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.
Viceroy GT
GT 8, GT 9, GT 10, GT 11,
GT 12, GT 13 & GT 14
2
Viceroy GT -
Installation & Servicing
GENERAL
Flow Connection
in.
3
3
3
4
4
4
4
Return Connection
in.
3
3
3
4
4
4
4
Drain Connection
in.
2
2
2
2
2
2
2
Maximum Operating Pressure
bar
6
6
6
6
6
6
6
Boiler Thermostat Setting
ēC
30 - 90
30 - 90
30 - 90
30 - 90
30 - 90
30 - 90
30 - 90
Safety Thermostat Setting
ēC
110
110
110
110
110
110
110
High / Low Setting
ēC
30 - 90
30 - 90
30 - 90
30 - 90
30 - 90
30-90
30-90
Nominal Flue
m m
250
250
250
300
300
300
300
Diameter
in.
10
10
10
12
12
12
12
Boiler Water
l
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
kg
1941
2027.5
2524
2492
2652.5
2881
3117
less Burner Unit
lb
4280
4470.5
5565
5494.5
5849
6353
6873
Maximum
m
3
/h
44.78
51.74
61.88
69.06
77.11
82.87
89.77
Gas Rate
ft
3
/h
1582
1827
2185
2439
2723
2927
3170
Maximum Flue
m
3
/s
0.279
0.322
0.386
0.429
0.479
0.515
0.558
Gas Volume
ft
3
/min
591
682
818
909
1015
1091
1182
Flue Gas CO
2
/ Temperature
% / ēC
9.5 / 220
9.5 / 220
9.5 / 220
9.5 / 220
9.5 / 220
9.5 / 220
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
3
(1038Btu/ft
3
) gross or 34.9MJ/m
3
(935Btu/ft
3
) nett at
15ēC 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
8
9
10
11
12
13
14
Maximum
kW
390
450
540
600
670
720
780
Heat Output
Btu/hx10
3
1330
1535
1842
2047
2286
2457
2661
Minimum
kW
300
390
450
540
600
670
720
Heat Output
Btu/hx10
3
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
2.5
2.5
3.5
Resistance (at zero draught)
in w.g.
0.44
0.6
0.8
1.0
1.0
1.0
1.4
Minimum Draught at Smokehood mbar
0
0
0
0
0
0
0
Outlet (for max. output)
in w.g.
0
0
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 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
m
3
/s
0.252
0.290
0.348
0.387
0.432
0.465
0.503
Gas Volume
ft
3
/min
534
614
737
820
915
985
1065
Flue Gas CO
2
/ Temperature
% / ēC
13 / 220
13 / 220
13 / 220
13 / 220
13 / 220
13 / 220
13 / 220
Oil
Table 2 General Data
Gas
3
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
4
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.
5
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.
6
Viceroy GT -
Installation & Servicing
GENERAL
1
BOILER DIMENSIONS
Water flow
tapping
B
(to be welded)
Water return tapping
B
(to be welded)
L
22
125
140
650
1000
=
=
S
G
D
F
H
E
A
183
1
149
80
=
=
J
=
=
130
=
=
147
183
153
530
1013
1500
140
638
C
Drain
2"
tapped
(plugged)
Sludge
removal hole
2
1
/
2
"
(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
250
250
300
300
300
300
B
3"
3"
3"
4"
4"
4"
4"
C
135 - 175 - 190 - 240 - 250 - 290 or plain plate
D
235
235
235
254
254
254
254
E
1427
1427
1427
1447
1447
1447
1447
L
1505
1665
1825
1985
2145
2305
2465
S
1183
1343
1503
1663
1823
1983
2143
Deluxe
F
113.5
113.5
113.5
113.5
113.5
113.5
113.5
Control
G
355
355
355
355
355
355
355
Panel
H
195
195
195
195
195
195
195
J
755
755
755
755
755
755
755
Standard
F
127.5
127.5
127.5
127.5
127.5
127.5
127.5
Control
G
130
130
130
130
130
130
130
Panel
H
105
105
105
105
105
105
105
J
738
738
738
738
738
738
738
7
Viceroy GT -
Installation & Servicing
GENERAL
Air inlet
B
Air outlet
0.546 m
1.5 m
1 m
*
1 m
*
A
C
vic7072
Refer to notes above
Refer to notes above
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:
ˇ
Access around the boiler for servicing.
ˇ
Space to open the boiler front door.
ˇ
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
15
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
105
105
105
105
105
105
195
195
195
195
195
195
195
1500
2000
2000
2000
2500
2500
2500
A
B
C
Dimension
Boiler
Standard Control Panel
Deluxe Control Panel
m m
m m
m m
m m
8
Viceroy GT -
Installation & Servicing
GENERAL
2" tapped drain
connection
E
B flow connection
B return connection
D
1149
183
140
vic7073
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:
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 25ēC
within 100 mm of the floor, 32ēC at mid height and 40ēC within
100 mm of the ceiling.
4
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
1
/
2
" connection is provided for sludge removal at the
bottom of the boiler front section.
2
1
/
2
" tapped sludge
removal hole
183
500
vic7074
DE-SLUDGE CONNECTION
Boiler
GT 8 to GT 10
GT 11 to GT 14
B
3"
4"
D mm
235
254
E mm
1427
1447
Required area (cm
2
) 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).
9
Viceroy GT -
Installation & Servicing
GENERAL
5
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.
7
SEALED (PRESSURISED) SYSTEMS
6
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 11ēC (20ēF) 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
50
38
600 and above
50
50
10
Viceroy GT -
Installation & Servicing
GENERAL
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 11ēC (20ēF) 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 30ēC 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
GT 13
GT 14
Normal water flow rate
l/s
8.47
9.77
11.73
13.03
14.55
15.63
16.94
temperature difference 11ēC (20ēF) g.p.m.
111.77
128.96
154.75
171.95
192.01
206.34
223.53
Minimum water flow rate
l/s
2.66
3.07
3.69
4.09
4.57
4.91
5.32
temperature difference 35ēC (63ēF) g.p.m.
35.13
40.53
48.64
54.04
60.35
64.85
70.25
11
Viceroy GT -
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
7 26
25 7
10
9
11
3
6 7
6
18
20
7
19
13
7
17
4
5
7
7
7
Note. Minimum static head
requirements with limit thermostat
set at 110ēC (230ēF) 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.
LEGEND
1. Heating flow
2. Heating return
3. 3bar 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 7bar with indicator type
discharger
19. Pressure reducer (if mains press >5.5bar)
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
12
Viceroy GT -
Installation & Servicing
INSTALLATION
10 FLUING
According to the output, the difference between the temperature of
the flue gas and the ambient temperature can be as low as 160ēC.
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 flue. Please note that Viceroy GT 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: 80ēC (ambient temperature : 20ēC).
11 DIMENSIONAL INFORMATION REQUIRED FOR THE FLUE CONNECTION
45
1000mm min.
har5968
However, care must be taken to comply with any
applicable national or local regulations.
GT 8
390
0
0.184
0.193
220
250
GT 9
450
0
0.212
0.223
220
250
GT 10
540
0
0.255
0.267
220
250
GT 11
600
0
0.283
0.297
220
300
GT 12
670
0
0.316
0.332
220
300
GT 13
720
0
0.340
0.357
220
300
GT 14
780
0
0.368
0.386
220
300
Boiler
Heat
Output
Required
Draught
Mass Flow of Flue Gases
kg/s
Natural Gas
9.5% CO
2
Flue Gas
Temperature
(1) (2)
Chimney:
Minimum
Recommended
Diameter
kW
mbar
ēC
Ø min
m m
Fuel Oil
13% CO
2
1013
130
500
500
vic7075
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.
FLUE OUTLET
13
Viceroy GT -
Installation & Servicing
INSTALLATION
REAR
FRONT
vic7086
turbul
Baffle
Burner
door
insulation
vic7085
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 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)
- 12mm Allen key
- Cross head screwdriver
- 13, 19 and 24mm spanners
- Knife
- Hammer
- 22mm Box spanner
- JDTE 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.
Burner Door Opening and Fixings
vic7076
Base frame
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
IE20
IE 20
IE20
IE20
IE20
IE20
IE20
Boiler accessories in bulk
1
1
1
1
1
1
1
(contents according to model)
Baffles
IE30
IE31
IE31
IE32
IE32
IE33
IE33
Base insulation
IE51
IE53
IE53
IE55
IE55
IE57
IE57
Casing: common parts
IE10
IE10
IE10
IE10
IE10
IE10
IE10
Casing: varying parts
IE12
IE13 &
IE11 &
IE12 &
IE13(2)
IE11 &
IE12 &
IE14
IE13
IE13
IE14
IE13 (2)
IE 13 (2)
Wiring ducts
IE41
IE42
IE43
IE44
IE45
IE46
IE47
Control panel - Standard
FD167
FD167
FD167
FD167
FD167
FD167
FD167
- Deluxe
FD168
FD168
FD168
FD168
FD168
FD168
FD168
Burner door
1
1
1
1
1
1
1
Boiler
GT 8
GT 9
GT 10
GT 11
GT12
GT 13
GT 14
INST
ALLA
TION
14
Viceroy GT -
Installation & Servicing
INSTALLATION
2
2
3
M 12
M 12
vic7088
REAR
FRONT
GT 9, 11, 13
GT 8, 10, 12, 14
M 12
vic7087
1
2
14 PREPARING THE BASE FRAME AND FITTING THE BASE INSULATION
1. Fit the 2 rear attachment brackets
(in the body accessories pack)
and attach them onto the
framework using two M12 x 40
bolts, four washers and two nuts.
Caution: use the corresponding
holes according to the indications
on the framework.
2. Put the lower insulation in place
(fabric to top) packs IE 51 to IE 57.
Adapt length if necessary or fold
the lower insulation after the
casing has been completely
assembled.
Note.
For pre-assembled boilers proceed
to Frame 27.
15 POSITIONING THE REAR SECTION
1. Determine the required location of the
framework depending on the direction in
which the burner door will be opened and the
length of the burner.
2. Place the rear section on the framework and
support it with a wooden block. Attach it at the
brackets using two M12 x 40 bolts, four
washers and two nuts.
3. Carefully put the thermocord in place (body
accessories pack) in the sealing groove and
cut to the correct length.
Note.
Do not pull on the cord when it is being put in, to
avoid stretching and to preserve its thickness.
INST
ALLA
TION
15
Viceroy GT -
Installation & Servicing
INSTALLATION
vic7091
1
2
5
3
6
4
16 PREPARING THE REAR SECTION
1. Clean the nipple ports and nipples
with cleaning fluid.
2. Coat them with the lubricant
supplied with the sections.
3. Drive in the two nipples gently.
17 ASSEMBLING THE SPECIAL INTERMEDIATE SECTION
Note.
a. The section can be identified as having only three flueways.
b. This section must be positioned next to the rear section to ensure correct
flue gas path.
1. Place the special intermediate section onto the base frame. The arrow
marker points to the rear to denote the correct way to fit the section.
2. Fit the connections of the special 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. For safety reasons, insert an upper assembly rod (body accessories
pack) into the holes in the sections.
6. Insert the assembly tool through the nipples and tighten.
18 ASSEMBLING THE INTERMEDIATE AND FRONT SECTIONS
1. Proceed likewise for other
intermediate and front sections.
2. Leave the assembly tool in place
after fitting the front section.
1
vic7090
2
3
3
2
1
vic7092
INST
ALLA
TION
16
Viceroy GT -
Installation & Servicing
INSTALLATION
19 FITTING THE ASSEMBLY RODS AND UPPER CASING SUPPORTS
1. Fit the upper assembly rods (body accessories pack) in
the order given in the appropriate diagram.
2. Place the expansion spring and its washer on each rod
towards the rear. Stop tightening the nuts when the free
space between the threads is about 2 mm.
3. Fix the upper casing supports (pack IE 13) and the upper
crosspieces (packs IE 10, 11, 12, 14) with the assembly
rods. (body accessories pack) as shown in details 1, 2, 3
and 4.
4. Fit the lower assembly rods in the order given in the diagram
in the same manner.
5. Remove the assembly tool.
Lg=580
Lg=580
Lg=420
Lg=580
Lg=420
Lg=420
Lg=580
Lg=580
Lg=580
Lg=580
Lg=740
Lg=420
Lg=740
Lg=740
Lg=740
Lg=740
Lg=740
Lg=740
Lg=420
Lg=420
Lg=420
Lg=580
Lg=420
Lg=420
AVANT
VORN
ARRIERE
HINTEN
DETAIL 1
AVANT
VORN
ARRIERE
HINTEN
DETAIL 2
AVANT
VORN
ARRIERE
HINTEN
DETAIL 3
AVANT
VORN
ARRIERE
HINTEN
DETAIL 4
GT 8
GT 9
GT 10
GT 11
GT 12
GT 13
GT 14
FRONT
REAR
REAR
FRONT
REAR
FRONT
REAR
FRONT
REAR
FRONT
TOP VIEW
Lg 620
Lg 620
Lg 425
Lg 425
Lg 425
Lg 425
Lg 425
Lg 425
Lg 425
Lg 784
Lg 425
Lg 620
Lg 620
Lg 620
Lg 620
Lg 620
Lg 620
Lg 784
Lg 784
Lg 784
Lg 784
Lg 784
Lg 784
Lg 425
2
1
2
3
1
2
3
1
2
3
1
2
4
4
1
2
3
3
1
2
3
3
1
vic7077
INST
ALLA
TION
17
Viceroy GT -
Installation & Servicing
INSTALLATION
20 PREPARATION FOR FITTING THE FLUE CLEANOUT AND BURNER DOORS
1. Screw in and tighten the eight M12x50 studs
for the cleaning doors and the burner door
and the M12x85 studs for the hinges of the
flue cleanout doors. (short end into the
section)
2. Fit the hinges for the flue cleanout doors
(pack IE 20) using two M12x25 bolts,
serrated washers (DEI2) and nuts.
3. Fit the combustion chamber door hinge
(body accessories pack) on the left or the
right according to the direction in which the
door will be opened, and fix using three
M12x30 bolts and washers.
4. Fix the burner door guide bracket (body
accessories pack) using two M12x25 bolts
and washers (L12).
21 ASSEMBLING THE BURNER AND FLUE CLEANOUT DOORS
1. Position the burner door in place and
secure with four M12 nuts and washers.
2. Locate the hinge and secure with the
hinge pin.
3. Remove the three M12x30 bolts and washers on the side
the burner door is to be hinged.
4. Swing the hinge into place and secure to the burner door.
5. Leave the three M12x30 bolts and washers in the other
side of the burner door.
6. Fit the left and right hand flue cleanout doors in place with
their pins (pack IE 20)
Note.
Do not close and secure the doors at this time.
1
2
vis7093
3x
2x
1
2
vis7094
6
6
4
3
5
3 x M12x30
vis7095
INST
ALLA
TION
18
Viceroy GT -
Installation & Servicing
INSTALLATION
1
2
vis7093
3x
2x
22 POSITIONING THE FLUE BAFFLES
1. Install the upper (1), middle (2) and lower (3) + (4) baffles,
respecting the sequence of assembly given in the chart.
2. Important: Interlock the baffles one into another before
placing them in the flue way.
Baffles (by flue way)
Viceroy GT 8
Viceroy GT 9-10
Viceroy GT 11-12
Viceroy GT 13-14
pack IE 30
pack IE 31
pack IE 32
pack IE 33
Upper
8229-0010
2x8229-0010
then
then
8229-0022
2x8229-0010
1x8229-0022
3x8229-0010
Middle
8229-0011
2x8229-0011
then
then
8229-0023
2x8229-0011
1x8229-0023
3x8229-0011
Lower
8229-0012
2x8229-0012
then
then
8229-0024
2x8229-0012
1x8229-0024
3x8229-0012
1
2
4
3
and
Note. The part number of the baffles is marked on the casting.
3. Close the cleaning doors and secure with three M12
locknuts and washers.
23 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.
1
vic7098
3
vic7097
2
vic7096
INST
ALLA
TION
19
Viceroy GT -
Installation & Servicing
INSTALLATION
vic7101
3
2
2
1
2
2
GT11 - GT14
GT8 - GT10
1
vic7099
vic7100
4
3
5
5
2
3
3
5
2
5
3
24 FITTING THE SMOKEHOOD
1. Fix the flue outlet spigot (body accessories pack) to the
smokehood using four M12x40 bolts, nuts and washers.
2. Screw in the two threaded rods (body accessory pack)
M12x175 for the flue outlet.
25 ASSEMBLING THE FLOW AND RETURN TAIL PIPES
1. Fit eight M16 studs into the flow and return flange
faces on the rear section.
2. Fix the flow and return flanged tail pipes using
four M16 nuts for each flange with a gasket as
shown.
Note.
A. The flow tail pipe outlet must face upwards to
accommodate the flow switch.
B. The return flange for models GT11-14
incorporates a distributor tube and must be
fitted the correct way as shown.
3. Screw the flow switch into the flow tail pipe using
suitable compound ensuring the arrow on the
casing corresponds to the direction of water flow.
Note.
The flow switch may be fitted after conducting the
hydraulic test described in Frame 26 in order that
the tapping may temporarily be used for venting.
3. Secure the flue outlet onto the rear section with six M12 nuts
and washers.
4. Fit two M12 bolts and nuts on the smokehood for the
cleaning doors (see detail).
5. Secure the cleaning doors using four M12 and two washers
(L12) and two washers (M12).
INST
ALLA
TION
20
Viceroy GT -
Installation & Servicing
INSTALLATION
vic7078
2
1
3
26 HYDRAULIC TEST
1. Seal off the flow and return
connections.
2. Fit a suitable supply line with
valves and union connection.
3. Fit a suitable valve to vent the
boiler. (Temporary only.)
vic7079
4
6
5
7
8
9
10
bar
0
4. Fill the boiler then shut off the
supply water.
5. Shut off the inlet valve.
6. Close the vent valve.
7. Disconnect the supply water.
8. Connect the pressure system
water.
9. Open the fill valve.
10. Pressurise the boiler. Maintain
pressure for 30 minutes.
Any drop in pressure indicates a
leakage in the boiler body.
11. After successfully conducting the
test, release the pressure and
drain.
After assembling the boiler body, the installer must carry out a water
tightness test at a hydraulic pressure of 1.5 times the design pressure
for a period of 30 minutes. The test must be done at room temperature.
INST
ALLA
TION
21
Viceroy GT -
Installation & Servicing
INSTALLATION
1
2
vic7118
27 FITTING THE CASING SUPPORTS
1. Fix the lower casing supports to the framework using
one M8x25 bolt and lock washer for each support.
Note.
The quantity varies according to the boiler length.
28 INSTALLING THE INSULATING MATERIAL
1. Lay the insulation panels over the boiler.
2. Secure the insulation in place by tying each
strap to the lower casing support at each
side of the boiler.
Note.
The table below indicates the quantity of
insulation panels supplied for each boiler and
the appropriate position according to their
width.
3. Fit the rear insulation.
Note.
This will be held in place by the rear panels
when fitted later (Frame 35).
1
vic7102
HM 8x25
vic7117
Note.
For pre-assembled boilers loosen
the base frame securing bolts.
3
vis7103
Boiler
Body insulation width
Front
Rear
500
500
600
800
900
GT 8
1
1
GT 9
1
1
1
GT 10
1
1
1
GT 11
1
1
1
GT 12
1
2
1
GT 13
1
2
1
GT 14
1
2
1
INST
ALLA
TION
22
Viceroy GT -
Installation & Servicing
INSTALLATION
vic7104
1
3
2
1
2
3
vic7080
29 ASSEMBLING THE WIRING DUCTS AND FRONT TOP PANEL
1. Fit the left and right wiring ducts,
respecting the assembly direction
and attach each to the casing
support using one M5x12 bolt and
lock washer at each support.
2. Fit the cross pieces using two M5x12
bolts and lock washer.
3. Fit the front top panel and secure to
the wiring ducts using M5x12 bolts
and lock washers.
30 INSTALLING THE MAINS AND CONTROL WIRING
1. Route the mains supply in at the
rear, along one of the wiring ducts
and up through the opening in the
front top panel.
2. Route any remote sensor cables
similarly in the other wiring duct.
3. Secure the cables with the cable
ties.
INST
ALLA
TION
23
Viceroy GT -
Installation & Servicing
INSTALLATION
5
6
31 INSTALLING THE CONTROL PANEL - FD167 Standard
1. Route the sensors through the left or right hand opening
in the front top panel.
2. Route the burner leads through the other opening in the
front top panel.
3. Lower the control panel onto the location buttons nearer
the front and slide the control panel forwards.
4. Remove the three screws from the rear of the
control panel and remove the top/rear cover.
5. Secure the control panel to the casing top front
panel with two self tapping screws and shakeproof
washers provided.
6. Pull the mains cable and any other sensors into the
control panel through the appropriate opening
ready to make the connections.
3
4
REAR
FRONT
vic7081
32 INSTALLING THE CONTROL PANEL - FD168 Deluxe
1. Route the sensors through the left or right hand opening
in the front top panel.
2. Route the burner leads through the other openings in the
front top panel.
3. Lower the control panel onto the location buttons farther
away from the front and slide the control panel forwards.
4. Remove the two screws from the sides of the control
panel.
5. Tilt the control panel back.
6. Secure the control panel to the casing top front panel
with two self tapping screws and shakeproof washers.
7. Pull the mains cable and any other sensors into the
control panel through the appropriate opening ready to
make the connections.
Front
Rear
vic7105
3
4
5
vic7106
INST
ALLA
TION
24
Viceroy GT -
Installation & Servicing
INSTALLATION
vic7109
3
vic7108
2
1
2
33 INSTALLING THE SENSORS AND ROUTING THE BURNER CABLE
1. Route the burner cable inside the
front edge return of one side of the
casing side panels opposite the
burner hinges. (RH side shown for
clarity. See Frame 34.)
2. Insert the sensors into the sensor
pocket.
3. Loop the sensor leads back over the
sensor pocket.
4. Secure the leads with the spring clip.
34 ASSEMBLING THE CASING SIDE PANELS
1. Position the front side panels
(length 520) in the lower
casing supports, then hook
onto the wiring ducts.
2. Fix at the sides onto the lower
casing supports using M5x12
bolts and lock washers and at
the front top panel using self
tapping screws and lock
washers.
3. Fit the remaining side panels
in the order given in the table
below. Position each panel in
the lower casing supports
then hook onto the wiring
duct.
3
4
2
Boiler
Side panel width
Front
Rear
GT 8
520(IE10)
930(IE12)
GT 9
520(IE10)
480(IE13
610(IE14)
GT 10
520(IE10)
480(IE13)
770(IE11)
GT 11
520(IE10)
480(IE13)
930(IE12)
GT 12
520(IE10)
480(IE13)
480(IE13)
610(IE14)
GT 13
520(IE10)
480(IE13)
480(IE13)
770(IE11)
GT 14
520(IE10)
480(IE13)
480(IE13)
930(IE12)
INST
ALLA
TION
25
Viceroy GT -
Installation & Servicing
INSTALLATION
3
2
1
vic7112
view from rear
35 ASSEMBLING THE REAR PANELS
1. Hook the lower rear panel onto the side panel
buttons and secure onto the side panels using
two self tapping screws and lockwashers.
2. Hook the middle rear panel onto the side
panel buttons and secure onto the side panels
using two self tapping screws and lock
washers.
3. Hook the left and right upper rear panels onto
the side panel buttons and secure onto the
middle rear panel using one self tapping
screw and lock washer and onto the rear top
cover using two self tapping screws and lock
washers.
36 ASSEMBLING THE CASING TOP PANEL
1. Fix the top covers from front to rear in the order given in the table below.
2. Fix the first intermediate top cover (length 480) onto the wiring duct using
four M5x12 bolts and lock washers.
3. Fix the remaining top covers onto the wiring duct using two M5x12 bolts
and lock washers.
37 ASSEMBLING THE LOWER FRONT PANELS
1. Fit the lower front panel onto the
crosspiece (two self tapping
screws and lock washers.)
2. Fit the lower crosspiece assembly
by securing onto the side panels
using two self tapping screws and
lock washers.
3. Fit the burner upper front panel
onto the burner door and secure
using two M12x25 bolts and
washers.
Boiler
Front Top
Intermediate
Rear
Pack
Panel
Top Panel
Top Panel
Viceroy GT 8
480(IE10)
480
490
IE12
Viceroy GT 9
480(IE10)
480 480
170
IE13+IE14
Viceroy GT 10 480(IE10)
480 480
330
IE11+IE13
Viceroy GT 11 480(IE10)
480 480
490
IE12+IE13
Viceroy GT 12 480(IE10)
480 480 480
170
IE14+IE13
Viceroy GT 13 480(IE10)
480 480 480
330
IE11+IE13
Viceroy GT 14 480(IE10)
480 480 480
490
IE12+IE13
3
3
2
1
vic7110
vic71
11
4
3
2
INST
ALLA
TION
26
Viceroy GT -
Installation & Servicing
INSTALLATION
Boiler
Date of manufacture
Unit serial no.
XX - XX
Year
Week
(1)
vic7083
40 CONTROL PANEL (General)
Refer to Frames 52 or 54 for specific details of Standard or
Deluxe panels.
Electrical control panel, equipped with temperature control.
The control panel carton contains:
1 control panel complete with burner connection harness.
The control panel incorporates a boiler thermostat controller, a
thermometer and a safety thermostat.
38 ASSEMBLING THE FRONT PANELS
1. Hook the left and right lower front panels on the side
panel buttons.
2. Hook the front casing support (two slots) into the side
panel slots.
vic7082
39 NAMEPLATE
1. Affix the identification plate and CE
label (supplied in the instructions
bag) on the casing (on the left or right-
hand side) in an easily accessible
location.
The boiler thermostats - one controls the maximum boiler
operating temperature. The other controls the high/low
operation if a two stage burner is fitted.
The safety thermostat (with manual reset) - if the boiler
temperature rises abnormally (110ē), the safety thermostat cuts
off the burner electricity power supply.
WARNING. In this case, you must call your installer.
1
vis7113
3. Position the upper front cover lower edge behind the front
casing support and hook it over the front top cover.
3
2
INST
ALLA
TION
27
Viceroy GT -
Installation & Servicing
INSTALLATION
41 ELECTRICAL CONNECTIONS
WARNING. The electrical connections must be made by a
qualified professional. The electrical wiring has been carefully
checked in the factory and the internal connections of the
control panel must not be modified in any event.
The electrical connections should be made following the
information shown on the electrical diagrams delivered with
the unit and the directions given in the instructions.
The electrical connection must comply with standards in force.
The equipment must be powered by a circuit containing a
remote double-pole switch with opening > 3mm.
WARNING. The boiler must be earthed.
All connections must be made using the terminal blocks
provided for this purpose at the back of the boiler control panel.
Connections cables are brought inside the boiler through cut-
outs provided in the boiler back panel, which are large enough
for use of commercially available conduit if required.
These cables are secured at the back of the control panel using
cable clamps (cable clamps supplied in a separate pack) that
are to be installed on the sheet metal.
3
4
1
2
5
6
7
8
9
10
11
12
L
4
N
ALI
5
6
7
8
9
10
11
12
230 V / 50 Hz
N
L1
T1
T2
T6
T7
T8
S3
VA
3 x 0,75 mm
2
har7049
42 BASIC CONNECTIONS - FD167 Standard Control Panel
1. To gain access to the connection strip, unscrew the three
screws on the rear of the control panel and open the
panel.
2. Pass the connecting cables to the control panel through
the two cut-outs in the rear panel of the boiler and route
them to the front via the cable channels. (See Frame 30).
3. Pass the cables into the control panel through the
rectangular openings in the front top panel.
4. Secure the cables to the base of the control panel with the
cable clamps.
5. Connect the main supply to terminals 1, 2 and 3 of the
connecting strip as shown. (See also Frame 43)
3
5
1
4
2
12
11
10
9
8
7
6
5
4
VA
S3
T8
T7
T6
T 2
T1
L1
N
230V
50H
z
L
N
A
L
I
43 CONNECTING OPTIONAL FEATURES - FD167 Standard Control Panel
Flow Switch / Optional Safety Devices
If a flow switch or other safety control is to be
included in the system, connect the
device(s) in series in the safety circuit, (i.e.
between terminal 5 of the connecting strip
and burner terminal L1).
Burner Alarm Indicator
If an alarm indicator is to be included it
should be connected across terminal 12
(live) and terminal 4 (neutral).
Safety Thermostat Alarm Indicator System
1. The unused insulated terminal on the
safety thermostat may be used to
connect an alarm signal. (This terminal
becomes live if the safety thermostat
trips.)
2. Remove the insulation and connect the
live wire from the alarm indicator to the
unused terminal using a suitable spade
connector and the neutral to terminal 4.
12
11
10
9
8
7
6
5
4
VA
S3
T8
T7
T6
T 2
T1
L1
N
230V
50Hz
L
N
AL
I
har7050
INST
ALLA
TION
28
Viceroy GT -
Installation & Servicing
INSTALLATION
44 WIRING DIAGRAM - FD167 Standard Control Panel
VA
TCH1
TCH2
N
N
TS1
ZB
ZB
Dj6A
ZTB
(B)
L1
T1
BA
BA
T2
T6
T7
T8
S3
5
BA 4
2
L
BA
3
BA 6
BA 7
BA 8
BA 9
BA 10
BA 11
BA 12
B
Burner
BA
Connection strip
Dj 6 A
6 A circuit-breaker
L
Live
N
Neutral
TCH1
Stage 1 boiler thermostat
TCH2
Stage 2 boiler thermostat
TS1
Safety thermostat
VA
Alarm indicator
ZB
Burner switch
ZTB
STB-Test switch
Connecting strip
*
*
Optional
Connector
har7051
45 BASIC CONNECTIONS - FD168 Deluxe Control Panel
1. To gain access to the connection strip,
loosen the two screws located on either side
of the front of the panel.
2. Tilt the panel back.
3. Unscrew the two terminal strip cover screws
and remove the cover.
4. Pass the connecting cables to the control
panel through the two cut-outs in the rear
panel of the boiler and route them to the front
via the wiring ducts. (See Frame 30).
5. Pass the cables into the control panel
through the rectangular openings in the front
top panel.
6. Secure the cables to the base of the control
panel with the cable clamps.
7. Connect the mains to terminals 1, 2 and 3 of
the connecting strip as shown. (See also
Frame 46.)
N
L
VA
AL
I
230V
50
Hz
N
L
N
L
N
L
N
L
10
9
8
13
12
11
3
2
1
VA -
TS
5
4
7
6
CS
14
15
AL
IM
EN
T A
TI
ON
ST
RO
M
ZU
F
HR
M
AI
N
SUP
PL
Y
POM
PE
D
E
REC
YC
LA
GE
KE
SS
ELK
RE
IS
PU
M
PE
SH
UN
T
PUM
P
AL
IM
EN
T A
TI
ON
ST
RO
M
ZUF
H
R
M
AI
N
SUP
PL
Y
VO
Y A
NT
A
LA
RM
E T
S
TS
A
LA
RM
LE
UCH
TE
TS
A
LA
RM
IN
DI
CA
TO
R
VO
Y A
NT
A
LA
RM
E
TS
TS
A
LA
RM
LE
UC
HT
E
TS
A
LAR
M
IND
IC
A T
OR
CO
NT
ACT
D
E
SE
CUR
IT
E
SI
CH
ER
HE
IT
SK
ONT
AC
T
SA
FE
TY
C
ON
T A
CT
N
L
VA
AL
I
23
0V
50
Hz
N
L
N
L
N
L
N
L
VA
- T
S
CS
N
L
VA
AL
I
23
0V
50
Hz
N
L
N
L
N
L
N
L
VA
- T
S
1
3
1
2
6
INST
ALLA
TION
29
Viceroy GT -
Installation & Servicing
INSTALLATION
46 CONNECTING OPTIONAL FEATURES - FD168 Deluxe Control Panel
Circulating Pump
The CH circulating pump should be connected across
terminals 8, 9 and 10.
Shunt Pump
The shunt pump should be connected across terminals 11, 12
and 13.
Flow Switch / Optional Safety Device
If a flowswitch or other safety control is to be included in the
system, connect the device(s) in series in the safety circuit,
across terminals 14 and 15.
Burner Alarm Indicator
If an alarm indicator is to be included it should be connected
across terminals 6 and 7.
Safety Thermostat Alarm Indicator
If an alarm indicator is to be included it should be connected
across terminals 4 and 5.
N
L
VA
ALI
230V 50Hz
N
L
N
L
N
L
NL
10
9
8
13
12
11
3
2
1
VA - TS
5
4
7
6
CS
14 15
14 15
3
x
2
x
1
.
5
mm
2
mi
n
.
0
.
75
mm
2
mi
n
.
2
x
0
.
75
mm
2
mi
n
.
3
x
0
.
75
mm
2
mi
n
.
Ma
i
ns
supp
l
y
Safety
T/
stat
I
nd
i
ctor
(not
supp
li
ed)
2
x
0
.
75
mm
2
mi
n
.
Fl
ow
Sw
i
tch
(not
supp
li
ed)
Burner
A
l
arm
I
nd
i
cator
(not
supp
li
ed)
C
H
Pump
(not
supp
li
ed)
3
x
0
.
75
mm
2
mi
n
.
Shunt
Pump
(not
supp
li
ed)
har7053
Remove white
link wire
47 FITTING OPTIONAL FEATURES - FD168 Deluxe Control Panel
Hours Run Meters (IC8)
One or two optional hours run meters (stage 1
and 2) may be fitted on the front of the control
panel.
Proceed as follows:
1. Cut the cover with a cutter along the edges
of the coloured rectangle.
2. Pull out the two wires standing by in the
control panel.
3. Connect the wires to the hours run meter
(the wires are interchangeable).
4. Clip the hours run meter into the control
panel.
If the burner is a one-stage burner, the counter
displays the burner operating time.
If the burner has two stages, the hours run
meters display the operating time of each
stage.
Flue Gas Thermometer (ID28)
An optional flue gas thermometer may be fitted
on the front of the control panel.
Proceed as follows:
1. Cut the cover with a cutter along the edges
of the coloured rectangle.
2. Clip the thermometer into the opening.
3. Route the sensor to the back of the boiler
via the cable channel and insert it in the flue
gas pipe.
9
8
7
6
5
4
3
2
1
9
8
7
6
5
4
3
2
1
6A
har705
4
3
2
4
1
9
8
7
6
5
4
3
2
1
9
8
7
6
5
4
3
2
1
6A
har7055
3
2
1
INST
ALLA
TION
30
Viceroy GT -
Installation & Servicing
INSTALLATION
48 WIRING DIAGRAM - FD168 Deluxe Control Panel
har7056
A
WARNING. The Manual/Auto/Test switch may be put in either the Manual or Auto position for normal operation
Heating pump
B
Burner
BA
Connecting strip
CA
Cascade connection block
CH1
Stage 1 hours run meter (optional)
CH2
Stage 2 hours run meter (optional)
CS
Safety contact
Dj6A
6 A circuit-breaker
ECS
Domestic hot water control
P2
Shunt pump
RG
Connection block
TCH1
Stage 1 boiler thermostat
TCH2
Stage 2 boiler thermostat
TS
Safety thermostat
VA
Alarm indicator
VA-TS
Safety thermostat alarm indicator
VB1
Stage 1 operating indicator
VB2
Stage 2 operating indicator
ZB2
Stage 2 burner switch
ZEH
Summer/Winter switch
ZG
Main switch
ZT
Test switch
1
1a
1
2
2a
2
1
2
6
9
11
6
3
12
9
8
5
8
1
8
9
11
12
4
2
1
3
4
5
2
1
7
8
9
6
7
N L1
T1
T2
S3
1
2
B4
T6
T7
T8
B5
6
14
10
13
15
5
1a
1b
1b
1
1
1a
1b
2
2a
2b
1
2
1
2
2b
2a
6
1
14
15
2
4
9
7
4
4
10
7
2
1
1
4
2
2
3
4
3
7
1
2
1a
ZG
BA
DJ6A
ECS
CA
CA
ZT
ZEH
BA
BA
A
P2
RG
ZG
BA
BA
TS
BA
ZEH
TCH1
CA
ECS
RG
CA
ZT
CS
RG
BA
CA
CA
CA
BA
B
BA
BA
CH2
CH1
VA-TS
VA
VA
VB2
VB1
BA
BA
ZB2
TCH2
h
h
INST
ALLA
TION
31
Viceroy GT -
Installation & Servicing
INSTALLATION
49 BURNER WIRING HARNESS - FD167 Standard Control Panel
Control Panel Connections
Connect the terminal block with the male connecting
terminals to terminals 4-12 in the control panel.
12
11
10
9
8
7
6
5
4
VA
S3
T8
T7
T6
T 2
T1
L1
N
230V
50H
z
L
N
A
L
I
har7058
Burner Connections without Plug-in Connectors
In this case, the connectors supplied with the burner cable
must be rewired.
The diagram shows the wire numbers and terminals of the
burner connectors.
The table below specifies the way in which the cables are to
be connected to the burner control box.
B4 S3 T2 T1 N
g/y
L1
B5 T6 T7 T8
8
4
5
6
7
1
3
2
har7059
Burner Cable
The control panel is supplied with a burner
power supply cable, with one 7 and one 4-pin
European plugs on one end and a terminal
block with male connecting terminals on the
other end.
VIS5146
7-pin plug for
one-stage burners
or stage 1 of
two-stage burners.
4-pin plug for
stage 2 of the
burner.
Terminal block for
connecting to the
control panel.
Note.
If the electrical characteristics of the burner exceed the
following values:
-
start up current > 16 A or
-
P > 450 W (or 1/2 cont. hp. motor), or
-
I > 2A cos
= 0,7
The burner controls circuit must use a relay.
Burner
Wire
Connector
No.
From
Connection to the Burner Control Box
Terminal No.
L1
7
Permanent Live supply from the safety thermostat
Burner main supply
g/y
Earth connection
Earth connection
N
6
Neutral taken after On/Off Switch
Neutral terminal
T1/T2
5/4
Volt free contact of the stage 1 boiler thermostat
Insert in the control circuit of boiler stage 1
S3
8
Burner alarm indicator
Alarm output (live)
T6
1
Stage 2 boiler thermostat input
Insert in the control circuit of burner stage 2
T7
3
Stage 2 "boiler off" thermostat output
Connect only if the burner is of the modulating type
T8
2
Stage 2 "boiler on" thermostat output
Insert in the control circuit of burner stage 2
INST
ALLA
TION
32
Viceroy GT -
Installation & Servicing
INSTALLATION
50 BURNER WIRING HARNESS - FD168 Deluxe Control Panel
Burner Cable
The control panel is supplied with a burner power supply
cable with one 7 and one 4-pin European plugs which
connect to the burner connectors. The other end of the cable
connects to the control panel.
har7057
7-pin plug for
one-stage burners
or stage 1 of
two-stage burners.
4-pin plug for
stage 2 of the
burner.
Burner Connections without Plug-in Connectors
In this case, the connectors supplied with the burner cable
must be rewired.
The diagram shows the wire numbers and terminals of the
burner connectors.
The table below specifies the way in which the cables are to
be connected on the burner control box.
B4 S3 T2 T1 N
g
/
y
L1
B5 T6 T7 T8
6
5
4
3
1
2
4
1
2
3
har7061
Note.
If the electrical characteristics of the burner exceed the
following values:
-
start up current > 16 A or
-
P > 450 W (or 1/2 cont. hp. motor), or
-
I > 2A cos
= 0,7
The burner controls circuit must use a relay.
51 FUEL OIL OR GAS CONNECTIONS
Refer to the instructions supplied with the burner.
Burner
Wire
Connector
No.
From
Connection to the Burner Control Box
Terminal No.
L1
2
Permanent Live supply from the safety thermostat
Burner main supply
g/y
Earth connection
Earth connection
N
1
Neutral taken after On/Off Switch
Neutral terminal
T1/T2
3/4
Volt free contact of the stage 1 boiler thermostat
Insert in the control circuit of boiler stage 1
S3
5
Burner alarm indicator
Alarm output (live)
B4
6
Stage 1 On indicator (or hours run meter)
Stage 1 operation monitoring output (live)
B5
4
Stage 2 On indicator (or hours run meter)
Stage 2 operation monitoring output (live)
T6
1
Stage 2 boiler thermostat input
Insert in the control circuit of burner stage 2
T7
3
Stage 2 "boiler off" thermostat output
Connect only if the burner is of the modulating type
T8
2
Stage 2 "boiler on" thermostat output
Insert in the control circuit of burner stage 2
INST
ALLA
TION
33
Viceroy GT -
Installation & Servicing
INSTALLATION
52 COMMISSIONING - FD167 Standard Control Panel
IMPORTANT. Domestic hot water circuits (if they exist and
heating circuits must have been filled and bled, and leak
tightness tests must have been carried out on them, in
accordance with the instructions for the domestic hot water
calorifier (if existing) and boiler.
Refer to the following instructions and Frame 56 to start up the
boiler.
-
the instructions delivered with the burner.
-
the instructions delivered with the domestic hot water
calorifier, (if existing).
°C
30
0
I
6A
7
4
5
6
1
2
3
har7066
1.
Boiler ON/OFF switch.
Position .....ON
Position .....OFF
2.
TEST STB:
When held in the pressed (momentary use) position it
tests the safety thermostat.
3.
Boiler Thermostats:
Adjustment range 30-90ēC
For ON/OFF burners use 1st stage thermostat only.
For two stage burners set 2nd stage 5ēC below 1st
stage setting.
Built in stops may be reset (See Frame 53).
Factory set at 75ēC.
4.
Boiler Thermometer:
Indicates boiler flow water temperature.
5.
Flue Gas Thermometer:
Optional. Location if fitted.
6.
Circuit Breaker:
6 amp. Manual reset.
7.
Safety Thermostat:
Set at 110ēC. Manual reset.
53 BOILER THERMOSTAT (Maximum Setting Adjustment)
The boiler thermostats maximum setting are factory set at
75ēC. The fixed stop controlling the maximum setting is
adjustable as follows:
1. Carefully remove the control knob.
2. Pull out the pin from the back of the knob.
3. Relocate in the desired position.
4. Carefully replace the knob ensuring that the new pin
position is at the correct side of the stop.
5. Rotate the knob to the new desired maximum position to
check correct setting. (The setting numbers 3-9 are
approximately scaled to represent 30-90ēC).
9
8
7
6
5
4
3
9
8
7
6
5
4
har7063
INST
ALLA
TION
34
Viceroy GT -
Installation & Servicing
INSTALLATION
54 COMMISSIONING - FD168 Deluxe Control Panel
IMPORTANT. Domestic hot water circuits (if they exist and
heating circuits must have been filled and bled, and leak
tightness tests must have been carried out on them, in
accordance with the instructions for the domestic hot water
calorifier (if existing) and boiler.
Refer to the following instructions and Frame 56 to start up the
boiler.
-
the instructions delivered with the burner.
-
the instructions delivered with the domestic hot water
calorifier, (if existing).
9
10
11
12
8
5
6
4
3
2
1
7
30
l
0
6A
har7067
1.
Boiler ON/OFF switch:
Position .....ON
Position .....OFF
2a.
Burner Summer/Winter switch:
Winter
starts the burner.
Summer stops the burner.
2b.
Heating Pump Summer/Winter switch:
Winter
starts the heating pump.
Summer stops the heating pump.
3.
Three-Position Switch:
TEST STB:
When held in the pressed (momentary use) position it
tests the safety thermostat.
Note. If two stage burner control fitted operation will
continue on 1st stage after 2nd stage cut-off.
AUTO : automatic position:
Used for normal operation of the boiler.
: Manual Position:
May also be used for normal operation.
4.
Burner Alarm Indicator:
Indicates burner lockout.
5.
Stage Switch:
Used to select number of burner stages requested.
6.
Boiler Thermostats:
Adjustment range 30-90ēC.
For ON/OFF burners use 1st stage thermostat only.
For two stage burners set 2nd stage 5ēC below 1st
stage setting.
Built in stops maybe reset (See Frame 53).
Factory set at 75ēC
7.
Boiler Thermometer:
Indicates boiler flow water temperature.
8.
Flue Gas Thermometer:
Optional. Location if fitted.
9.
Safety Thermostat:
Set at 110ēC. Manual reset.
10.
Circuit Breakers:
6 amp. Manual reset.
11.
Stage 1 and 2 Indicators:
Illuminate when relevant thermostat calling for heat.
INST
ALLA
TION
35
Viceroy GT -
Installation & Servicing
INSTALLATION
55 COMMISSIONING AND TESTING
A. ELECTRICAL INSTALLATION
1. Checks to ensure electrical safety should be carried
out by a competent person.
2. ALWAYS carry out the preliminary electrical system
checks, i.e. earth continuity, polarity, resistance to earth
and short circuit, using a suitable meter.
B. FOR GAS INSTALLATION
1. The whole of the gas installation, including the meter,
should be inspected and tested for soundness and then
purged in accordance with the recommendations of the
relevant standards listed on page 4.
WARNING. Whilst effecting the required gas soundness test and purging air from the gas
installation, open all windows and doors, extinguish naked lights and DO NOT SMOKE.
56 INITIAL LIGHTING
1. Check that the system has been filled and the boiler is not
air locked - air in the boiler could damage the heat
exchanger.
2. Check that all the drain cocks are closed and any valves in
the flow and return are open.
3. Check that the GAS SERVICE COCK IS ON.
4. Unscrew the safety thermostat (overheat) reset button cap
(7) or (Deluxe model 9) and press the reset button.
5. Set the boiler thermostats (3) or (Deluxe model 6) to
maximum.
6. If Deluxe control panel fitted set the 3 position switch (3) to
Manual or Auto.
7. If Deluxe control panel fitted set the burner and pump
summer/winter switches (2) to the winter setting ( ).
8. Switch the electricity supply ON and check that all the
external controls are calling for heat. Set the main boiler
switch (1) to ON ( ).
9. The burner will commence the ignition sequence. If the
burner has failed to light then it will lock out. Press the reset
button to restart the ignition sequence.
10. Operate the boiler for 20 minutes and for gas fired boilers
check the gas rate (Table 1).
11. Refer to the burner instructions for specific operating
features.
12. Set the boiler thermostats (3) or (Deluxe model 6) to
appropriate settings ensuring the second stage is 5ēC lower
than the first stage if a 2 stage burner is fitted.
57 GENERAL CHECKS
Make the following checks for correct operation.
1. The correct operations of ANY secondary system controls
should be proved. Operate each control separately and
check that the main burner or circulating pump, as the
case may be responds.
2. Water circulation system;
a. With the system HOT examine all water connections for
soundness.
b. With the system still HOT, turn off the gas or oil burner,
water and electricity supplies to the boiler and drain
down to complete the flushing process.
c. Refill and vent the system, clear all air locks and again
check for water soundness.
d. Balance the system.
3. Finally set the controls to the User's requirements.
Note.
We advise never to set the boiler thermostat below position 4
(approx. 40ēC) in order to avoid the risk of combustion products
condensing on the walls of the boiler.
58 HANDING OVER
ROUTINE OPERATION
Describe the function of the boiler and system controls and
show how they are adjusted and used.
Hand these Installation and Servicing Instructions, User's
Instructions and Log book to the customer and request him to
keep them in a safe place for ready reference.
IMPORTANT. Point out the owner that the boiler must have
regular maintenance and cleaning, at least annually, in order to
ensure reliable and efficient operation. Regular attention will
also prolong the life of the boiler and should preferably be
performed at the end of the heating season.
Recommend that a contract for this work should be made with
the regional gas authority or a CORGI registered heating
installer for gas fired boilers.
INST
ALLA
TION
36
Viceroy GT -
Installation & Servicing
INSTALLATION
VIC7115
Vacuum
cleaner
59 MAINTENANCE
WARNING
The operations described below shall always be performed
with the boiler and the power supply switch off.
The boiler front panel has to be removed to access the
various devices to be maintained and checked.
1. Unhook the front panels and remove.
Cleaning the Casing Material
Use a soapy solution and sponge only. Rinse with clean
water and dry with chamois leather or soft cloth.
60 CLEANING THE FLUEWAYS
1. Close off the fuel supply to the burner.
2. Ensure that the boiler has been cooled
to ambient temperature.
3. Isolate the mains supply to the boiler
and burner.
4. Disconnect the cable and supply pipe
to the burner.
5. Open the combustion chamber (four
nuts) and flue way (three nuts) doors
by removing the nuts.
6. Remove the flue way baffles.
7. Thoroughly clean the flue ways and
baffles.
8. Release and allow to swing down the
rear cleanout covers by undoing the two
upper nuts and loosening the two lower
nuts. Dispose of the debris/soot that
may have accumulated.
9. Replace the rear cleanout covers after
first inspecting and if necessary
replacing the seal.
10. Brush out the combustion chamber
and vacuum the soot from beneath the
flue ways.
11. Replace the flue baffles into the flue
ways (refer to Frame 22 for number
and location).
12. Check the condition of the combustion
chamber door insulation and replace if
necessary.
13. Check the condition of the combustion
chamber door seal and replace if
necessary.
14. Refer to the burner manufacturer's
Instructions for burner maintenance.
vic7082
Brush and
vacuum cleaner
Brush
vic7114
Vacuum
cleaner
vic7116
servicing
37
Viceroy GT -
Installation & Servicing
INSTALLATION
61 SYSTEM MAINTENANCE
Water Level
Check the water level in the installation regularly and if
necessary top it up without allowing a sudden inlet of cold
water into the hot boiler.
The operation should only be necessary a few times per
season; if it has to be done more frequently, there is probably
a leak which should be found and corrected without delay.
Safety Devices
Check that safety devices, particularly the heating circuit safety
valve, are working correctly at regular intervals and at least when
the boiler is cleaned.
Draining
It is recommended that the installation should not be emptied
unless absolutely necessary.
For example: when leaving for several months and/or there is a
risk of frost in the building.
62 SAFETY
For boilers with gas burners:
It is the law that any service work must be carried out by a
registered CORGI installer.
WARNING. Always turn off the gas supply at the gas service
cock, switch off and disconnect the electricity supply to the
appliance and any external controls before servicing.
IMPORTANT. After completing the servicing or replacement of
components always:
ˇ
Test for gas soundness.
ˇ
check the water system is correctly filled and free of air. Air
in the boiler could cause damage to the heat exchanger.
ˇ
With the system hot examine all water connections for
soundness.
ˇ
Check the gas rate and measure the combustion CO/CO
2
content.
ˇ
Complete the boiler log book.
ˇ
Carry out functional checks as appropriate.
63 SERVICING SCHEDULE
To ensure the continued safe and efficient operation of the
appliance it is recommended that it is checked at regular
intervals and serviced as necessary. The frequency of
servicing will depend upon the installation condition and
usage but should be carried out at least annually.
Caradon Ideal Limited does not accept any liability resulting
from the use of unauthorised parts or the repair and servicing
of appliances not carried out in accordance with the
Company's recommendations and specifications.
1. Light the boiler and carry out function checks, noting any
operational faults.
2. Run the boiler for 10 minutes and then check the burner
rate.
3. Optional test for gas fired boilers - Connect a suitable gas
analyser to the sampling point fitted in the flue adapter. For
correct boiler operation the CO/CO2 ratio of the flue gas
should not be greater than 0.004 ratio. If this is the case
and the gas input is at least 90% of the nominal, no further
action need be taken. If not proceed to 4.
4. Remove and clean the burner.
5. Inspect the heat exchanger through the burner opening.
Clean the flueways.
6. Check that the flue terminal is unobstructed and that the
flue system is sealed correctly.
7. After completion of servicing refer to previous frame for
reference to final safety checks.
SER
VICING
38
Viceroy GT -
Installation & Servicing
NOTES
39
Viceroy GT -
Installation & Servicing
NOTES
Ideal Boilers, P.O. Box 103, National Ave, Kingston upon Hull,
HU5 4JN. Telephone: 01482 492 251 Fax: 01482 448 858.
Registration No. London 322 137.
July 2006
UIN 200 284 A03
Technical Training
Caradon Ideal Limited pursues a policy of continuing
improvement in the design and performance of its products. The
right is therefore reserved to vary specification without notice.
The Ideal Boilers Technical Training Centre offers a series of first class training courses for domestic, commercial and
industrial heating installers, engineers and system specifiers. For details of courses please ring: .......... 01482 498 432
Ideal Commercial/Technical Helpline: 01482 498 376
www.idealboilers.com