ideal commercial HARRIER GTS 5 User manual

300014485-001-C
January 2016
UIN 203620 A04
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.

2Harrier GTS - Installation & Servicing
GENERAL
Note.
Fuel rates and ue gas data relate to maximum output ratings.
Gas ring data relates to the use of NATURAL GAS ONLY.
Details for the use of LPG are available on request from
Ideal Boilers
Natural gas consumption is calculated using a caloric value of
38.7MJ/m3 (1038Btu/ft3) gross or 34.9MJ/m3 (935Btu/ft3) nett at
15oC and 1013.25mbar.
Oil rates relate to Gas Oil using a caloric value of 45.56 MJ/kg
gross or 42.69 MJ/kg nett.
Table 1 Performance Data
Boiler GTS 5 GTS 6 GTS 7 GTS 8 GTS 9
Number of Sections 5 6 7 8 9
Maximum kW 140 180 230 280 330
Heat Output Btu/hx103 478 614 785 955 1126
Minimum kW 105 140 180 230 280
Heat Output Btu/hx103 358 478 614 785 955
Hydraulic mbar 20.3 37.9 55.8 82.7 118.6
Resistance at 11k in w.g. 8.1 15.2 22.3 33.1 47.5
Hydraulic mbar 6.1 11.5 16.9 25.0 35.9
Resistance at 20k in w.g. 2.5 4.6 6.8 10.0 14.4
Combustion Chamber mbar 0.6 1.1 1.6 2.2 2.5
Resistance (at zero draught) in w.g. 0.24 0.44 0.64 0.88 1.0
Minimum Draught at Smokehood mbar 0 0 0 0 0
Outlet (for max. output) in w.g. 0 0 0 0 0
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 certied for safety
and performance. It is, therefore, important that no external
control devices, e.g. ue dampers, economisers etc., are
directly connected to these appliances unless covered by
these Installation and Servicing Instructions or as otherwise
recommended by Ideal Boilers in writing. If in doubt please
enquire.
Any direct connection of a control device not approved
by Ideal Boilers could invalidate the certication and the
normal appliance warranty. It could also infringe the Gas Safety
Regulations and the above regulations.
Maximum l/h 15.52 19.76 25.10 30.66 35.81
Oil Rate gal/h 3.41 4.35 5.52 6.75 7.88
Maximum Flue m3/s 0.090 0.114 0.145 0.178 0.208
Gas Volume ft3/min 191 242 308 376 440
Flue Gas CO2 / Temperature % / oC 13 / 210 13 / 210 13 / 210 13 / 210 13 / 210
Oil
Table 2 General Data
Flow Connection in./DN R21/2 / 65 R21/2 / 65 R21/2 / 65 R21/2 / 65 R21/2 / 65
Return Connection in./DN R21/2 / 65 R21/2 / 65 R21/2 / 65 R21/2 / 65 R21/2 / 65
Drain Connection in R11/2 R11/2 R11/2 R11/2 R11/2
Safety Valve & Expansion in R11/2 R11/2 R11/2 R11/2 R11/2
Maximum Operating Pressure bar 6 6 6 6 6
Boiler Thermostat Setting oC 30 - 90 30 - 90 30 - 90 30 - 90 30 - 90
Safety Thermostat Setting oC 110 110 110 110 110
High / Low Setting oC 30 - 90 30 - 90 30 - 90 30 - 90 30 - 90
Nominal Flue mm 180 180 200 200 200
Diameter in. 7 7 8 8 8
Boiler Water l 116 136 156 176 196
Content gal 25.5 29.9 34.3 38.7 43.1
Boiler DRY Weight kg 736 846 981 1103 1230
less Burner Unit lb 1622.5 1865 2162.5 2431.5 2711.5
Maximum m3/h 16.13 20.56 26.09 31.87 37.23
Gas Rate ft3/h 569 726 921 1125 1315
Maximum Flue m3/s 0.092 0.117 0.149 0.182 0.213
Gas Volume ft3/min 196 249 316 386 452
Flue Gas CO2 / Temperature % / oC 9.5 / 210 9.5 / 210 9.5 / 210 9.5 / 210 9.5 / 210
Gas

3
Harrier GTS - Installation & Servicing
GENERAL
CONTENTS
Assembly.....................................................................11-28
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.........................................................................4
Hydraulic Resistance........................................................2
Initial Lighting..................................................................33
Introduction........................................................................3
Installation........................................................................11
Option Kits.........................................................................3
Performance Data..............................................................2
Servicing..........................................................................34
Ventilation..........................................................................7
Water Circulation...............................................................5
Water Connections............................................................7
Water System Requirements............................................8
Water Treatment................................................................5
Wiring Diagrams..............................................................30
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.
Harrier GTS
Gas and Fuel Oil
PI No. 1312 BR 4783
Destination Countries: GB, IE
INTRODUCTION
The Harrier GTS boilers are a range of cast iron sectional pressure
jet boilers offering high efciency operation, ease of maintenance,
fuel exibility and low emissions. Suitable for oil or gas operation
the Harrier GTS range is supplied in a choice of 5 standard
models, rated in outputs from 105kW (358,000 Btu/h) to 330kW
(1,126,000 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 horizontal ue
ways incorporating ns and cast iron turbulators, the Harrier GTS
ensures maximum heat transfer efciency (up to 91.5% net).
The boilers are 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 boilers are NOT suitable for:
1. Gravity DHW systems
2. Gravity heating systems
3. Direct domestic hot water supply
Options
Flue Gas Thermometer (ID28)

4Harrier GTS - Installation & Servicing
GENERAL
SAFETY
Current Gas Safety (Installation and Use) Regulations or
rules in force.
It is law that all gas appliances are installed and serviced by a
CORGI registered installer in accordance with the regulations
below. 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 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.
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.
The installation of the boiler MUST also be in accordance with
the latest I.E.E. (BS7671) Wiring Regulations, local buildings
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 Codes
of Practice:
BS 799 Pt4 & 7 Oil burning equipment.
BS 799 Pt5 Oil storage tanks.
BS 5410 Pt1 Installation for space heating and hot water
supply.
BS 5854 Flues and ue structures in buildings.
BS 5885 Pt1 Gas burners - with inputs 60kW and above.
BS 6644 Installation of gas red hot water boilers of
rated input between 70kW and 1.8MW (net)
(2nd and 3rd family gases).
BS 6880 Low temperature hot water heating systems of
output greater than 45kW.
Part 1 Fundamental and design considerations
Part 2 Selection of equipment.
Part 3 Installation, commissioning and maintenance.
BS 6891 Installation of low pressure gas pipework of
up to 28mm (R1) in domestic premises (2nd
family gas).
EN 303.1 Heating boilers with forced draught burners.
General requirements.
EN 303.2 Heating boilers with forced draught burners
NOTE TO THE INSTALLER: LEAVE THESE INSTRUCTIONS ADJACENT TO THE BOILER.
with atomising oil burners.
EN 304 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 Efciency Directive.
IGE/UP/1 Soundness testing and purging of industrial and
commercial gas installation.
IGE/UP/2 Gas installation pipework, boosters and
compressors on industrial and commercial
premises.
IGE/UP/10 Installation of gas appliances in industrial and
commercial premises.
SAFE HANDLING OF SUBSTANCES
Care should be taken when handling the boiler insulation panels,
which can cause irritation to the skin. No asbestos, mercury or
CFCs are included in any part of the boiler or its manufacture.
GAS SUPPLY
The local gas supplier should be consulted, at the installation
planning stage, in order to establish the availability of an adequate
supply of gas. An existing service pipe must NOT be used without
prior consultation with the local gas supplier.
A gas meter can only be connected by the local gas supplier or by
a registered CORGI engineer.
An existing meter should be checked, preferably by the gas
supplier, to ensure that the meter is adequate to deal with the
rate of gas supply required. A minimum working gas pressure of
17.5mbar MUST be available at the boiler inlet for Natural gas
and 37mbar for Propane.
Do not use pipes of smaller size than the burner inlet gas
connection.
The complete installation MUST be tested for gas soundness and
purged in accordance with the appropriate standards listed on
page 4.
Gas Boosters
A gas booster is required if the gas pressure available at the
burner is lower than that required by the burner manufacturer to
attain the ow rate for maximum burner input rating.
Location of the booster requires careful consideration but
should preferably be closer to the burner rather than the gas
meter. Ventilation should also be considered to ensure ambient
temperatures do not exceed designed recommendations. Further
guidance is provided in IGE/UP/2 as listed above.
FLUE INSTALLATION
IMPORTANT
Assembly and Installation Instructions for Ideal Harrier GTS heating boilers should be read in conjunction with the general
technical data tables enclosed and any other technical publication supplied with the burner.

5
Harrier GTS - Installation & Servicing
GENERAL
It is the responsibility of the installer to ensure, in practice, that
products of combustion discharging from the terminal cannot
re-enter the building or any other adjacent building through
ventilators, windows, doors, other sources of natural air inltration,
or forced ventilation / air conditioning.
If this should occur the appliance MUST be turned OFF, labelled
as 'unsafe' and corrective action taken.
The ue must be installed in accordance with the appropriate
standards listed on page 4.
WATER CIRCULATION SYSTEM
The system pump MUST be connected to the boiler.
The boiler must NOT be used for direct hot water supply. The hot
water storage cylinder MUST be of the indirect type.
The appliances are NOT suitable for gravity central heating nor
are they suitable for the provision of gravity domestic hot water.
The hot water cylinder and ancillary pipework, not forming part of
the useful heating surface, should be lagged to prevent heat loss
and any possible freezing - particularly where pipes run through
roof spaces and ventilated underoor spaces.
The boiler must be vented.
Draining taps MUST be located in accessible positions, which
permit the draining of the whole system - including the boiler
and hot water storage vessel. They should be at least 1/2" BSP
nominal size and be in accordance with BS. 2879.
The central heating system should be in accordance with the
relevant standards listed on page 4.
Due to the compact nature of the boiler the heat stored within
the castings at the point of shutdown of the burner must be
dissipated in order to avoid overheating. In order to allow pump
operation after burner shutdown the boiler control system should
incorporate a pump overrun device.
WATER TREATMENT FOR HOT WATER AND
HEATING BOILERS
There is a basic need to treat the water contained in all heating
and indirect water systems, particularly open vented systems.
It is assumed, incorrectly, that because boilers are operating
in conjunction with what is apparently a closed circuit an open
vented system will not, under normal circumstances, allow
damage or loss of efciency due to hardness salts and corrosion
once the initial charge of water has been heated up a few times.
1mm of lime reduces the heat transfer from metal to water by
10%.
In practice the deposition of these salts is liable to cause noises
from the boiler body or even premature boiler failure. Corrosion
and 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 ll 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.
Conversely, when the system cools, water previously expelled is
drawn back from the tank into the system together with a quantity
of dissolved oxygen.
Even if leakage from the heating and hot water system is
eliminated there will be evaporation losses from the surface of the
tank which, depending upon ambient temperature, may be high
enough to evaporate a large portion of the system water capacity
over a full heating season.
There will always be corrosion within a heating or hot water
system to a greater or lesser degree, irrespective of water
characteristics, unless the initial ll water from the mains is
treated. Even the water in closed systems will promote corrosion
unless treated. For the reason stated, Ideal Boilers strongly
recommend that when necessary the systems is thoroughly
cleaned, prior to the use of stable inhibitor, which does not require
continual topping up to combat the effects of hardness salts and
corrosion on the heat exchangers of the boiler and associated
systems.
Ideal Boilers advise contact directly with specialists on water
treatment such as:
GE Betz Ltd., Sentinel Division, Foundry Lane,
Widnes, Cheshire, WA8 8UD,
Tel: [phone]
Fernox Manufacturing Co. Ltd., Cookson Electronics,
Forsyth Road, Sheerwater, Woking, Surrey, GU21 5RZ
Tel: [phone]
ELECTRICAL SUPPLY
WARNING This appliance must be earthed.
The control system requires a 230V - 50Hz mains supply.
Wiring external to the appliance MUST be in accordance with
the current I.E.E. (BS7671) Wiring Regulations and any local
regulations which apply.
Burner and Pump
These may be 1ph or 3ph. Refer to manufacturer's instructions.
The point of connection to the mains should be readily accessible
and adjacent to the boiler.
LOCATION OF THE BOILER
The boiler must stand on a non-combustible oor (i.e. concrete
or brick) which must be at, level and of a suitable load bearing
capacity to support the weight of the boiler (when lled with water)
and any ancillary equipment.
If the boiler is mounted on a plinth then the dimensions must
exceed the plan area of the boiler by at least 75mm on each side.
The boiler must not be tted outside.

6Harrier GTS - Installation & Servicing
GENERAL
1 BOILER DIMENSIONS
2 BOILER CLEARANCES
The minimum dimensions as indicated must be respected
to ensure good access around the boiler.
Note. To allow the inlet of the combustion air, the boiler
room must be adequately ventilated, the section and the
location of which must comply with local recommendations.
Refer also to Frame 3.
The boiler must be positioned so that there is enough
space available to allow the following:
• Access around the boiler for servicing.
• Space to open the boiler front door.
• Space to access the burner.
Recommended minimum clearances are as shown.
Rear 1000mm or adequate space to make the ue
connections and access to the ue sample point,
drain connection, ue 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 sides may
be 100mm except at one end consideration must
also be given to the burner door hinge position and
consequent clearance for access to the rear.
1017
827
137
115
B
OR
1192
137
387
H
105
CA
L
153
D
800
53
98
153
195P103103 597
har9077
1.5m
1m
1.19m
0.15m
A
B
0.5m 0.5m
0.8m
har9078
Dimension Boiler GTS 5 GTS 6 GTS 7 GTS 8 GTS 9
A mm 1000 1160 1320 1480 1640
B Standard Control Panel mm 105 105 105 105 105
Boiler GTS 5 GTS 6 GTS 7 GTS 8 GTS 9
A 130 130 130 130 130
B 105 105 105 105 105
C 165 165 165 165 165
D 738 738 738 738 738
H 1297 1297 1297 1297 1297
L 1151 1311 1471 1631 1791
P 650 810 970 1130 1290
OR 180 180 200 200 200

7
Harrier GTS - Installation & Servicing
GENERAL
3 VENTILATION
Safe, efcient and trouble-free operation of conventionally
ued gas boilers is vitally dependent on the provision of an
adequate supply of fresh air to the room in which the appliance
is installed.
Ventilation by grilles communicating directly with the outside
air is required at both high and low levels. The minimum free
areas of these grilles must be according to the following scale:
Position ventilation grilles to avoid the risk of accidental
5 FILLING THE SYSTEM
obstruction by blockage or ooding. If further guidance on
ventilation is required then consult BS 6644.
The supply of air by mechanical means to a space housing
the boiler should be by mechanical inlet with natural or
mechanical extraction. Mechanical extract ventilation with
natural inlet must not be used.
Where a mechanical inlet and a mechanical extract system is
applied, the design ventilation ow rates should be as in BS
6644.
Note.
For mechanical ventilation systems an automatic control
should be provided to cause safety shutdown or lockout of
the boiler(s) in the event of failure of air ow 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 tted (or if it is intended to t an
extractor fan after installation of the appliance) the advice of
the gas supplier should be obtained.
The temperature within a boiler room shall not exceed 25oC
within 100 mm of the oor, 32oC at mid height and 40oC within
100 mm of the ceiling.
Filling shall be performed with a low ow rate from a low point in
the boiler room in order to ensure that all the air in the boiler is
bled from the high point of the system.
Always stop the pump before lling.
IMPORTANT. Instructions for starting up the boiler for the rst
time after the system is fully or partly drained:
If all the air is not bled naturally to an expansion tank which is
open vented, the system must include manual bleed valves, in
addition to automatic air vents which bleed the system when it is
operating. The manual bleed valves are used to bleed all the high
points of the system and to make sure that the lled system is free
of air before the burner is turned on.
General
Recommendations relating to the water system are contained in
BS. 6880.
4 BOILER WATER CONNECTIONS
Flow and return connections are
positioned at the rear of the boiler.
The ow and returns are provided with
21/2"/65DN anged connections.
A Rp 11/2 drain connection is provided at
the bottom of the boiler rear section.
A Rp 21/2 connection is provided for
sludge removal at the bottom of the
boiler front section.
==
105
827
1017
137
har9076
Flow
Connection
Return
Connection
Drain
Connection
115
Required area (cm2) per kW of total rated input (net)
Boiler room Enclosure
Low level (inlet) 4 10
High level (outlet) 2 5
Note: Where a boiler installation is to operate in summer
months (e.g. DHW) additional ventilation requirements
are stated, if operating for more than 50% of time (refer
to BS6644).
Dimension Boiler GTS 5 GTS 6 GTS 7 GTS 8 GTS 9
A mm 1000 1160 1320 1480 1640
B Standard Control Panel mm 105 105 105 105 105

8Harrier GTS - Installation & Servicing
GENERAL
7 SEALED (PRESSURISED) SYSTEMS
6 OPEN VENTED SYSTEM REQUIREMENTS - minimum static head requirements
The Harrier GTS boiler has a minimum static head requirement
of 5.0 metres (16.5 feet approx.) depending on the particular
characteristics of the system design (see diagram). The information
provided is based on the following assumptions.
1. An open vent/safety pipe connection is made immediately after
the ow connection.
2. A cold feed/expansion pipe connection is made to the system
return pipe within 0.75m of the boiler return connection.
3. The maximum ow rate through the boiler is based on a
temperature difference of 11oC (20oF) at full boiler output with
the circulating pump positioned in the ow of the system.
4. The boiler is at the highest point of the system. Systems
designed to rise above the ow connections will, of course,
automatically require a minimum static head higher than shown.
5. The position of the open vent/safety pipe above the expansion
cistern water level is given as a guide only. The nal position will
depend upon particular characteristics of the system. Pumping
over of water into the expansion cistern should be avoided.
6. Both open vent/safety pipe and cold feed/expansion
pipes must be of adequate diameter to suit 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 requirements of the local authority, gas or water
undertakings.
In general commercial closed pressurised systems are provided
with either manual or automatic water make up.
In both instances it will be necessary to t automatic controls
intended to protect the boiler, circulating system and ancillary
equipment by shutting down the boiler plant if a potentially
hazardous situation should arise.
Examples of such situations are low water level and operating
pressure or excessive pressure within the system. Depending
on circumstances, controls will need to be either manual or
automatic reset. In the event of a shutdown both visual and
audible alarms may be necessary.
Open vent
safety pipe 750mm
Cold feed/
expansion pipe
H = 5.0m
To
pump
Pressure
relief
valve
FLOW
RETURN
Shunt pump
(if required)
Note: Height, H, MUST be
increased if necessary to
comply with the min.
head required by the
pump manufacturer
BOILER
This diagram does not show safety valves & water
flow switches etc necessary for safe operation
Expansion
cistern
har7404
Expansion vessels used must comply with BS. 4814 and must be
sized on the basis of the total system volume and initial charge
pressure.
Initial minimum charge pressure should not be less than 0.5
bar (7.2psi) and must take account of the static head and
specication of the pressurising equipment. The maximum water
temperatures permissible at the point of minimum pressure in the
system are specied in Guidance Note PM5.
When make up water is not provided automatically it will be
necessary to t controls which shut down the plant in the event
of the maximum system pressure approaching to within 0.35bar
(5psi) of the safety valve setting.
Other British Standards applicable to commercial sealed systems
are:
BS. 6880: Part 2
BS. 1212
BS. 6281: Part 1
BS. 6282: Part 1
BS. 6283: Part 4
8 SYSTEM DESIGN
Minimum Water Flow
Design Flow Rates
The following table gives the ow rate required for each boiler
based on a design temperature difference of 11oC (20oF)
at the maximum rated output. For hydraulic resistance see
Performance Data table (page 2).
Minimum Flow Rates
It may be necessary to t a shunt pump to ensure minimum
ow rates.
Boiler Output kW Open Vent (mm) Cold Feed (mm)
60 to 150 32 25
151 to 300 38 32
301 to 600 50 38
Boiler Size GTS 5 GTS 6 GTS 7 GTS 8 GTS 9
Normal water ow rate l/s 3.04 3.91 5.00 6.08 7.17
temperature difference 11oC (20oF) g.p.m. 40.1 51.6 66.0 80.2 94.6
Minimum water ow rate l/s 0.96 1.23 1.57 1.91 2.25
temperature difference 35oC (63oF) g.p.m. 12.7 16.2 20.7 25.2 29.7

9
Harrier GTS - Installation & Servicing
GENERAL
7
2
15
16
10
14
13
7
24
23
7
12 1
7
21
7
13
22
8
7
10
27
726 25 7
10
9
11
3
67
6
18
20
7
19
13
7
17
45
7
7
7
Note. Minimum static head
requirements with limit thermostat
set at 110oC (230oF) is 2.5m.
The example illustrated is intended
as a general guide only. Ideal
Boilers will be pleased to advise on
specic applications.
Design and minimum ow rate
tables are shown in Frame 8.
System Design
Recommendations relating to water system design are
contained in BS. 5410: Part 2 and BS. 6880.
System design must allow for adequate internal circulation
within the boiler and sufcient heat release from the boiler body
during and immediately after burner ring. Heating and/or hot
water controls should be interlocked electrically with the burner,
to prevent ring when the system does not demand heat.
Depending on system design it may be necessary to interrupt
electrical supply to the burner before any mixing valves are
completely closed to the boiler ow. This will dissipate residual
heat. Also a pump overrun of at least 5 minutes is required on
plant shutdown to avoid interference trip out 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 Ideal Boilers for further information.
LEGEND
1. Heating outlet
2. Heating return
3. 3 bar safety valve and pressure gauge
4. Flow switch (if necessary)
5. Air separator
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 calorier
18. Sealed safety unit calibrated to 7 bar with indicator type
discharger
19. Pressure reducer (if mains press >5.5 bar)
20. Domestic cold water inlet
21. Domestic hot water outlet
22. DHW pump
23. DHW circulation pump (optional)
24. DHW circulation loop return
25. Water meter (if any)
26. Water treatment for hard water
27. Heating circuit lling (with disconnecter if required under
applicable regulations).
9 SYSTEM DESIGN CONTINUED
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 events, comply with applicable
codes of practice and national or local regulations.
Example shows a sealed system with domestic hot water
production via independent caloriers.
Typical Sealed System Example
A shunt pump sized on the minimum ow rate required MUST
be tted. Provided adequate heat dissipation can be achieved
at all times the shunt and DHW primary pumps only may run
on during the overrun period allowing the heating pump to be
switched off. This example assumes the DHW primary pump
ow rate required is less than that required for the shunt pump.

10 Harrier GTS - Installation & Servicing
INSTALLATION
GTS 5 105-140 0 0.060 0.066 210 180
GTS 6 140-180 0 0.076 0.084 210 180
GTS 7 180-230 0 0.097 0.107 210 200
GTS 8 230-280 0 0.118 0.130 210 200
GTS 9 280-330 0 0.139 0.152 210 200
10 FLUING
According to the output, the difference between the temperature of
the ue gas and the ambient temperature can be as low as 160o
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. The use of a draught stabiliser is also
recommended.
FLUE SIZE
Refer to applicable regulations while determining the size and height
of the ue. Please note that Harrier GTS boilers have pressurised and
sealed combustion chambers and that the pressure at the outlet must
not exceed 0 mbar.
Detailed recommendations relating to the design of ues for GAS red
appliances are quoted in BS. 6644 and IGE/UP/10, whilst BS. 5410 Pt.
1 similarly applies to OIL red boilers.
The table below contains the minimum dimensions of the ue required
for each boiler model in order to ensure sufcient draught at the
outlet.
(1) : at boiler maximum input.
(2) : Boiler ow temperature: 80oC (ambient temperature : 20oC).
11 DIMENSIONAL INFORMATION REQUIRED FOR THE FLUE CONNECTION
Connection
The connection must be made in a competent manner with
airtight pipe in a material that is resistant to hot gases from the
combustion and possible acid condensation. This pipe must
be as short as possible, be removable and without any sudden
change in its section.
The diameter must always be at least equal to that of the boiler
outlet.
Boiler Heat
Output
Required
Draught
Mass Flow of Flue Gases
kg/s
Natural Gas
9.5% CO2
Flue Gas
Temperature
(1) (2)
Chimney:
Minimum
Recommended
Diameter
kW mbar oC Ø min
mm
Fuel Oil
13% CO2
However, care must be taken to comply with any
applicable national or local regulations.
har9080
827 98
FLUE OUTLET

11
Harrier GTS - Installation & Servicing
INSTALLATION
12 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.
Oil Storage Tank
The oil storage tank, oil supply pipe and
connections to the burner unit MUST comply with
the requirements of BS. 799.
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.
IMPORTANT. The burner head deector must
be in line with the door insulation as shown
opposite.
If there is space between the burner blast tube and door insulation after mounting the burner, a suitable
insulation material must be used to pack the space.
Connection, adjustment, start-up and maintenance. (Refer to the instructions delivered with the burner)
13 ASSEMBLY
Packaging:
The tables below show the numbers of the packages which
make up the boiler. The packages are listed in the order in
which they are opened for assembly.
Tools required:
(not supplied)
- Phillips head screwdriver
- Wide at screwdriver
- 13 and 17mm spanners
- hammer
- Silicone glue
- JDTE assembly tool
- Simplied 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.
45
45
har5981
125
Deflector
Burner
door
insulation
Stud
tappings
Burner
opening (1)
(1) Different burner openings are available
to suit the burner being fitted.
Burner Door Opening and Fixings
Boiler body delivered loose
- front section 1 1 1 1 1
- intermediate section 3 4 5 6 7
- rear section 1 1 1 1 1
- set of assembly rods 1 1 1 1 1
- accessory package FD10 FD11 FD12 FD13 FD14
Casing ID40 & 41 ID40 & 42 ID40 & 43 ID40 & 44 ID40 & 45
Base Frame FD31 FD32 FD33 FD34 FD35
Burner Door 1 1 1 1 1
Bafe Pack ID17 ID17 ID19 ID19 ID19
IMPORTANT NOTE: For models GTS7, GTS8 and GTS9 more bafes are supplied than are required.
Refer to Frames 24 and 25 for the correct quantities and location and discard any extra bafes.
Control Panel ID46 ID46 ID46 ID46 ID46
Boiler GTS 5 GTS 6 GTS 7 GTS 8 GTS 9
INSTALLATION

12 Harrier GTS - Installation & Servicing
INSTALLATION
14 PREPARING THE BASE FRAME
1. Insert the inner cross members into the slots in the side
components.
2. Assemble the front and rear components into the ends of the
15 FITTING THE BASE FRAME INSULATION
1. Locate the insulation between the sides and end with the
black fabric on the underside.
2
2
fal5982
1
1
2
2
har5983
side components and secure with the 4 bolts.
INSTALLATION

13
Harrier GTS - Installation & Servicing
INSTALLATION
1
1
har5985
har5984
1
4
3
2
4
2
4
4
M12
M12
M12
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. Pass the rods through the rear
section and secure both ends with
the 4 washers and M12 nuts.
(This may be conducted after
preparing the section (Frame 17)
and tting thermocord (Frame 18) if
preferred.)
17 PREPARING THE REAR SECTION
(This may be conducted before Frame 16 with the section laid at on
the oor.)
1. Clean the nipple ports and nipples with cleaning uid.
2. Coat the nipples with the coating material supplied.
3. Push in the two nipples moderately.
4. Gently tap in the nipples using a wooden block to avoid damage.
2
3
3
har5986
har5987
4
INSTALLATION

14 Harrier GTS - Installation & Servicing
INSTALLATION
har5990
1
2
3
18 FITTING THE THERMOCORD
(This may be conducted before Frame 16 with the sections laid at
on the oor)
1. Put a drop of silicone at about every 200mm of the groove.
har5988
200 mm
1
1
har5989
A
2
3
thermocord
2. Working from point A, insert the thermocord into the groove.
3. Cut it to the correct length
4. Repeat for intermediate sections.
19 ASSEMBLING THE INTERMEDIATE SECTIONS
1. Place the rst intermediate section onto the base
frame.
2. Fit the connections of the intermediate section
onto the nipples in the rear section.
3. Ensure that the thermocord ts 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. Insert the assembly tool through the nipples and
tighten.
4
4
har5991
5
5
har5992
INSTALLATION

15
Harrier GTS - Installation & Servicing
INSTALLATION
20 ASSEMBLING THE INTERMEDIATE SECTIONS CONT'D
Proceed likewise for other intermediate sections
A
20 cm
har5993
1 32
45 6
8
7
INSTALLATION

16 Harrier GTS - Installation & Servicing
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.
4. Slide the threaded tie rods through the
front section and tighten to secure the
complete assembly.
5. Clean off any surplus silicone.
6. Remove the assembly tool.
7. Level the boiler by adjusting its feet.
22 PREPARATION FOR FITTING THE FLUE CLEANOUT AND BURNER DOORS
FOR RH OPENING
1. Screw in and tighten all the studs in
the appropriate tappings as shown
for items A and B.
2. Position the burner door hinge
bracket and secure with two M12
nuts and washers.
3. Position the burner door catch
and secure with two M12 nuts and
washers.
Note. For LH opening, exchange the
position of the catch and hinge bracket.
24
har5994
1
4
7
4
4
1
4
3
3
2
M12
M12
M12
M12 x 50
M12 x 80
M12
4x
8x
4x
har5995
A
A
B
B
B
C
C
B
B
A
B
C
B
A
B
B
B
A
C
C
3
2
1
INSTALLATION

17
Harrier GTS - Installation & Servicing
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 ue cleanout door hinge bracket
as shown and secure with two M12 nut and
washers.
Note.
For left hand opening position the hinge bracket
on the left.
4. Position the ue cleanout door in place and
insert the hinge pin.
Note.
Do not close and secure the door at this time.
har5996
1
har5998
4
M12
M12
4x
2x
har5997
A
A
B
A
A
A
B
B
3
2
2
INSTALLATION

18 Harrier GTS - Installation & Servicing
INSTALLATION
24 POSITIONING THE FLUE BAFFLES IN THE UPPER FOUR FLUEWAYS
1. Models GTS 5 and GTS 6. Place 2
ue bafes in each of the four upper
ueways.
2. The bafes should be hooked together
as shown.
3. Models GTS 7, GTS 8 and GTS 9.
Place one ue bafe only in each of
the four upper ueways.
IMPORTANT
The ue bafe pack for models GTS 7,
GTS 8 and GTS 9 will contain two sizes
of bafe. Use only the 570 mm long ones
and discard the shorter ones.
4. In all cases the bafes should be
pushed in to be ush with the front.
har5999
3
2
1
25 POSITIONING THE FLUE BAFFLES IN THE LOWER FLUEWAYS
1. All Models. Place one bafe in each
of the two lower ue ways.
2. In all cases the ue bafes should be
pushed in to be ush with the front.
3. Close the ue clean out door evenly
and secure with four M12 nuts and
washers in the same manner as the
burner door (see Frame 23).
1
har7000
INSTALLATION

19
Harrier GTS - Installation & Servicing
INSTALLATION
M8
M8
M8
M8
8553N030
5
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.
har7001
1
2
2
27 FITTING THE SMOKEHOOD
1. Screw the four M8 studs into the rear section.
2. Put a drop of silicone at about every 100mm of the
groove.
3. Insert the thermocord into the groove.
4. Cut it to the correct length.
5. Assemble the smokehood onto the studs and secure
with four anged M8 nuts.
M8
4x
har7002
1
har7003
2
3
4
INSTALLATION

20 Harrier GTS - Installation & Servicing
INSTALLATION
28 ASSEMBLING THE FLOW, RETURN AND DRAIN COCK
har9081
1
1
2
2
2
1
2
Drain cock
GTS 5
GTS 6
GTS 7
GTS 8
GTS 9
Tightness sealant
(not supplied)
Plumb
Line
=
=
fal7006
3
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 ow and return pipes and the drain
cock into the rear section. (Ensure the tapping on
the ow connection faces upwards to accept the
pressure relief valve.)
Note.
This tapping is not to be used for venting.
3. Use plumbline to ensure the anges are vertical
and equally screwed into the tappings.
INSTALLATION