IDEAL Harrier GTE 5 User manual

installation and
servicing
Your Ideal installation and servicing guide
ENGINEERED FOR PEACE OF MIND
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.
Harrier GTE
GTE 5, GTE 6, GTE 7, GTE 8 & GTE 9
9486 2069
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2
Harrier GTE - Installation & Servicing
GENERAL
Note.
Fuel rates and flue gas data relate to maximum output ratings.
Gas firing data relates to the use of NATURAL GAS ONLY.
Details for the use of LPG are available on request from
Caradon
IdealLtd.
Natural gas consumption is calculated using a calorific 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 calorific value of 45.56 MJ/kg
gross or 42.69 MJ/kg nett.
Table 1 Performance Data
Boiler GTE5 GTE6 GTE7 GTE8 GTE9
Number of Sections 5 6 7 8 9
Maximum kW 140 180 230 280 330
Heat Output Btu/hx103478 614 785 955 1126
Minimum kW 105 140 180 230 280
Heat Output Btu/hx103358 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 &SAFETYDOCUMENT 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 certified 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 enquire.
Any direct connection of a control device not approved by
Caradon Ideal Limited could invalidate the certification 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 R11/2R11/2R11/2R11/2R11/2
Safety Valve & Expansion in R11/2R11/2R11/2R11/2R11/2
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 608 694 791 886 977
less Burner Unit lb 1340 1530 1744 1953 2154
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
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3
Harrier GTE - Installation & Servicing
GENERAL
CONTENTS
Assembly.................................................................... 11-29
Boiler Clearances. ............................................................ 6
Burner Connection. ........................................................ 11
Commissioning and Testing. ................................ 36 & 37
Electrical Connections. .............................................30-32
ElectricalSupply. .............................................................. 5
FlueInstallation................................................................. 5
Fluing. .............................................................................. 10
Gas Safety Regulations .................................................... 4
GasSupply......................................................................... 4
Hydraulic Resistance. ...................................................... 2
InitialLighting. ................................................................. 38
Introduction....................................................................... 3
Installation....................................................................... 10
OptionKits......................................................................... 3
Performance Data. ........................................................... 2
Servicing. ........................................................................ 28
Ventilation. ........................................................................ 7
Water Circulation. ............................................................ 5
Water Connections. ......................................................... 7
Water System Requirements. ......................................... 8
Water Treatment. ............................................................. 5
Wiring Diagrams.................................................... 31 & 33
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 GTE
GasandFuel Oil
PI No. 49AQ950
Destination Countries: GB,IE
INTRODUCTION
The Harrier GTE boilers are a range of cast iron sectional
pressure jet boilers offering high efficiency operation, ease of
maintenance, fuel flexibility and low emissions. Suitable for oil or
gas operation the Harrier GTE 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
flue ways incorporating fins and cast iron turbulators, the Harrier
GTE ensures maximum heat transfer efficiency (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)
Hours run meter (IC8) (may only be fitted on Deluxe control
panel)
Deluxe control panel (FD168) with indicator lights etc.
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4
Harrier GTE - 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 flue structures in buildings.
BS 5885 Pt1 Gas burners - with inputs 60kW and above.
BS 6644 Installation of gas fired hot water boilers of
rated input between 60kW and 2MW (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.
NOTE TO THE INSTALLER: LEAVE THESE INSTRUCTIONS ADJACENT TO THE BOILER.
EN 303.2 Heating boilers with forced draught burners
with atomising oil burners.
EN 304 Test code for heating boilers for atomizing oil
burners.
73/23EEC 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.)
92/42EEC Boiler Efficiency 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 flow 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.
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.
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5
Harrier GTE - Installation & Servicing
GENERAL
FLUE INSTALLATION
IMPORTANT
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
infiltration, or forced ventilation / air conditioning.
If this should occur the appliance MUST be turned OFF, labelled
as 'unsafe' and corrective action taken.
The flue 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 underfloor 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 efficiency 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 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.
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 fill water from the mains is
treated. Even the water in closed systems will promote
corrosion unless treated. For the reason stated, Caradon Ideal
Limited 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.
Caradon Ideal Limited 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]
Salamander Engineering Ltd., Unit 24, Reddicap Trading Estate,
Sutton Coldfield, West Midlands, B75 7BU
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 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.
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 fitted outside.
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6
Harrier GTE - Installation & Servicing
GENERAL
1 BOILER DIMENSIONS
2 BOILER CLEARANCES
796
D
A
L
P
1
95
1
05
R
p
1
1
/
2
drainin
g
outlet
(
supplied with plu
g)
2
1
/
2
heatin
g
flo
w
(
flan
g
e + counter flan
g
e
)
R
p
2
1
/
2
heatin
g
retur
n
(
flan
g
e + counter flan
g
e
)
R
p
2
1
/
2
diameter slud
g
e
r
e
m
o
v
a
l h
o
l
e
C
B
398
398
594
1
01
1
01
1
1
9
2
387
137
8
2
7
10
1
7
137
Ø
R
1
53
1
53
53
H
har
5963
1
1
5
R
p
1
1
/
2
for safet
y
r
e
li
e
f v
a
lv
e
onl
y
har5964
B
1,192m
1m
1,5m
A
0,795m
see notes
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 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 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.
Boiler GTE5 GTE6 GTE7 GTE8 GTE9
Standard A 130 130 130 130 130
Control B 105 105 105 105 105
Panel C 165 165 165 165 165
Fitted D 738 738 738 738 738
H 1297 1297 1297 1297 1297
Deluxe A 355 355 355 355 355
Control B 195 195 195 195 195
Panel C 145 145 145 145 145
Fitted D 755 755 755 755 755
H 1387 1387 1387 1387 1387
All L 1151 1311 1471 1631 1791
Models P 650 810 970 1130 1290
ØR 180 180 200 200 200
Dimension Boiler GTE5 GTE6 GTE7 GTE8 GTE9
A mm 1000 1160 1320 1480 1640
B Standard Control Panel mm 105 105 105 105 105
Deluxe Control Panel mm 195 195 195 195 195
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7
Harrier GTE - Installation & Servicing
GENERAL
3
VENTILATION
Safe, efficient and trouble-free operation of conventionally
flued 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:
5 FILLING THE SYSTEM
Total input rating of
boilers Position of air vents Air vent areas (air direct from outside)
Up to 2 MW
HIGH LEVEL 270 cm2plus
2.25cm2per kW in
excess of 60 kW
total rated input
540 cm2plus
4.5cm2per kW in
excess of 60 kW
total rated input
LOWLEVEL
Position ventilation grilles to avoid the risk of accidental
obstruction by blockage or flooding. 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 flow rates should be as in Table 4
of 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 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 advice of the
gas supplier should be obtained.
The temperature within a boiler room shall not exceed 25ºC
within 100 mm of the floor, 32ºC at mid height and 40ºC within
100 mm of the ceiling.
Filling shall be performed with a low flow 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 filling.
IMPORTANT. Instructions for starting up the boiler for the first
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 filled 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 flow and returns are provided with
2 1/2"/65DN flanged connections.
A Rp 1 1/2drain connection is provided
at the bottom of the boiler rear section.
A Rp 2 1/2connection is provided for
sludge removal at the bottom of the
boiler front section.
1
05
8
27
1017
137
h
a
r
5965
Fl
ow
C
onnectio
n
R
e
t
u
r
n
C
onnectio
n
D
r
a
in
C
onnectio
n
1
1
5
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8
Harrier GTE - Installation & Servicing
GENERAL
7 SEALED (PRESSURISED) SYSTEMS
6 OPEN VENTED SYSTEM REQUIREMENTS - minimum static head requirements
The Harrier GTE boiler has a minimum static head requirement of
2.5 metres (8 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 flow 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 flow rate through the boiler is based on a
temperature difference of 11ºC (20ºF) at full boiler output with
the circulating pump positioned in the flow of the system.
4. The boiler is at the highest point of the system. Systems
designed to rise above the flow 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 final 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, as 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 fit 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 = 2.5m
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
har5966
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
specification of the pressurising equipment. The maximum
water temperatures permissible at the point of minimum
pressure in the system are specified in Guidance Note PM5.
When make up water is not provided automatically it will be
necessary to fit 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 flow 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 fit a shunt pump to ensure minimum
flow 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 GTE5 GTE6 GTE7 GTE8 GTE9
Normal water flow 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 flow 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
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9
Harrier GTE - 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. Caradon
Ideal Limited will be pleased to
advise on specific applications.
Design and minimum flow rate
tables are shown 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 sufficient heat release from the boiler
body during and immediately after burner firing. Heating and/
or hot water controls should be interlocked electrically with the
burner, to prevent firing 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 flow. 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 Caradon Ideal Limited 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 calorifier
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 filling (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 calorifiers.
Typical Sealed System Example
A shunt pump sized on the minimum flow rate required MUST
be fitted. 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
flow rate required is less than that required for the shunt pump.
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10
Harrier GTE - Installation & Servicing
INSTALLATION
GTE5 105-140 0 0.060 0.066 210 180
GTE6 140-180 0 0.076 0.084 210 180
GTE7 180-230 0 0.097 0.107 210 200
GTE8 230-280 0 0.118 0.130 210 200
GTE9 280-330 0 0.139 0.152 210 200
10 FLUING
According to the output, the difference between the temperature of
the flue gas and the ambient temperature can be as low as 160ºC.
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.
FLUESIZE
Refer to applicable regulations while determining the size and height
of the flue. Please note that Harrier GTE 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 flues for GAS
fired appliances are quoted in BS. 6644 and IGE/UP/10, whilst BS.
5410 Pt. 1 similarly applies to OIL fired boilers.
The table below contains the minimum dimensions of the flue
required for each boiler 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
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
FlueGas
Temperature
(1) (2)
Chimney:
Minimum
Recommended
Diameter
kW mbar ºCØmin
mm
FuelOil
13%CO2
45
1000mm min.
har5968
However, care must be taken to comply with any
applicable national or local regulations.
827
98
FLUE OUTLET
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11
Harrier GTE - Installation & Servicing
INSTALLATION
12
BURNER CONNECTION
GasSupply
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 deflector must be
in line with the door insulation as shown
opposite.
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 flat screwdriver
- 13 and 17mm spanners
- hammer
- Silicone glue
- JDTE assembly tool
- Simplified 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
12
5
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 FD169 FD170 FD171 FD172 FD173
Base Frame FD31 FD32 FD33 FD34 FD35
Burner Door 1 1 1 1 1
Baffle Pack ID17 ID17 ID19 ID19 ID19
IMPORTANT NOTE: For models GTE7, GTE8 and GTE9 more baffles are supplied than are required.
Refer to Frames 24 and 25 for the correct quantities and location and discard any extra baffles.
Control Panel
- Standard FD167 FD167 FD167 FD167 FD167
- Deluxe FD168 FD168 FD168 FD168 FD168
Boiler GTE5 GTE6 GTE7 GTE8 GTE9
INSTALLATION
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12
Harrier GTE - Installation & Servicing
INSTALLATION
14 PREPARING THE BASE FRAME
1. Insert the inner cross members into the slots in the side
components.
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
2. Assemble the front and rear components into the ends of the
side components and secure with the 4 bolts.
INSTALLATION
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13
Harrier GTE - 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 fitting thermocord (Frame 18) if
preferred.)
17 PREPARING THE REAR SECTION
(This may be conducted before Frame 16 with the section laid flat
on the floor.)
1. Clean the nipple ports and nipples with kerosene/paraffin.
2. Coat the nipples with the coating material (linseed oil)
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
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14
Harrier GTE - Installation & Servicing
INSTALLATION
har5990
1
2
3
18 FITTING THE THERMOCORD
(This may be conducted before Frame 16 with the sections laid
flat on the floor)
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 first 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 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. Insert the assembly tool through the nipples
and tighten.
4
4
har5991
5
5
har5992
INSTALLATION
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15
Harrier GTE - 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
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16
Harrier GTE - 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
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17
Harrier GTE - 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 flue 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 flue 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
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18
Harrier GTE - Installation & Servicing
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.
Place one flue baffle only in each of
the four upper flueways.
IMPORTANT
The flue baffle pack for models GTE 7,
GTE 8 and GTE 9 will contain two sizes of
baffle. Use only the 570 mm long ones
and discard the shorter ones.
4. In all cases the baffles should be
pushed in to be flush with the front.
har5999
3
2
1
25 POSITIONING THE FLUE BAFFLES IN THE LOWER FLUEWAYS
1. All Models. Place one baffle in each
of the two lower flue ways.
2. In all cases the flue baffles should be
pushed in to be flush with the front.
3. Close the flue 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
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19
Harrier GTE - 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 flanged M8 nuts.
M8
4x
1
har7003
2
3
4
INSTALLATION
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20
Harrier GTE - Installation & Servicing
INSTALLATION
28
ASSEMBLING THE FLOW, RETURN AND DRAIN COCK
har7005
1
1
2
2
2
1
2
Drain cock
GTE 5
GTE 6
GTE 7
GTE 8
GTE 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 flow and return pipes and the drain
cock into the rear section. (Ensure the tapping on
the flow 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 flanges are vertical
and equally screwed into the tappings.
INSTALLATION
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