156830-2.pmd

Ideal Viscount GTE

- Installation, Assembly & Servicing

Contents

1. General ........................................................................ 2

1.1 Technical Specifications of Combination Boilers .. 3
1.2 Main Dimensions .................................................. 4

2. Installing The Boiler ................................................... 5

2.1 Boiler Location ...................................................... 5
2.2 Ventilation ............................................................. 5

3. Assembly .................................................................... 5

4. Hydraulic Connections .............................................. 6

4.1 Dimensional Information Required ....................... 6
4.2 Installation Recommendations ............................. 6
4.3 Filling the System ................................................. 7
4.4 Sludge Removal ................................................... 7

5. Chimney Connection ................................................. 7

5.1 Flue Size ............................................................... 7
5.2 Connecting to the Flue ......................................... 8

6. Assembly of Viscount GTE Boilers .......................... 9

7. Control Panel ............................................................ 41

7.1 Standard ............................................................. 41
7.2 Deluxe ................................................................. 47

8. Fuel-Oil or Gas Connections .................................. 54

9. Servicing and Maintenance ..................................... 54

9.1 Cleaning .............................................................. 54
9.2 Cleaning the Casing Material ............................. 57
9.3 Precautions Required in the Case of Long ......... 57

Boiler Stops (one or more years)
9.4 Precautions Required if the Heating is ............... 57

Stopped when there is a Risk of Freezing

10. Burner Maintenance .............................................. 57

11. System Maintenance .............................................. 57

11.1 Water Level ....................................................... 57
11.2 Draining ............................................................. 57

12. Identification Plate ................................................. 57

GENERAL

The boilers of the Viscount GTE range are pressurised hot water
boilers designed for connecting to a flue pipe which require a
separate automatic fuel-oil or gas burner. The heat output of
Viscount GTE boilers is between 754 and 1450 kW.
Models available :
·

Viscount GTE
Boiler with standard control panel designed to be connected
to the electrical cabinet.

Viscount GTE De Luxe
Boiler with "De Luxe" control panel, providing additional
features including running lights and extra wiring facilities.

Option Kits:
Flue Gas Thermometer

Pack ID28

Hour Run Meter

Pack IC8

M.T.H.W. Kit

Pack CM21

WARNING

The boiler shall be assembled and installed by a qualified professional only.
Strict compliance with these assembly, installation and maintenance instructions is a precondition for the correct

operation of the boiler

CONFORMITY / MARKING

This Product complies with the requirements of the following European directives and standards:
-

90.396 CEE Gas Appliance Directive Relevant standard : EN 303.1 / EN 303.2 / EN 304.

73.23 CDD Low Voltage Directive Relevant standard : EN 60.335.1.

89.336 CEE Electromagnetic Compatibility Directive Relevant standard : EN 50.081.1 / EN 50.082.1 / EN 55.014.

VIS5054

VIS5055

Ideal Viscount GTE -

Installation, Assembly & Servicing

1.1 Technical Specifications

Boiler:
Maximum operating pressure

6 bar

Maximum operating temperature

100ºC

Notes:
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.
The gas rate at calorific values differing from the standard quoted
above may be calculated by direct proportion. CALORIFIC VALUE:
38.5 MJ/m

(1,035 Btu/ft

Boiler thermostat setting 30 - 85ºC
Safety thermostat setting 110ºC

Boiler Size (no. of sections)

Maximum heat output

Minimum heat output

Boiler water content

Hydraulic resistance at 15K

Combustion chamber
Resistance (at zero draught)

Boiler Dry weight less
Burner unit

Maximum oil rate

Maximum flue gas volume (oil)*

Maximum gas rate

Maximum flue gas volume (gas)*

812

2770

754

2573

655

144

2.3

0.92

3217.5

7094.5

82.73

18.2

0.51

1081

84.4

2980

0.57

1208

870

2968

812

2770

693

152

34.7

13.8

2.4

0.96

3430

7563

88.64

19.5

0.55

1166

90.4

3192

0.61

1293

928

3166

870

2968

731

161

5.6

2.5

3629

8002

94.55

20.8

0.59

1250

96.4

3403

0.65

1377

986

3364

928

3166

769

169

2.6

1.04

3814

8410

100.5

22.1

0.62

1314

102.4

3616

0.69

1462

1044

3562

986

3364

807

177

17.5

2.7

1.08

3950

8710

106.4

23.4

0.66

1399

108.5

3831

0.73

1547

1102

3760

1044

3562

845

186

7.6

2.85

1.14

4127.5

9101

112.3

24.7

0.70

1483

114.5

4043

0.77

1632

1160

3958

1102

3760

905

199

21.5

8.6

1.2

4368.5

9632.5

118.2

0.73

1547

120.5

4255

0.81

1717

1218

4156

1160

3958

943

207

23.7

9.5

3.1

1.24

4567

10,070

124

27.3

0.77

1632

126.5

4466

0.85

1801

1276

4354

1218

4156

981

216

10.4

3.2

1.28

4755

10,485

130

28.6

0.81

1717

132.5

4678

0.89

1886

1334

4552

1276

4354

1019

224

28.3

11.3

3.3

1.32

4950.5

10,122

135.9

29.9

0.84

1780

138.6

4894

0.94

1992

1392

4749

1334

4552

1057

232

12.4

3.4

1.36

5140

11,334

142

31.2

0.88

1865

144.6

5106

0.98

2077

1450

4947

1392

4749

1095

241

33.5

13.4

3.5

1.4

5340

11,775

147.7

32.5

0.92

1950

150.6

5317

1.02

2162

Btu/h x 10

gal

mbar

in.w.g.

mbar

in.w.g.

I/h

gal/h

/sec

/min

/sec

/min

* 13% CO2 at 210C

* 9.5% CO2 at 210C

Ideal Viscount GTE

- Installation, Assembly & Servicing

GENERAL

1.2 Main Dimensions

Viscount GTE

Min. height for sweeping = 850

Flow detector

1566

543

496

370

Ø F

815

1080

200

420

616

791

565

17,5

3/4"

140

370

208

240

Max. 500

Max. 700

Burner centre line

610

Ø E

300

223

100

741

The sizes are given in mm

Plain plate, requires cutting. Maximum

cut-out 500 x 700m

Length required for clearing the

water distributing tube

Dimension representing the end of the

100 mm long chimney connection

Note: with models 21, 22, 23, 24 and

25, a plain plate which must be cut out

is supplied without the 100 mm

chimney connection.

G =

VIS5056

(mm)

B (mm)

C (mm)

D (mm)

E (weld)

F (mm)

G (mm)

H (mm)

K** (mm)

(mm)

M (mm)

De Luxe

Standard

De Luxe

Standard

De Luxe

Standard

(mm)

U (mm)

GTE Boiler

1674

1744

1488

217

139.7

450

-2

2105

259

355

130

175

1760

1670

1483

2132.5

1785

1744

1488

188

139.7

450

150

-31

-19

2245

324

355

130

175

1760

1670

1594

2243.5

1896

1966

1488

189

139.7

450

150

-30

-18

2355

269

355

130

175

1760

1670

1705

2354.5

2007

1966

1488

210

139.7

500

370

-9

2445

321

355

130

175

1760

1670

1816

2465.5

2188

1504

236

159

500

370

-8

2555

265

355

130

175

1760

1670

1927

2576.5

2229

2188

1504

257

159

500

370

2645

299

355

130

175

1760

1670

2038

2687.5

2380

2450

1504

208

159

500

650

-36

-24

2845

269

355

130

175

1760

1670

2189

2838.5

2491

2450

1504

209

159

650

-35

-23

2955

324

355

130

175

1760

1670

2300

2949.5

2602

2672

1504

230

159

650

-14

-2

3045

269

355

130

175

1760

1670

241

3060.5

2713

2672

1504

231

159

980

-13

-1

3155

324

355

130

175

1760

1670

2522

3171.5

2824

2894

1504

252

159

980

3245

249

355

130

175

1760

1670

2633

3282.5

2935

2894

1504

253

159

980

3355

303

355

130

175

1760

1670

2744

3393.5

(mm)

R (mm)

S (mm)

Ideal Viscount GTE -

Installation, Assembly & Servicing

INSTALLATION

INSTALLING THE BOILER

2.1 Boiler Location

For the assembly and because of their design, GTE boilers require
no special base or stand and their closed furnace system means
that the floor need not have refractory properties. All you have to

ensure is that the floor can support the weight of the boiler when it
is fitted for operation. If the boiler location is not determined precisely,
leave enough space around the boiler to facilitate monitoring and
maintenance operations.

0.85 m

min.

0.281 m

1.566 m

1.172 m

0.195 m

Air outlet

Air inlet

VIS5057

300

Boiler

body

D min.

(1)

VIS5058

Straight connection (not supplied)

Angled connection (not supplied)

(1)

In order to facilitate subsequent work on the boiler
(replacing the water distributing tube etc.) use a flanged
connection from the boiler to the system, making sure you
comply with minimum clearance dimension D.

If A = 1.2 m (door opening side), A' = 0.5 m
If A = 0.5 m, A' = 1.2 m (door opening side) : adapt the dimensions
on the basis of the dimensions of the burner when the door is
open.
B = 1.5 m : adapt the dimensions on the basis of the dimensions
of the burner.

GTE

2105

2245

2355

2445

2555

2645

2845

2955

3045

3155

3245

3355

259

324

269

321

265

299

269

324

269

324

249

303

Cmin.

300

436

656

936

1266

Dmin.

136

356

636

966

2.2 Ventilation

The ventilation shall comply with applicable regulations, particularly
codes of practice.
Detailed recommendations for air supply are quoted in B.S. 6644.

Please note : remember that boilers installed in or close to rooms
in which the atmosphere is polluted with chlorine or fluorine
compounds may be subject to high corrosion.
For example : hairdressing salons, industrial premises (solvents),
cooling equipment, etc.
Boiler installed in such locations shall not be covered by the warranty.

Ideal Viscount GTE

- Installation, Assembly & Servicing

ASSEMBLY

For boiler assembly refer to relevant later pages of this instruction book.

HYDRAULIC CONNECTIONS

4.1 Dimensional Information Required

1080mm

200mm

Heating return:

- 14 to 17 sections : 139.7 - 5"

- 18 to 25 sections : 159 - 6"

requires welding

Draining outlet

3/4" tap

Heating outlet:
- 14 to 17 sections : 139.7 - 5"
- 18 to 25 sections : 159 - 6"
requires welding

* dimension without connection
(see figure on page 5,
connection 1 or 2)

VIS5059

GTE

C (mm)

1488

1504

D (mm)

217

188

189

210

236

257

208

209

230

231

252

253

H (mm)

-2

-31

-30

-9

-8

-36

-35

-14

-13

4.2 Installation Recommendations

The installation of the boiler MUST be in accordance with the
following British Standards and Codes of Practice:
BS. 799 Pts. 4, 5, 6 & 7

Oil Burning Equipment

BS. 5410 Pts. 2 & 3

Installations for Space Heating and Hot
Water Supply

BS. 5449 PT. 1

Hot Water Systems

BS. 5854

Flues and Flue Structures in Buildings

BS. 5885 Pt. 1

Gas Burners - with outputs of 60kW
upwards

BS. 6644

Installation of Gas Fired Boilers

BS. 6880

Low Temperature Hot Water
Heating Systems

BS. 6891

Low Pressure Gas Pipework

British Gas

Industrial Gas Fired Boilers and

Publication No. IM.11

Air Heaters

General
Recommendations relating to the water system are contained in
BS. 5449 Pt. 1, BS. 1, BS. 5401 Pt.2, and BS. 6880.
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.
All electrical wiring MUST comply with the current I.E.E. regulations
for the electrical equipment of buildings. In the interests of safety, a
competent installer should be employed to effect the installation of
the appliance. Manufacturer's notes must NOT, in any way, be taken
as over riding statutory obligations.

Ideal Viscount GTE -

Installation, Assembly & Servicing

ASSEMBLY

4.3 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.
VERY IMPORTANT :
Instructions for starting up the boiler for the first time after the
system is fully or partly drained :

NOTE:

Never replace a boiler in an existing system
without carefully rinsing the system first. Install a
sludge trap on the return pipe, very close to the
boiler.

If all the air is not bled naturally to an expansion vessel which opens
out onto the air, the system must include manual bleeder valves, in
addition to automatic bleeder valves with the capability to bleed the
system by themselves when it is operating. The manual bleeder
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. 5449 Pt. 2 and BS. 6880.

4.4 Sludge Removal

A tapped ø 2" hole with a plug has been provided on the bottom of
the front of the boiler. Fit a quarter-turn valve on the opening to
remove the sludge.
Sludge removal leads to the draining of large quantities of water, so
remember to refill the system after the operation.

586mm

150mm

2" tapped sludge

removal hole

VIS5060

CHIMNEY CONNECTION

The high-performance features of modern boilers and their use in
specific conditions as a result of the advance in burner technology
(e.g. first-stage or low modulation range operation) lead to very low
flue gas temperatures (less than 160°C).
This requires :
-

Flue insulation.

the use of flue pipes designed to enable the flow of
condensates which may result from such operating modes,
in order to prevent damage to the chimney.

the installation of a draining tee at the foot of the chimney.

The use of a draught moderator is recommended as well.

5.1 Flue Size

Refer to applicable regulations while determining the size and height
of the flue. Please note that GTE boilers have pressurised and tight
furnaces and that the pressure at the outlet must not exceed 0 mbar,
unless special sealing precautions have been taken, for instance in
order to connect a static condenser.
Detailed recommendations relating to the design of flues for GAS
fired appliances are quoted in BS. 6644 and British Gas Publication
No. IM11, whilst BS. 5410 Pt. 3 similarly applies to OIL fired boilers.

Ideal Viscount GTE

- Installation, Assembly & Servicing

ASSEMBLY

5.2 Connecting to the flue

The connection shall be removable, and offer minimum load losses,
i.e. it must be as short as possible with no sudden change in section.
Its diameter shall always be at least equal to that of the boiler outlet,
i.e. :
-

ø 450 mm for 14-16 sections

ø 500 mm for 17-20 sections

Boilers with 21-25 sections are supplied with a plain plate.
The maximum cutout dimensions are 500 x 700 mm.

Fit a measuring point (ø 10 mm hole) on the flue, in order to adjust
the burner (combustion check).

815mm

chimney

connection

586mm

VIS5061

GTE

F (mm)

450

500

K (mm)

-19

-18

-24

-23*

-2*

-1*

20*

21*

plain

plate

plain

plate

plain

plate

plain

plate

Plain

plate

* Dimension representing the end of the 100 mm long chimney connection.

Note: with models 21, 22, 23, 24 and 25 a plain plate which requires cutting out is supplied without the 100 mm long chimney connection.

Ideal Viscount GTE -

Installation, Assembly & Servicing

ASSEMBLY

ASSEMBLY OF VISCOUNT GTE BOILERS

IMPORTANT

Important : Assemble the boiler in the
order given by the numbers of each figure,
in compliance with all the instructions.

Packaging :

Before starting to assemble the boiler, refer to the table below to
check if you have received all the packages required.

Boiler Body and Accessories

GTE boiler Number of sections

Assembled boiler body (contents depend upon model)

Cleaning tool kit (contents depend upon model)

Boilers supplied with an assembled body: start assembly from figure 11

GTE boiler Number of sections

Frame (dimensions depend upon model)

Rear section

Normal intermediate section

Special intermediate section

Front section