IDEAL Viceroy GT Series Guide

Viceroy G.T.
Installation, Assembly and Servicing
Oil or Dual Gas 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 Viceroy Oil, Gas or Dual Fired 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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GENERAL
CONTENTS
Boiler Models..................................................................4
Packing ...........................................................................5
Installation ......................................................................6
Assembly/Hydraulic Connection ..................................7
Filling the Installation.....................................................8
Desludging/Chimney Connection.................................9
Dimensions/Connection ..............................................10
Oil or Gas Connection .................................................11
Control Panels ..............................................................12
Start Up .........................................................................16
Maintenance .................................................................19
Precautions...................................................................20
Data Table .....................................................................21
Main Dimensions..........................................................22
2
INTRODUCTION
DUTY
The range of boilers 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 boilers 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. 6798 Installation of gas fired hot water boilers of rated
input not exceeding 60 kW.
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)
BS. 5440:2 Ventilation (for gas appliances of rated input not
exceeding 60 kW)
Viceroy GT Range - Installation
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.
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
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Viceroy GT Range - Installation 3
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The technical instructions for boiler installation given in the
document must be scrupulously followed, otherwise the
guarantee will be invalidated.
GENERAL
4Viceroy GT Range - Installation
1 THE BOILERS COVERED BY THIS DOCUMENT
The Viceroy 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 175 to 780kW.
Boiler models:
VICEROY GT “DELUXE”: boiler with “DIEMATIC-m” integral
electronic control panel. Used as the «master» boiler for
installations of 2 or 3 boilers in cascade where the other
boilers are fitted with an «E» control panel.
VICEROY GT “STANDARD”: boiler with “E” control panel: on
option can be fitted a SV-matic weather compensator or a
SVR module for domestic hot water priority. Used as a
«slave» boiler for installations of two or three boilers in
cascade where one is fitted with a “DIEMATIC-m” control
panel.
VICEROY GT: boiler with standard control panel to be
connected, if needed, to main control cabinet.
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Viceroy GT Range - Installation 5
Before installing your boiler, you can check with the chart
below if you have all the component packages
For optional equipment you may use with this boiler, see the current price list.
GENERAL
PACKING
Item Box nr. Viceroy Viceroy Viceroy Viceroy Viceroy Viceroy Viceroy
8 9 10 11 12 13 14
Underframe 1 1 1 1 1 1 1
(dimensions according to model)
Front section 1 1 1 1 1 1 1
Normal intermediate section 5 6 7 8 9 10 11
Special intermediate section 1 1 1 1 1 1 1
Rear Section 1 1 1 1 1 1 1
Common accessories IE 20 1 1 1 1 1 1 1
Accessories boiler in bulk 1 1 1 1 1 1 1
(composition according to model)
Baffles IE 30 1
IE 31 1 1
IE 32 1 1
IE 33 11
Inner body insulation * IE 51 1
IE 53 1 1
IE 55 1 1
IE 57 11
Casing: common parts IE 10 1 1 1 1 1 1 1
Casing: varying parts IE 11 1 1
IE 12 1 1 1
IE 13 1 1 1 2 2 2
IE 14 1 1
Wiring ducts IE 41 1
IE 42 1
IE 43 1
IE 44 1
IE 45 1
IE 46 1
IE 47 1
Control panel -E ID 22 or 1 1 1 1 1 1 1
-Standard ID 24
Technical documents IE 408 1
IE 409 1
IE 410 1
IE 411 1
IE 412 1
IE 413 1
IE 414 1
Table 1 - Viceroy GT in bulk
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GENERAL
6Viceroy GT Range - Installation
2 INSTALLATION OF THE BOILER
The minimum dimensions indicated on the following drawing
must be respected to ensure good access around the boiler
Remark: To allow the inlet of the combustion air, the boiler
room must be adequately ventilated, the section and the
location must comply with local recommendations.
* Caution: Pay particular care to the space required for the boiler when the door is open. For an installation of several
boilers side by side, these dimensions need to be modified.
Sections 8 9 10 11 12 13 14
Dimensions A mm 1505 1665 1825 1985 2145 2305 2465
Dimensions B mm 130 -40 120 -40 120 -40 120
Dimensions C m 1.5 2 2 2 2.5 2.5 2.5
Section cm2 S 840 960 1090 1240 1390 1550 1710
Burner door open
8229-EN-05 A
8229-EN-54
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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.
INSTALLATION
Viceroy GT Range - Installation 7
4 HYDRAULIC CONNECTION
Dimensional information required
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 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 Systems
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 confirmed 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.
3 ASSEMBLY
For the assembly of the boiler, refer to the removable leaflet
in the middle of the instruction book.
Water flow/return tapping
GT 8 to 10: Ø2”1/2
GT 11 to 14: Ø3”
Threaded drain 2”
Viceroy Viceroy
GT 8 to 10 GT 11 to 14
D mm 235 254
E mm 1427 1447
8229-EN-06
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INSTALLATION
8Viceroy GT Range - Installation
Example of installation of a Viceroy GT boiler with production
of domestic hot water through independent calorifier(s)
1. Water flow flange
2. Water return flange
3. 4 bars safety valve + manometer*
4. Flow control device
5. Air separator
6. Air vent
7. Valve
8. Recycling pump
9. Expansion tank
10. Drain valve
11. Desludging valve
12. Mixing valve
13. Check valve
14. Circulating pump
15. Pressure gauge
16. Sludge decantation pot
(particularly recommendation for older installations)
17. Independent calorifier
18. Safety unit, set and sealed at 7 bars with over flow
19. Pressure reducer (if system pressure >5.5bars)
20. Domestic cold water inlet
21. Domestic hot water flow
22. Calorifier heating pump
23. Domestic water circulating pump (optional)
24. DHW circuit return
25. Water meter (eventually)
26. Water treatment when TH > 25°
27. Heating system filler
(with circuit breaker in accordance with regulations).
* 6 bars maxi
Heating
Circuit
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.
General
Recommendations relating to the water system are contained
in BS.5449 Pt.1, BS5401 Pt.2. and BS.6880.
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.
8219-EN-12
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INSTALLATION
Viceroy GT Range - Installation 9
DESLUDGING
Desludging hole
threaded 2”1/2
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.
5 CHIMNEY CONNECTION
As the Viceroy 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 deterioration 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.
8229-EN-07
8219-EN-21
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INSTALLATION
10 Viceroy GT Range - Installation
DETERMINING THE FLUE
DIMENSIONAL INFORMATION NEEDED FOR CONNECTION
To size the height and cross section of the chimney, refer to
the regulations currently in force. 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 the flue.
The installer should provide a measuring point (Ø10mm 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.
Chimney connection (outer Ø)
VICEROY GT 8 to 10: Ø250
VICEROY GT 11 to 14: Ø300
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
condensation. The connection should be removable 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, 250mm for the 8, 9 and 10 section boilers and
300mm for the 11, 12, 13 and 14 section boilers.
8229-EN-08
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