................................6
4.4 Desludging .................................................................6
Installation of the Boiler ................................................4
2.1 Installation..................................................................4
2.2 Levelling .....................................................................5
Maintenance .................................................................16
9.1 Boiler........................................................................16
9.2 Precautions to be observed in case of long
stop of the boiler .....................................................18
Oil or Gas Connection ...................................................8
Start Up.........................................................................12
8.1 Deluxe (option) - control panel ................................12
8.2 Standard control panel ............................................15
2
INTRODUCTION
DUTY
The range of boiler is suitable for: combined indirect pumped
domestic hot water and central heating systems; independent
indirect pumped domestic hot water or central heating
systems.
Fully pumped systems may be open vented or sealed.
The range of boiler is NOT suitable for:
1. Gravity DHW systems.
2. Gravity heating systems.
3. Direct domestic hot water supply.
GAS SAFETY (INSTALLATION AND USE)
REGULATIONS, 1994
It is law that all gas appliances are installed and serviced by a
CORGI registered installer in accordance with the above
regulations.
Failure to install appliances correctly could lead to
prosecution. It is in your own interest, and that of safety, to
ensure the law is complied with.
The installation of the boiler MUST also be in accordance with
the latest l.E.E Wiring Regulations, local building regulations,
bye-laws of the local water authority, the building regulations
and the Building Standards (Scotland) and any relevant
requirements of the local authority.
Detailed recommendations are contained in the following
British Standard Codes of Practice:
BS. 6891 Low pressure installation pipes.
BS. 5449 Forced circulation hot water systems.
BS. 5546 Installation of gas hot water supplies for
domestic purposes (2nd Family Gases).
BS. 6644 Ventilation (for gas appliances of rated input
exceeding 60 kW).
Harrier GT Range - Installation
The Harrier GT boilers are a range of steel shell pressure jet
boilers offering high efficiency operation, ease of maintenance,
fuel flexibility and low emissions. Suitable for oil or gas
operation the Harrier GT range is supplied in a choice of 5
standard models, rated in outputs from 105 kW (358,000
Btu/h) to 330 kW (1,126,000 Btu/h). The range has a maximum
operating pressure of 5 bar.
Designed with a large combustion chamber that is positioned
in the lower part of the heat exchanger, the Harrier GT range
ensures maximum heat transfer efficiency (up to 91% net).
Through the use of an increased number of flue way tubes
which are positioned in the hottest area of the heat exchanger
and constructed from a thicker steel construction than that of
of traditional boilers, the Harrier GT Range is capable of
impressive output to size ratio.
FOUNDATION
The boiler must stand on a non-combustible floor
(i.e. concrete or brick) which must be flat, level and of a
suitable load bearing capacity to support the weight of the
boiler (when filled with water) and any ancillary equipment.

GENERAL
Harrier GT Range - Installation 3
1.1 THE BOILERS COVERED BY THIS DOCUMENT
The Harrier GT range of boilers is an automatic range of
pressurised hot water boilers, connected to a chimney, to be
fitted with an independent burner using domestic fuel oil or
gas, with a working power rating from 70 to 330 kW.
Boiler models:
HARRIER GT: boiler with standard control panel.
HARRIER GT: boiler with DELUXE control panel: option can
be fitted (a) SV-matic weather compensatc or (b) SVR module
for domestic hot water priority.
1.2 PACKING
Harrier GT in bulk
ITEM Box No. Harrier GT 5 Harrier GT 6 Harrier GT 7 Harrier GT 8 Harrier GT 9
Front section 8219 - 0002 11111
Intermediate section 8219 - 0001 34567
Rear section 8219 - 8960 11111
Tie rod pack 4 sect.
5 sect. 1
6 sect. 1
7 sect. 1
8 sect. 1
9 sect. 1
Body accessories ID 8 1
ID 9 1
ID 10 1
ID 11 1
ID 12 1
Burner door ID 13 11111
Baffles ID 17 1
ID 18 1
ID 19 1
ID 20 1
ID 21 1
Casing ID 2 1
ID 3 1
ID 4 1
ID 5 1
ID 6 1
Control panel - E ID 22
- Standard ID 24 11111
For the optional equipment, see the current price list
HEALTH & SAFETY DOCUMENT NO 635
The Electricity at Work Regulations, 1989.
The manufacturer’s notes must NOT be taken, in any way, as
overriding statutory obligations.
IMPORTANT. These appliances are CE certificated for safety
and performance. It is, therefore, important that no external
control devices, e.g. flue dampers, economisers etc., are
directly connected to these appliances unless covered by
these Installation and Servicing Instructions or as otherwise
recommended by Caradon Ideal Limited in writing.
If in doubt please inquire.
Any direct connection of a control device not approved by
Caradon Ideal Ltd. could invalidate the certification and the
normal appliance warranty. It could also infringe the Gas
Safety Regulations and the above regulations.
Notes.
To obtain the gas consumption:-
a. For l/s divide the gross heat input (kW) by
C.V. of the gas (MJ/m3).
b. For ft3/h divide the gross heat input (Btu/h)
by C.V. of the gas (Btu/ft3).

4Harrier GT Range - Installation
2.1 INSTALLATION
The minimum dimensions indicated on the following drawing
must be respected to ensure good access around the boiler.
VENTILATION GENERAL
Detailed recommendations for air supply are quoted in BS.
6644. The ventilation requirements in this gas fired boiler
standard are also valid for oil fired boilers of the same heat
input.
Remark: We draw your attention to the risks of corrosion of
boilers which are installed in or near rooms in which the
atmosphere can be polluted by chloride or fluoride
substances E.g.: industrial buildings (solvents), refrigerating
machines, etc...
In these cases, we cannot provide a warranty.
INSTALLATION
Boiler Type Harrier GT 5 Harrier GT 6 Harrier GT 7 Harrier GT 8 Harrier GT 9
Dimension A 968 1128 1288 1440 1608
Dimension B Standard control panel 105
Diematic and E control panel 195
Section S cm2500 650 800 990 1210
8219-EN-16
* Caution: Pay particular care to the space required for the boiler when the door is open.
For an installationof several boilers side by side, these dimensions need to be modified.

Harrier GT Range - Installation 5
INSTALLATION
2.2 LEVELLING
Insert the cylinder into the hole provided in each foot of the heating body and screw the adjustable foot into it. Level.
8219-EN-20
3 ASSEMBLY
For the assembly of the boiler, refer to the relevant paragraph of the instruction book.
4.1 DIMENSIONAL INFORMATION REQUIRED
8219-EN-17
4 HYDRAULIC CONNECTION

6Harrier GT Range - Installation
4.2 INSTALLATION RECOMMENDATIONS
The installation of the boiler MUST be in accordance with
the following British Standards and Codes of Practice:
BS. 799 Pts. 4, 5, 6 & 7 Oil Burning Equipment
BS. 5410 Pts. 2 & 3 Installations for Space Heating
and Hot Water Supply
BS. 5449 Pt. 1 Hot Water Systems
BS. 5854 Flues and Flue Structures in
Buildings
BS. 5885 Pt. 1 Gas Burners ~ with outputs of
60kW upwards
BS. 6644 Installation of Gas Fired Boilers
BS. 6880 Low Temperature Hot Water
Heating Systems
BS. 6891 Low Pressure Gas Pipework
British Gas Industrial Gas Fired Boilers and
Publication No. IM. 11 Air Heaters
The following must be conformed with:
Current Building Regulations and Clean Air Act
Water Authority Regulations
Local Authority Regulations and Regional bylaws
Gas Safety Regulations
Any Special regional requirements of local Electricity and Gas
undertaking.
Fire Service and Insurance Company requirements.
All electrical wiring MUST comply with the current I.E.E.
regulations for the electrical equipment of buildings. In the
interests of safety, a competent installer should be employed
to effect the installation of the appliance.
Manufacturer’s notes must NOT, in any way, be taken as over
riding statutory obligations.
General
Recomendations relating to the water system are contained
in BS. 5449 Pt. 1, BS. 5401 Pt.2. and E3S. 6880.
INSTALLATION
4.3 FILLING THE INSTALLATION
The boiler may be filled by the drain tap. Filling should be.
done at a slow flow rate in order to purge all the air
contained in the boiler by the upper point of the installation.
Filling is always done with circulating pumps stopped.
MOST IMPORTANT: start up after partial or total drain of
the installation.
If all air does not purge naturally via an opened expansion
system, then in addition to automatic airvents able to ensure
continuous automatic elimination of air from the system while
it is running, the installation must also include manual
airvents so that all upper points of the installation can be
vented and so that when the installation is full of water it can
be verified that all air is eliminated before the boiler are fired.
A desludging hole of ø1“1 /2 supplied with a plug is
provided in the lower part of the boiler to enable sludge to be
drained out. The installer can fit 1/4 turn valve. Draining
sludge involves the loss of significant quantities of water
from the system, which must be refilled after the procedure.
Comment: Any replacement of boilers in an old system must
include a careful washing out of the full installation. Fit a
sludge trap on the return and close to the boiler.
4.4 DESLUDGING
8219-EN-19

Harrier GT Range - Installation 7
INSTALLATION
5 CHIMNEY CONNECTION
8219-EN-21
As the Harrier GT is a high performance boiler, the
temperature of the flue gases may be less than 160˚C.
The installer ought to take all precautions (padding out,
casing, T for draining condensation) in order to avoid deterio-
ration of the chimney.
If necessary, the baffles of the 4 upper smoke chambers may
be partially removed with a resulting increase in temperature
of the flue gases.
5.1 FLUE SIZING
To size the height and cross section of the chimney, refer to
the regulations currently in force. Harrier GT boilers are
boilers with pressurised combustion chambers and the
pressure of the outlet must not exceed 0 mbar unless special
precautions are taken to seal carefully between the outlet
and flue.
The installer should provide a measuring point (ø10 mm
hole) on the flue for burner adjustment and control of the
combustion. Detailed recommendations, relating to the
design of flues for GAS fired appliances are quoted in BS.
6644 and British Gas Publication No. IM 11., whilst BS. 5410
Pt. 3 similarly applies OIL fired burners.
5.2 DIMENSIONAL INFORMATION NEEDED FOR CONNECTION
5.3 CONNECTION
Connection should be made according to regulation and
practice by using a sealed pipe in a material able to
withstand hot combustion gases and possible acidic conden-
sation. The connection should be removeable and present
minimal loss of load, it means it should be as short as
possible and without sudden change of cross section.
Its diameter should always be at least equal to that of the
boiler outlet, 180 mm for the 4, 5 and 6 section boilers and
200 mm the 7, 8 and 9 section boilers.
8219-EN-18

INSTALLATION
8Harrier GT Range - Installation
6 OIL OR GAS CONNECTION
See specific technical information supplied with the burner.
Burner positioning
Caution: the baffle at the head of the burner must be in line
with the burner door insulation level.
GAS SUPPLY
The gas supply MUST be sized in accordance with British
Gas recommendations and be fabricated in compliance with
CP.331 Pt. 3 and any Local Gas Board installation standards.
The Local Gas Board should be contacted, at a stage prior to
actual insallation, for any advice or information required.
Details and advice, relating to the use of L.PG. for firing the
IDEAL HARRIER GT range of heating boilers, are available on
request to Caradon Ideal Ltd.
OIL STORAGE TANK
The oil storage tank, oil supply pipe and connections to the
burner unit MUST comply with the requirements of BS. 779
and CP.541 0.
The installation should conform to the recognised standards
of good practice in the trade and comply with the relevant
Codes of Practice, Building Regulations and Local Authority,
Fire and insurance requirements. 8219-EN-22
8219-EN-61
Drilling ø for burner door:
Harrier GT
5 to 9 sections
ø A 135
øB 170
7 ELECTRICAL CONNECTIONS TO THE CONTROL PANEL
CAUTION: The connection must be carried out by a
qualified professional.
As the electrical wiring has been carefully checked in the
factory, the internal connections of the control panel must
not be modified under any circumstances.
The electrical connections of the boiler must conform with
the lEE wiring regulations in force and with the specifications
shown on the electrical drawings provided with the
equipment, and the directions given below. The equipment
should be supplied by a circuit using an omnipolar circuit
breaker with an opening gap greater than 3 mm.

INSTALLATION
Harrier GT Range - Installation 9
7.1 DELUXE (OPTION) - CONTROL PANEL
All the connections are made to the 2 terminal blocks
provided for this purpose in the control panel.
The connection cables are routed towards the front via the 2
cut outs in the panel behind the boiler, and run in the wiring
duct towards the panel via the two rectangular cut outs of
the front top panel. The sensor cables run on one side, the
cables carrying the 230 V supply on the other and are
supported on both sides by plastic clips.
Caution: the sensor wiring must be kept separate from
the other circuits. Inside the boiler use the 2 cable runs.
Outside the boiler, 2 wiring ducts at least 10 cm apart
should be used.
Wiring is secured in the control panel using cable clips (6
cable clips are supplied in a separate packet) ; these are to
be fitted into the control panel base - see diagram below.
Caution: the maximum current which may be switched by
the outlet is 2 A, cos ϕ= 0,7 (= 450 W at the motor of 0.5
méch., hp signal current less than 16 A), if the charge
exceeds one of these values, the control must be relayed
by means of a contractor. The outlet group is protected
by a 5 A fuse.
•Burner connection
Connection of the burner is made using European 7 and 4
pin plugs supplied with the boiler, which simply need to be
fitted into the female plugs supplied with the burners.
To open the control panel
8219-EN-238219-EN-23

INSTALLATION
10 Harrier GT Range - Installation
7.1 DELUXE (OPTION) - CONTROL PANEL (continued)
•Fitting the SVR option
8219-EN-248219-EN-13
1
4
2
3
8219-EN-118219-EN-9
The SVR option box is to be fitted in the front part of the
control panel. To do this:
- Remove the blank by cutting the surface with a stanley
knife following the black line (1) and by breaking the perfo
rations in the steel plate behind with a pair of snips (2).
- Connect the two connections, situated behind the blank
(3), to the back of the SVR unit: blue connector to the blue
plug, red connector to the red plug.
- Locate the unit by its front (3) and fix it using the two
screws sited in the front part of the equipment (1/4 turn
clockwise).
The limit thermostat supplied with the SVR option is to be
fitted in the control panel in the place provided for this
purpose, using the two self tapping screws supplied (4). The
3 pin thermostat male terminal is to be connected in the
position provided on the 25 pin terminal block after having
taken out the bridge ; the thermostat bulb is to be located in
the small pocket in the body of the boiler.