200284-3.pmd

Viceroy GT -

Installation & Servicing

GENERAL

Flow Connection

in.

Return Connection

in.

Drain Connection

in.

Maximum Operating Pressure

bar

Boiler Thermostat Setting

ºC

30 - 90

Safety Thermostat Setting

ºC

110

High / Low Setting

ºC

30 - 90

30-90

Nominal Flue

m m

250

300

Diameter

in.

Boiler Water

366

409

452

495

538

581

624

Content

gal

80.5

89.9

99.4

109

118.4

127.8

137.3

Boiler DRY Weight

1941

2027.5

2524

2492

2652.5

2881

3117

less Burner Unit

4280

4470.5

5565

5494.5

5849

6353

6873

Maximum

44.78

51.74

61.88

69.06

77.11

82.87

89.77

Gas Rate

1582

1827

2185

2439

2723

2927

3170

Maximum Flue

0.279

0.322

0.386

0.429

0.479

0.515

0.558

Gas Volume

/min

591

682

818

909

1015

1091

1182

Flue Gas CO

/ Temperature

% / ºC

9.5 / 220

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
Ideal Ltd.
Natural gas consumption is calculated using a calorific value of
38.7MJ/m

(1038Btu/ft

) gross or 34.9MJ/m

(935Btu/ft

) 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

GT 8

GT 9

GT 10

GT 11

GT 12

GT 13

GT 14

Number of Sections

Maximum

390

450

540

600

670

720

780

Heat Output

Btu/hx10

1330

1535

1842

2047

2286

2457

2661

Minimum

300

390

450

540

600

670

720

Heat Output

Btu/hx10

1024

1330

1535

1842

2047

2286

2457

Hydraulic

mbar

31.6

49.3

75.9

84.2

104.9

127.9

161.4

Resistance at 11k

in w.g.

12.6

19.7

30.3

33.7

42.0

51.2

64.6

Hydraulic

mbar

9.6

14.9

23.0

25.5

31.7

38.7

48.8

Resistance at 20k

in w.g.

3.8

6.0

9.2

10.2

12.7

15.5

19.5

Combustion Chamber

mbar

1.1

1.5

2.0

2.5

3.5

Resistance (at zero draught)

in w.g.

0.44

0.6

0.8

1.0

1.4

Minimum Draught at Smokehood mbar

Outlet (for max. output)

in w.g.

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 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

43.08

49.76

59.51

66.42

74.17

79.71

86.35

Oil Rate

gal/h

9.48

10.95

13.09

14.61

16.32

17.54

19.00

Maximum Flue

0.252

0.290

0.348

0.387

0.432

0.465

0.503

Gas Volume

/min

534

614

737

820

915

985

1065

Flue Gas CO

/ Temperature

% / ºC

13 / 220

Oil

Table 2 General Data

Gas

Viceroy GT -

Installation & Servicing

GENERAL

CONTENTS

Assembly. ................................................................... 13-26

Boiler Clearances. ............................................................ 7

Burner Connection. ........................................................ 13

Commissioning and Testing. .................................... 33-35

Electrical Connections. ............................................. 27-29

Electrical Supply. .............................................................. 5

Flue Installation. ................................................................ 5

Fluing. .............................................................................. 12

Gas Safety Regulations .................................................... 4

Gas Supply. ........................................................................ 4

Hydraulic Resistance. ...................................................... 2

Initial Lighting. ................................................................. 35

Introduction. ...................................................................... 3

Installation. ...................................................................... 13

Option Kits. ........................................................................ 3

Performance Data. ........................................................... 2

Servicing. ............................................................... 36 & 37

Ventilation. ........................................................................ 8

Water Circulation. ............................................................ 5

Water Connections. ......................................................... 8

Water System Requirements. ......................................... 9

Water Treatment. ............................................................. 5

Wiring Diagrams. ................................................... 28 & 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.

Viceroy GT

Gas and Fuel Oil
Destination Countries: GB, IE

INTRODUCTION

The Viceroy GT 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 Viceroy GT range is supplied in a choice of
7 standard models, rated in outputs from 300kW (1,024,000 Btu/h)
to 780kW (2,661,000 Btu/h) and has a maximum operating
pressure of 6 bar. All models may have high/low operation.

Designed with a large combustion chamber, 3 pass horizontal
flue ways incorporating fins and cast iron turbulators, the
Viceroy GT ensures maximum heat transfer efficiency.

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.

vic7069

Viceroy GT -

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 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.

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.

73/23 EEC

Low voltage directive. (Relevant standard is
EN60335.1)

89/336 EEC

Electromagnetic Compatibility Directive.
(Relevant standards are EN50081.1,
EN50082.1 and EN55014.)

90/396 EEC

Gas Appliance Directive. (Relevant standards
are EN303.1, EN303.2 and EN304.)

92/42 EEC

Boiler Efficiency Directive.

IGE/UP/1

Soundness testing and purging of 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 Viceroy GT heating boilers should be read in conjunction with the general
technical data tables enclosed and any other technical publication supplied with the burner.

Viceroy GT -

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 design 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: 0151 424 5351

Fernox Manufacturing Co. Ltd., Cookson Electronics,
Forsyth Road, Sheerwater, Woking, Surrey, GU21 5RZ
Tel: 01799 521 133

Salamander Engineering Ltd., Unit 24, Reddicap Trading Estate,
Sutton Coldfield, West Midlands, B75 7BU
Tel: 0121 378 0952

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.

Viceroy GT -

Installation & Servicing

GENERAL

BOILER DIMENSIONS

Water flow
tapping

(to be welded)

Water return tapping

(to be welded)

125

140

650

1000

183

149

130

147

183

153

530

1013

1500

140

638

Drain

tapped

(plugged)

Sludge

removal hole

(plugged)

638

Effective diameter of combustion chamber :

- front section :

455 mm

- intermediate section :

530 mm

Effective diameter of combustion chamber :

573 mm

vic7071

Boiler

GT 8

GT 9

GT 10

GT 11

GT 12

GT 13

GT 14

A (outside dia)

250

300

135 - 175 - 190 - 240 - 250 - 290 or plain plate

235

254

1427

1447

1505

1665

1825

1985

2145

2305

2465

1183

1343

1503

1663

1823

1983

2143

Deluxe

113.5

Control

355

Panel

195

755

Standard

127.5

Control

130

Panel

105

738

Viceroy GT -

Installation & Servicing

GENERAL

Air inlet

Air outlet

0.546 m

1.5 m

1 m

vic7072

Refer to notes above

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 follows:
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.

Front See Table below.

567

R = 415

R = 751,5

240

burner door open

View from top

R = 751.5

vic7084

GT 8

GT 9

GT 10

GT 11

GT 12

GT 13

GT 14

1505

1665

1825

1985

2145

2305

2465

105

195

1500

2000

2500

Dimension

Boiler

Standard Control Panel

Deluxe Control Panel

m m

Viceroy GT -

Installation & Servicing

GENERAL

2" tapped drain

connection

B flow connection

B return connection

1149

183

140

vic7073

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:

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.

BOILER WATER CONNECTIONS

Flow and return connections are positioned at the rear of
the boiler.

The flow and returns are provided with stub pipes sized as
in Table 2.

A 2" drain connection is provided at the bottom of the boiler
rear section.

A 2

" connection is provided for sludge removal at the

bottom of the boiler front section.

" tapped sludge

removal hole

183

500

vic7074

DE-SLUDGE CONNECTION

Boiler

GT 8 to GT 10

GT 11 to GT 14

D mm

235

254

E mm

1427

1447

Required area (cm

) per kW of total rated input (net)

Boiler room

Enclosure

Low level (inlet)

High level (outlet)

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).

Viceroy GT -

Installation & Servicing

GENERAL

FILLING THE SYSTEM

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.

SEALED (PRESSURISED) SYSTEMS

OPEN VENTED SYSTEM REQUIREMENTS - minimum static head requirements

The Viceroy GT 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, 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 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

Boiler Output kW

Open Vent (mm)

Cold Feed (mm)

301 to 600

600 and above

Viceroy GT -

Installation & Servicing

GENERAL

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.

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.

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.

Boiler Size

GT 8

GT 9

GT 10

GT 11

GT 12