Viscount GTE. Installation, Assembly and Servicing. Oil, Gas or Dual Fuel Fired Boilers

Transcription

1 Viscount GTE Installation, Assembly and Servicing Oil, Gas or ual Fuel Fired oilers Assembly and Installation Instructions for Ideal Viscount Oil, Gas or ual Fired heating boilers should be read in conjunction with the general technical data tables enclosed and any other technical publication supplied with the burner. AUTION: 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 A, 05/0

2 0 0 I 0 I 0 I 0 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 ontents. General.... Technical Specifications of ombination oilers... Main imensions.... Installing The oiler oiler Location Ventilation 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 75 and 50 kw. Models available : Viscount GTE oiler with standard control panel designed to be connected to the electrical cabinet.. Assembly Hydraulic onnections imensional Information Required Installation Recommendations Filling the System Sludge Removal himney onnection Flue Size onnecting to the Flue... 8 VIS505 Viscount GTE e Luxe oiler with e Luxe control panel, providing additional features including running lights and extra wiring facilities. 6. Assembly of Viscount GTE oilers ontrol Panel Standard eluxe Fuel-Oil or Gas onnections Servicing and Maintenance leaning leaning the asing Material Precautions Required in the ase of Long oiler Stops (one or more years) 9. Precautions Required if the Heating is Stopped when there is a Risk of Freezing 0. urner Maintenance System Maintenance Water Level raining Identification Plate Option Kits: Flue Gas Thermometer Hour Run Meter M.T.H.W. Kit Pack I8 Pack I8 Pack M VIS5055 ONFORMITY / MARKING This Product complies with the requirements of the following European directives and standards: EE Gas Appliance irective Relevant standard : EN 0. / EN 0. / EN Low Voltage irective Relevant standard : EN EE Electromagnetic ompatibility irective Relevant standard : EN / EN / EN Ideal Viscount GTE - Installation, Assembly & Servicing

3 . Technical Specifications of ombination oilers oiler: Maximum operating pressure : 6 bar Maximum operating temperature : 00º oiler thermostat setting 0-85º Safety thermostat setting 0º oiler Size (no. of sections) Maximum heat output kw tu/h x Minimum heat output kw tu/h x 0 I oiler water content gal Hydraulic resistance at 5K mbar in.w.g ombustion chamber Resistance (at zero draught) mbar in.w.g oiler ry weight less urner unit kg lb , , , ,59 Maximum oil rate I/h gal/h Maximum flue gas volume (oil)* * % O at 0 Maximum gas rate m /sec ft /min m /h ft /h Maximum flue gas volume (gas)* * 9.5% O at 0 m /sec ft /min Notes: Fuel rates and flue gas data relate to maximum output ratings. Gas firing data relates to the use of NATURAL GAS ONLY. etails for the use of LPG are available on request from aradon Ideal Ltd. The gas rate at calorific values differing from the standard quoted above may be calculated by direct proportion. ALORIFI VALUE: 8.5 MJ/m (,05 tu/ft ). Ideal Viscount GTE - Installation, Assembly & Servicing

4 Ideal Viscount GTE - Installation, Assembly & Servicing 08 S 566 GTE oiler A (mm) (mm) (mm) (mm) Ø E (weld) Ø F (mm) G (mm) H (mm) K** (mm) L (mm) M (mm) e Luxe P (mm) Standard e Luxe R (mm) Standard e Luxe S (mm) Standard T (mm) U (mm) 08 Flow detector ØE 66 K 080 ØF ØE 00 7 H M G P Min. height for sweeping = 850 A T urner centre line 70 7 U L * * * * * R 7, Max Max /" The sizes are given in mm VIS5056 * Plain plate, requires cutting. Maximum cut-out 500 x 700m G= Length required for clearing the water distributing tube ** imension representing the end of the 00 mm long chimney connection Note: with models,,, and 5, a plain plate which must be cut out is supplied without the 00 mm chimney connection. Viscount GTE. Main imensions GENERAL

5 INSTALLATION. INSTALLING THE OILER. oiler 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. oiler body 0.85 m min m Air outlet min. () 00 VIS5058. Straight connection (not supplied). Angled connection (not supplied) Air inlet () 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. A.7 m A L.566 m VIS5057 M 0.8 m If A =. m (door opening side), A = 0.5 m If A = 0.5 m, A =. m (door opening side) : adapt the dimensions on the basis of the dimensions of the burner when the door is open. =.5 m : adapt the dimensions on the basis of the dimensions of the burner. GTE L M min min Ventilation The ventilation shall comply with applicable regulations, particularly codes of practice. etailed recommendations for air supply are quoted in.s. 66. 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. oiler installed in such locations shall not be covered by the warranty. Ideal Viscount GTE - Installation, Assembly & Servicing 5

6 ASSEMLY. ASSEMLY For boiler assembly refer to relevant later pages of this instruction book.. HYRAULI ONNETIONS. imensional Information Required raining outlet /" tap Heating outlet: - to 7 sections : 9.7-5" - 8 to 5 sections : 59-6" requires welding Heating return: - to 7 sections : 9.7-5" - 8 to 5 sections : 59-6" requires welding H* 080mm 00mm * dimension without connection (see figure on page 5, connection or ) VIS5059 GTE (mm) (mm) H (mm) Installation Recommendations The installation of the boiler MUST be in accordance with the following ritish Standards and odes of Practice: S. 799 Pts., 5, 6 & 7 Oil urning Equipment S. 50 Pts. & Installations for Space Heating and Hot Water Supply S. 59 PT. Hot Water Systems S. 585 Flues and Flue Structures in uildings S Pt. Gas urners - with outputs of 60kW upwards S. 66 Installation of Gas Fired oilers S Low Temperature Hot Water Heating Systems S. 689 Low Pressure Gas Pipework ritish Gas Industrial Gas Fired oilers and Publication No. IM. Air Heaters General Recommendations relating to the water system are contained in S. 59 Pt., S., S. 50 Pt., and S The following must be conformed with: urrent uilding Regulations and lean 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 ompany 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. 6 Ideal Viscount GTE - Installation, Assembly & Servicing

7 ASSEMLY. 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 : 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 S. 59 Pt. and S Sludge Removal A tapped ø " 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. 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. 586mm " tapped sludge removal hole 50mm VIS HIMNEY ONNETION 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 60 ). 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. 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. etailed recommendations relating to the design of flues for GAS fired appliances are quoted in S. 66 and ritish Gas Publication No. IM, whilst S. 50 Pt. similarly applies to OIL fired boilers. Ideal Viscount GTE - Installation, Assembly & Servicing 7

8 ASSEMLY 5. onnecting 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 50 mm for -6 sections - ø 500 mm for 7-0 sections - oilers with -5 sections are supplied with a plain plate. The maximum cutout dimensions are 500 x 700 mm. Fit a measuring point (ø 0 mm hole) on the flue, in order to adjust the burner (combustion check). F Ø chimney connection 85mm K 586mm 586mm VIS506 GTE ø F (mm) plain plate plain plate plain plate plain plate Plain plate K (mm) * -* -* 0* * * imension representing the end of the 00 mm long chimney connection. Note: with models,,, and 5 a plain plate which requires cutting out is supplied without the 00 mm long chimney connection. 8 Ideal Viscount GTE - Installation, Assembly & Servicing

9 ASSEMLY 6. ASSEMLY OF VISOUNT GTE OILERS IMPORTANT Important : Assemble the boiler in the order given by the numbers of each figure, in compliance with all the instructions. Packaging : efore starting to assemble the boiler, refer to the table below to check if you have received all the packages required. oiler ody and Accessories oilers supplied with an assembled body: start assembly from figure GTE boiler Number of sections Assembled boiler body (contents depend upon model) leaning tool kit (contents depend upon model) oilers supplied with an unassembled body: GTE boiler Number of sections Frame (dimensions depend upon model) Rear section Normal intermediate section Special intermediate section Front section Set of assembly rods + cleaning tools (contents depend upon model) Standard accessory kit package (contents depend upon model) Additional accessory kit package (contents depend upon model) Plain furnace plate Flue gas connection plate ø 50 with opening ø 500 Plain flue gas connection plate Flue gas box istributing tube fitting * Flow switch and technical instructions * The distributing tube fitting for GTE boilers with 5-9 sections is included in the accessory package. ** The diaphragm fitting for GTE boilers with sections is included in the additional accessory kit package. affle Plates FA 9 FA 68** FA 50* FA 69 GTE boiler Number of sections affle Plates Package M Package M FA 5* FA 70 FA 5* FA 7 FA 5* FA 7 FA 5* FA 7 FA 55 FA 7 FA 56 FA 75 FA 57 FA 76 FA 58 FA 77 FA 59 FA 78 FA 60 FA 79 asing Fittings GTE boiler Number of sections asing Fittings Package FA 5 Package FA 6 Package FA 7 Package FA 8 Package FA 9 Package FA 0 Package FA Ideal Viscount GTE - Installation, Assembly & Servicing 9

10 ASSEMLY Variable asing Parts GTE boiler Number of sections Package FA 6 Package FA 7 Package FA 8 Package FA 9 Package FA 0 Package FA Package FA Package FA Package FA Package FA 5 Package FA 6 Package FA 7 ody Insulating Material GTE boiler Number of sections ody insulating material Package FA Package FA 5 Package FA 6 Package FA 7 Package FA 8 Package FA 9 Package FA 0 Package FA ontrol Panel GTE boiler Number of sections Standard control panel Package FA e Luxe control panel Package FA Accessories Available as an Option* GTE boiler Number of sections urner plate with 65, 86, 0, 0 or 95 ø hole Smokehood plate with 00 ø opening or plain smokehead plate Tools Required: - J-TE or J-TE Plus assembly tool (+ extension for GT or larger) - Flat screwdriver - No. Pozidrive screwdriver - 0,, 7 and 9 mm spanners - mm tubular box spanner - 7 mm tubular box spanner - electric screwdriver + No. Philips bit - Stanley knife - Silicone filler (supplied) If the boiler is supplied with an assembled body, start assembly from Figure 9. Assemble the boiler body from the rear to the front: - assemble the rear section, - assemble all the normal intermediate sections, - assemble all the special intermediate sections, - assemble the front section. 0 Ideal Viscount GTE - Installation, Assembly & Servicing

11 ASSEMLY The number of sections of each type is provided in the table below: Section Type: Rear Normal intermediate Special intermediate Front GTE 9 GTE 5 0 GTE 6 GTE 7 GTE 8 GTE 9 GTE 0 GTE 5 GTE 6 GTE 7 GTE 8 GTE 5 9 VIS506 Ideal Viscount GTE - Installation, Assembly & Servicing

12 ESSUS - OEN - TOP ESSUS - OEN - TOP ASSEMLY oilers with, 6, 8, 0, and sections TOP, 6, 8, 0, and sections OTTOM FRONT VORN AVANT 5, 7, 9,, and 5 sections FRONT VORN AVANT oilers with 5, 7, 9,, and 5 sections TOP ESSUS - OEN -TOP OTTOM VIS506 ESSUS - OEN -TOP FRONT VORN AVANT 9 FRONT VORN AVANT VIS506 Place the frame on the floor, taking care to note the TOP and FRONT positions. Fit the fastening brackets as shown, depending on the type of boiler (one ø x0 screw, 9 mm spanner). Establish the location of the frame on the basis of the opening direction of the furnace door and the length of the burner. Leave enough clearance at the rear of the boiler for water connections (see. of the instructions) and the distributing tube (see of the instructions and fig. in this booklet). Fit the rear section on the frame, behind the fastening brackets (see detailed drawing) and prop it up. Insert the lower assembly rods in the holes of the rear section and the fastening brackets of the frame, in order to position the rear section correctly according to the frame. VIS5065 VIS5066 lean all the openings in the section with a brush. Remove any deposit on the bottom of the section. arefully insert the thermocord in the grooves of the section and retain it in place with a few drops of silicone filler (every 0 cm approximately). Note : do not pull on the seal while inserting it. Otherwise, you may stretch it and reduce its thickness. Ideal Viscount GTE - Installation, Assembly & Servicing

13 ASSEMLY 5 7 VIS5067 lean the bores and nipples with solvent. Remove any traces of rust-protective paint so that the surface is perfectly smooth. oat with the lubricant supplied with the sections. 6 VIS5069 ARRIÈRE ESSUS - OEN - TOP AVANT Gently push in the two nipples ARRIÈRE ESSUS - OEN - TOP AVANT VIS5068 Place the first normal intermediate section, making sure that it is turned in the right direction, i.e. with the flattening groove against the thermocord. For safety, insert a lateral assembly rod (supplied) in the holes of the two sections. Push the section gently and simultaneously onto both nipples of the rear section with a hammer and a piece of wood positioned in line with the bores. 8 9 VIS507 VIS5070 Put the assembly tool in position. Tighten gradually so as to bring together the upper and lower connections evenly and simultaneously. Assemble the remaining intermediate sections one by one, to the procedure stated in figures,, 5, 6, 7 and 8. First assemble the normal intermediate sections, then the special ones (see page of this booklet). Leave the assembly tool in place. Ideal Viscount GTE - Installation, Assembly & Servicing

14 ASSEMLY 0 Trim off any projecting ends of the thermocords from the sweeping covers. VIS507 Fitting the Upper and Lower Assembly Rods Fitting the Upper and Lower Assembly Rods REAR FRONT mm mm mm VIS507 VIS507 On the lower assembly rods, fit the following at each end in the given order : an expansion spring, a washer and a nut (the holes of the front lugs must be aligned with the holes of the frame brackets as the assembly rods are used to make the boiler body integral with the frame). Stop tightening as soon as the gap between the spring spires is equal to about mm. Put in place the upper assembly rods in the two front and rear lugs. Mount the two crosspieces (supplied in package FA5 / FA6) with their bends turned backwards and fasten them to the rods with an expansion spring, a nut and a washer. Remove the assembly tool. Ideal Viscount GTE - Installation, Assembly & Servicing

15 ASSEMLY The side assembly rods must be assembled from the rear to the front. The rods must be inserted in the holes stated in the diagrams (the lugs of the sections in which the assembly rods are to be inserted have two holes). Place the expansion spring and washer on the rear of each rod. Stop tightening the nuts as soon as the gap between the spires of the springs is about mm. Rear Front A mm A 50 mm long 0 mm long 0 mm long 50 mm long GTE A 50 mm long 0 mm long 0 mm long 50 mm long Rear Front mm A 50 mm long 50 mm long 0 mm long 50 mm long GTE 5 A 50 mm long 50 mm long 0 mm long 50 mm long mm VIS507 Ideal Viscount GTE - Installation, Assembly & Servicing 5

16 ASSEMLY Rear Front E 00 mm long 50 mm long 0 mm long 50 mm long 0 mm long GTE 6 E 00 mm long 50 mm long 0 mm long 0 mm long 50 mm long mm Rear Front E 0 mm long 50 mm long 0 mm long 0 mm long 50 mm long GTE 7 E 0 mm long 0 mm long 50 mm long 0 mm long 50 mm long mm Rear Front E 50 mm long 0 mm long 50 mm long GTE 8 0 mm long 50 mm long mm AE E 50 mm long 50 mm long 0 mm long 0 mm long 50 mm long VIS Ideal Viscount GTE - Installation, Assembly & Servicing

17 ASSEMLY A AE mm mm mm mm Rear Front E 50 mm long 50mm long 50 mm long 0mm long 50 mm long GTE 9 E 50 mm long 50mm long 50mm long 0mm long 50 mm long Rear Front A 0 mm long 50 mm long 0 mm long 50 mm long 50 mm long 85 mm long GTE 0 A 0 mm long 50 mm long 0 mm long 50 mm long 50 mm long 85 mm long Rear Front A 50 mm long 0 mm long 50 mm long 50 mm long 50 mm long 85 mm long GTE A 0 mm long 50 mm long 50 mm long 50 mm long 50 mm long 85 mm long VIS5077 Ideal Viscount GTE - Installation, Assembly & Servicing 7

18 ASSEMLY A AE mm mm mm mm Rear Front A 50 mm long 50 mm long 50 mm long 50 mm long 85 mm long 50 mm long GTE A 50 mm long 50 mm long 50 mm long 50 mm long 85 mm long 50 mm long Rear Front E 0 mm long 0 mm long 50 mm long 50 mm long 0 mm long 50 mm long 85 mm long GTE E 0 mm long 0 mm long 50 mm long 0 mm long 50 mm long 85 mm long 50 mm long VIS Ideal Viscount GTE - Installation, Assembly & Servicing

19 ASSEMLY A AE mm mm mm mm Rear Front E 0 mm 0 mm 50 mm 50 mm 50 mm 85 mm 50 mm GTE E 0 mm 0 mm 50 mm 50 mm 50 mm 85 mm 50 mm Rear Front E 0 mm long 50 mm long 50 mm long 50 mm long 50 mm long 85 mm long 50 mm long GTE 5 E 0 mm long 50 mm long 50 mm long 50 mm long 50 mm long 85 mm long 50 mm long VIS5079 Ideal Viscount GTE - Installation, Assembly & Servicing 9

20 ASSEMLY Assembling the affle Plates oiler GTE GTE 5-9 GTE 0-5 Total number of baffle 6 8 plates Package no. M M + M xm Put the baffle plates into place in the upper front flue ways, taking care to interlock them with each other before fitting them. VIS5080 Assembling the Sweeping overs lean off the protective varnish on the ground surfaces with solvent. The covers are numbered from to, and must be fitted with a thermocord. The length of the thermocord depends upon the cover and is given below. Type Thermocord Length 5 mm 0 mm 890 mm 665 mm Handles turned REAR outward 9 over Model No No No No Type of Number of sweeping covers per type oiler FRONT REAR GTE 6 GTE 5 GTE 6 GTE 7 6 GTE 8 6 GTE 9 6 GTE 0 6 GTE 8 GTE 6 GTE 6 GTE 8 GTE 5 0 FRONT VIS508 Place the two no. sweeping covers (with the handles turned outward) on either side of the boiler starting from the front. istribute the other covers evenly. Each cover is fitted with a system whereby it can only be mounted with the handles turned outward. Fit the two locks of each cover between the sections. Push the cover towards the outside of the boiler, to the closed position. Fasten the two brass nuts of each cover. 0 Ideal Viscount GTE - Installation, Assembly & Servicing

21 ASSEMLY 5 6 Front and Rear VIS508 VIS508 Insert the thermocord in the sealing groove on each side and hold it in place with a few drops of silicone filler. Insert the thermocord in the sealing groove of the two lower flue ways, on the rear and front of the boiler. Put the four trap doors on the lower flue ways and fasten with the wing nuts. 7 8 Installing the Hinge of the Furnace oor Refractory Rigid refractory felt plate 7 Two.9 x 5. SIM screws Two.9 x 5. SIM screws VIS508 Put the furnace door insulating material in place and retain it with the four.9 x 5. SIM screws. VIS5086 VIS5085 Place the furnace door on the floor and fasten the articulation onto the door with three HM screws. Fix the furnace door hinge on the right or left-hand side of the front section by means of three H x 5 screws. Ideal Viscount GTE - Installation, Assembly & Servicing

22 ASSEMLY 9 0 Fit the door onto the hinge by inserting the pin. VIS5087 VIS5089 VIS5088 lose the furnace door on the 8 studs and fasten with 8 washers and nuts. Fit the two doors of the upper flue ways (wing nuts). Fit the plain flange onto the upper connection of the front section (using four H 8 nuts), with the 70 x gasket in between (first soak the gasket in warm water). Fit the flange with the sludge removal hole onto the lower connection of the front section (hole in the lower part of the flange) using four H 8 nuts, with the gasket in between (soak in warm water first). Flame Inspection Window The flame inspection window is fitted with a /" tapped hole for ventilation (optional) : - if a ventilation system is used, connect the hole to the one provided for that purpose before the burner combustion head. VIS5090 Ideal Viscount GTE - Installation, Assembly & Servicing

23 ASSEMLY Assembling the Return Flange on oilers GTE -5 oiler L Type (mm) GTE 5, 6 80 GTE GTE GTE -5 0 Package FA68 - sections L GTE Package FA9 - sections GTE5-5 Package FA50 to FA 60 VIS509 GTE : Fit the water balancing diaphragm with the notches vertical onto the boiler return with a ø 70 x gasket in between (first soak the gasket in warm water). Fit the heating return flange with a ø 70 x gasket in between and fix it with four H 8 nuts. GTE 5 - GTE 5 : Fit the water balancing tube onto the boiler return with a ø70 x gasket in between (first soak the gasket in warm water), using four H 8 nuts. Fit the heating return flange with a ø 70 x gasket in between (first soak the gasket in warm water) and fix it with four H 8 nuts. Fitting the oiler Outlet Flange GTE - GTE 5 Fitting the oiler Outlet Flange GTE - GTE 5 Package FA 9 to FA 50 GTE 6 - GTE 5 Package FA 5 to FA 60 VIS509 GTE - 5 : Place the nozzle turned outside from the boiler with a ø 70 x gasket in between (first soak the seal in warm water). Assemble the flange with angled piece so that the angle is turned upward, with a ø 70 x gasket in between (first soak the gasket in warm water) and fasten with four H 8 nuts. GTE 6-5 : Assemble the flange with angled piece so that the angle is turned upward, with a ø 70 x gasket in between (first soak the gasket in warm water) and fasten with four H 8 nuts. VIS509 arefully insert the ø 5 gasket in the groove of the rear section and hold it in place with a few drops of silicone. Ideal Viscount GTE - Installation, Assembly & Servicing

24 ASSEMLY 5 efore assembling the flue gas box, grease all bolts, studs and screws with high temperature grease (not supplied). 6 efore assembling the flue gas box, grease all bolts, studs and screws with high temperature grease (not supplied). VIS509 VIS5095 Put the flat adhesive seal in place on the flue gas box. Put the sweeping cover in place and fasten with two H 0 nuts and 0 ø washers. The flue gas outlet is fastened to the rear by means of six studs, washers and ø nuts. 7 8 Assembling the Flow Switch VIS5096 VIS5097 First adapt the steel connecting plate to the chimney connection flue. Then fasten that plate or the plate with a connecting piece supplied as an option with ten H 0 nuts and ø 0 washers. Screw the flow switch home onto the sleeve. (Package IP5-55) The direction of the arrow on the casing shows the direction of the flow of water in the pipe. Ideal Viscount GTE - Installation, Assembly & Servicing

25 ASSEMLY 9 Assembling the baffle plates (for boilers supplied with an assembled body only) in boilers supplied with an unassembled body, the baffle plates are already in place. oiler GTE GTE 5-9 GTE 0-5 Total number of baffle 6 8 plates Package no. M M + M xm Put the baffle plates in place in the upper front flue ways, taking care to interlock them with each other before fitting them. VIS Assembling the Upper rosspieces (package FA 5 or FA 6) (for boilers supplied with an assembled body only) In boilers supplied with an unassembled body, the crosspieces are already in place (see figure ) Assembly the Pocket GTE - 9 FRONT REAR FRONT mm REAR mm GTE 0-5 FRONT VIS500 FRONT VIS5099 Mount the two crosspieces and fasten them onto the rods with an expansion spring, a nut and a washer. Assemble the pocket for the thermostats and thermometer in : - the third special intermediate section - 50 mm wide, /" hole (GTE - 9) or - the fourth special intermediate section - 50 mm wide, /" hole (GTE 0-5). Plug the two (GTE - 9) or three (GTE 0-5) free /" holes in the special intermediate sections. Ideal Viscount GTE - Installation, Assembly & Servicing 5

26 ASSEMLY Assembling the able hannels ( - 7 sections) Assembling the Top Insulating Material ( - 7 sections) REAR AVANT FRONT VIS50 VIS50 Place the cable channels so that their bevelled end is to the front. Fasten with two H 8 x 6 screws + L8 washers in the third hole starting from the front and opposite the special nut. Fasten at the rear with two H8 x 6 screws + L8 washers opposite the oblong holes and special nut. Assembling the able hannels and rosspieces (8-5 sections) No. of Sections 5, 6 7 Length (mm) Put in place the 600 mm wide (packages FA - 6) top insulating material on the body of the boiler. 5 Assembling the Additional able hannels (8-5 Sections) A VIS50 Assemble the intermediate piece on the assembly rods by fitting one slotted side onto one rod and using the flexibility of the other rod. Place the two cable channels so that their bevelled end is to the front. Fasten the channels to the front crosspiece with two H 8 x 6 screws + L8 washers in the third hole starting from the front and opposite the special nut. Fasten the cable channels on the intermediate piece with two H8 x 6 screws + L8 washers. VIS50 No. of Sections A (mm) Align the two additional cable channels with the two others. Fasten them to the intermediate piece and the rear crosspieces with four H 8 x 6 screws and L8 washers. 6 Ideal Viscount GTE - Installation, Assembly & Servicing

27 ASSEMLY 6 Assembling the Top Insulating Material (8-5 sections) Put in place the two 600 mm wide (packages FA 7 - ) pieces of insulating material on the body of the boiler. Push the insulating material under the front and rear crosspieces No. of Sections Length (mm) x x x x x x x x VIS505 7 Assembling the asing Positioning rackets VIS506 Fasten the positioning brackets (package FA5 or FA6) onto the right and left-hand upper bosses of the front section with two H 8x6 screws and two serrated washers ( mm spanner). Ideal Viscount GTE - Installation, Assembly & Servicing 7

28 ASSEMLY 8 Assembling the Lower Rail Support rackets Example : GTE Fasten the lower rail support brackets using H8 x 6 screws. Note: for the assembly direction, see the drawings below. VIS507 Assembly irection of Lower Rail Support rackets (seen from the top of the frame) 8a 5, 7 sections, 6 sections Right-hand side Rail support brackets Right-hand side Rear Frame Front Rear Frame Front Left-hand side Rail support brackets Left-hand side VIS508 8 Ideal Viscount GTE - Installation, Assembly & Servicing

29 ASSEMLY 8b 8, 0 sections Right-hand side Rear Frame Front Rail support brackets Left-hand side Rail support brackets 9, sections Right-hand side Rear Frame Front Rail support brackets Left-hand side Note: two lower rail support brackets and two upper rail brackets are left unused with 8, 9, 0 and sections. 8c Rail support brackets, sections Right-hand side Rear Frame Front Rail support brackets Left-hand side Rail support brackets, 5 sections Right-hand side Rear Frame Front Left-hand side VIS509 Ideal Viscount GTE - Installation, Assembly & Servicing 9

30 ASSEMLY 9 Fasten the lower rail with H 8x0 screws and L8 washers. The other rail support brackets are fastened opposite the holes provided on the lower rail. FRONT Length required while assembling the two-piece rails (boilers with 8-5 sections) (see fig. ) VIS50 0 Assembly irection of Lower Rail Support rackets (seen from the top of the frame) ❷ ❷ ❷ VIS5 Fix the fastening bracket of the upper rails (package FA5 or FA6) on the upper lug (these brackets must be vertically aligned with the lower rail support brackets). Fit the bracket onto the stub. Fasten with H 0x50 screws and serrated washers and H0 nuts. Assemble the Rapid nut on the top of the bracket with the tapped shaft on the inside. 0 Ideal Viscount GTE - Installation, Assembly & Servicing

31 ASSEMLY Installing the Insulating Material Type of FRONT REAR oiler Side insulating material (length in mm) GTE GTE GTE GTE GTE GTE GTE GTE GTE GTE GTE GTE VIS5 Place the side insulating material against the positioning bracket and cut it so that it is flush with the upper lug on which the rail fastening bracket is fixed, along a 0 mm length. Push the insulating material in behind the lug and the rail fastening bracket. istribute the insulating material evenly so that you have the same side insulating material on either side of the boiler. ut the material similarly along the fastening brackets. REAR Example: GTE 6 FRONT A Length required while assembling the two-piece rails (boilers with 8-5 sections) (see table below). - 7 sections Fix the upper rail with H8 x 0 screws and L8 washers (the first hole from the front end of the rail must be opposite the first fastening bracket, and similarly with the other brackets). Push the insulating material behind the lower rail and underneath the boiler. Join the pieces of insulating material to each other with the clips. VIS5 8-5 sections Fix the upper rail with H8 x 0 screws and L8 washers (the first hole from the front end of the rail must be opposite the first fastening bracket, and similarly with the other brackets). Fix the additional upper and lower rails, making sure you comply with dimension A (see table below). Push the insulating material behind the lower rail and underneath the boiler. Join the pieces of insulating material to each other with the clips. No. of Sections A (mm) Ideal Viscount GTE - Installation, Assembly & Servicing

32 ASSEMLY Assembling the Side asing Panels Length and arrangement of panels for the boiler model 5 Type of FRONT REAR oiler Side Panels Length in mm GTE GTE GTE GTE GTE GTE GTE GTE GTE GTE GTE GTE mm long panel in Package FA mm long panel in Package FA 800 mm long panel in Package FA 7 90 mm long panel in Package FA mm long panel in Package FA 9 VIS5 First assemble the panels on the front using the assembly length table opposite and continue up to the rear section. Fix the front side panels to the positioning brackets with H 8 x 6 screws and serrated washers. Push the insulating material into the top of the side panels and fasten the panels to the lower rails by means of the self-tapping screws with the electric screwdriver ( screws per panel). Fasten the side panels to each other with the clips 5. Assembling the Furnace oor and Lower rosspiece Panels Put the furnace door panel in place (package FA5 or FA6) and fasten with two ø.9 x.7 tapping screws. The furnace door panel may be cut in two at the microjoints. Fit two Rapid nuts in the bottom of the front side panels. Fix the casing support lower crosspiece (package FA5 or FA6) by means of two H 6x0 screws and two serrated washers. VIS55 Ideal Viscount GTE - Installation, Assembly & Servicing

33 ASSEMLY 5 Assembling the ontrol Panel racket (all control panels) VIS56 Fit the four Rapid nuts on the front of the cable channels. Fit the Rapid nuts in the slots : - Rapid nuts for 7-7 sections, - 8 Rapid nuts for 8-5 sections. Fix the control panel bracket (package FA5 or FA6) underneath the two cable channels by means of two H 8x 6 screws and two serrated washers. 6 Standard ontrol Panel (Go directly to Figure 50 for the e Luxe ontrol Panel) VIS57 Place the front crosspiece underneath the control panel bracket and fasten from below with H8 x 0 screws and serrated washers. Fix to the side panels with two Ø.9 x.7 tapping screws and serrated washers Ideal Viscount GTE - Installation, Assembly & Servicing

34 ASSEMLY 7 Installing the Standard ontrol Panel 8 Standard ontrol Panel REAR FRONT x VIS58 VIS59 Position the control panel on the rear studs. Open the control panel ( screws at the back). ring the burner cable behind the casing support and down to the burner between the side panel and insulating material. 9 Standard ontrol Panel Fasten the control panel to the panel base with two ø.9 x 5 tapping screws and serrated washers. arefully unroll the various bulbs and bring them out of the control panel through the opening designed for that purpose. ut out the top insulating material and insert the bulbs in the boiler pocket and hold them in place using the spring. Fasten rear cover H (package FA5 or FA6) to the control panel bracket using two E x 0 screws and serrated washers. Make the electrical connections to the two terminal blocks provided for this purpose inside of the control panel. See the Electrical onnections section of the instructions (Section 7, page ). lose the control panel. VIS50 Ideal Viscount GTE - Installation, Assembly & Servicing

35 ASSEMLY 50 e Luxe ontrol Panel 80º VIS5 Take the front crosspiece and turn it by 80º in relation to the position for standard control panels (see fig. 6) and fasten it just like the standard control panel. 5 Fitting the e Luxe ontrol Panel 5 e Luxe ontrol Panel REAR FRONT VIS5 Position the control panel on the front studs. Open the control panel (two screws on the side). VIS5 ring the burner cable behind the casing support and down to the burner between the side panel and insulating material. Ideal Viscount GTE - Installation, Assembly & Servicing 5

36 ASSEMLY 5 Installing bulbs of e Luxe ontrol Panels 5 Installing bulbs of e Luxe ontrol Panels VIS5 VIS55 Fix the control panel to the rear of the control panel bracket using two H ø x 0 screws and serrated washers. arefully unroll the various bulbs and bring them out of the control panel through the opening in the bottom on the panel. 55 ut out the top insulating material to free the boiler pocket. Then, insert the bulbs inside the pocket and maintain them with the spring. 56 Putting in place the Insulating Material for e Luxe ontrol Panels Make the electrical connections to the terminal blocks provided for this purpose inside of the control panel. See the Electrical onnections section of the instructions supplied (Section 7., page 7). VIS56 Put in place the insulating material as shown above. 6 Ideal Viscount GTE - Installation, Assembly & Servicing

37 ASSEMLY Section A-A Serrated washer "Rapid" nut able channel ontrol panel bracket Front crosspiece ontrol panel trim Mounted screw A A VIS57 VIS58 Unfasten the screws (mounted in fig. 50) Slide the control panel trim along the screws. Fasten the screws. Fix the trim to the control panel using two tapping screws and serrated washers VIS59 VIS50 Place the insulating material in the lower central front panel (black cloth facing outward). Fit the lower central front panel (package FA5 or FA6) onto the lower front crosspiece and fix it to the furnace door panel. Fit the left and right-hand side front panels (package FA5 or FA6) onto the lower front crosspiece and fit them onto the studs of the side panels. Ideal Viscount GTE - Installation, Assembly & Servicing 7

38 ASSEMLY 6 6 VIS5 Place the retaining crosspiece (package FA5 or FA6) on the left and right-hand front panels, taking care to place the two central tabs behind the furnace door panel. Fit the upper front panel (package FA5 or FA6) onto the side panels via the four studs. 6 Put in place the insulation of the flue gas box and the lower rear insulating material (package FA5 or FA6). 6 VIS5 VIS5 VIS5 Put in place the two rear crosspieces (package FA5 or FA6) behind the bend of the rear side panels and fasten each crosspiece to the side panels using two ø.9 x.7 screws. Put the two clip-on nuts in place on the side panels. Fit the upper rear panel (package FA5 or FA6) onto the studs and push it up. Fasten with two H 8x6 screws and serrated washers. Fit the two lower rear panels (package FA5 or FA6) onto the rear crosspieces. 8 Ideal Viscount GTE - Installation, Assembly & Servicing

39 ASSEMLY 65 Assembling the entral Plate for - 7 Sections 66 Assembling the entral Plate for 8-5 sections VIS56 VIS55 Place the central plate on the cable channels with the round holes towards the front of the boiler. Fasten with H 8 x 0 screws and serrated washers. Place the rear plate, which is 00 mm long. Fasten with four H 8x0 screws and serrated washers. Place the front plate with the round holes towards the front of the boiler. Fasten with four H 8 x 0 screws and serrated washers. Fasten the joining plate with the round holes towards the front of the boiler with four tapping screws and serrated washers. 67 Put in place the sweeping cover insulating material (packages FA 0 - FA ): - GTE - 7 : pieces - GTE 8-5 : pieces. VIS57 Ideal Viscount GTE - Installation, Assembly & Servicing 9

40 ASSEMLY 68 VIS58 Type of oiler FRONT REAR entral and Side overs (Length in mm) GTE GTE GTE GTE GTE GTE GTE GTE GTE GTE GTE GTE mm long panel in Package FA mm long panel in Package FA 800 mm long panel in Package FA 7 90 mm long panel in Package FA mm long panel in Package FA 9 Place the side covers (package FA7 to FA, see table) from the front to rear. They have the same lengths as the side panels. 69 Identification Plate and E Marking Type of boiler XX - XX year () week ate of manufacture F 670 NIEERRONN Unit serial no. Glue the identification plate and E marking on the casing of the boiler in an easily visible location. () 08 = 998, 09 = 999,... VIS59 0 Ideal Viscount GTE - Installation, Assembly & Servicing

41 ONTROL PANEL 7. ONTROL PANEL 7. Standard ontrol Panel IMPORTANT The boiler connections shall be performed by a qualified professional only. Strict compliance with these operating, starting up and connecting instructions is a precondition for the correct operation of the boiler. 7.. Overview 0 0 6A I VIS5. Main On/Off switch. Test ST switch : temporary action to test the safety thermostat.. oiler thermostats (with 0-85 adjustment range) : A factory-set stop limits the maximum temperature to 75. The stop may be moved if necessary (see section 6).. oiler thermometer 5. Location for flue gas thermometer (optional) A ircuit-breaker with delayed action and manual reset. 7. Safety thermostat with manual reset, set to Operating Principle The boiler may be regulated : - either by the boiler thermostats, If the burner fitted in the boiler is a two-stage burner, each thermostat may be allocated to the operating of a single stage. In this case, the second-stage thermostat must always be set to a value which is at least 5 below that of the firststage thermostat. - or by a control unit in the electrical cabinet In this case, safe operation is ensured by the safety thermostat with manual reset. Ideal Viscount GTE - Installation, Assembly & Servicing

42 VA S T8 T7 T6 T T L N 0V 50Hz L N I AL ONTROL PANEL 7.. Electrical onnections The electrical connections shall be made in compliance with the instructions given in the electrical diagrams supplied with the device and the guidelines provided in the manual. are shall be taken to comply with applicable standards and regulations. The unit shall be powered by a circuit with an omnipole switch with an opening distance greater than mm. The earth connection shall comply with standards in force. IMPORTANT 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. Access to the connecting strip Unscrew the three fastening screws on the rear of the control panel and open the panel. able passage Pass the connecting cables through the two cutouts on the rear of the boiler and bring them to the front via the cable channels. Then bring them towards the control panel through the rectangular openings in the front cover. VIS5 Main supply onnect the main supply to terminals, and of the connecting strip as shown opposite Flow switch onnect the flow switch contact in series to the safety circuit (e.g. between terminal 5 of the terminal block and burner terminal L). VA S 0 T8 9 T7 8 T6 7 T 6 T 5 L L N ALI N 0V/50Hz x 0,75 mm VIS55 Ideal Viscount GTE - Installation, Assembly & Servicing

43 I AL ONTROL PANEL ONNETING THE URNER urner cable The control panel is supplied with the burner power supply cable, with two 7 and -pin European plugs on one end and a terminal block with male connecting terminals on the other. 7-pin plug for one-stage burners or stage of two-stage burners. -pin plug for stage of the burner. Terminal block for connecting to the control panel. VIS56 ontrol panel connections onnect the terminal block with the male connecting terminals to fixed terminals - in the control panel L N VA S T8 T7 T6 T T L N 0V 50Hz VIS57 urner connections urners with plug Refer to the figure of the burner cable. urners without plugs In this case, you will need to rewire the connectors supplied with the burner cable. The diagram opposite shows the wire numbers and terminals of the burner connectors. The table on the following page specifies the way in which the cables are to be connected to the burner control box. S T T N V/J L 5 T6 T7 T8 VIS58 onnector Wire From onnection to the burner ontrol ox Terminal No No L 7 ontinuous phase from the safety thermostat urner main supply V/J Earth connection Earth connection N 6 Neutral taken after On/Off Neutral terminal T/T 5/ ry contact of the stage boiler thermostat Insert in the control circuit of boiler stage S 8 urner alarm indicator Alarm output (phase) T6 Stage boiler thermostat input Insert in the control circuit of burner stage T7 Stage "boiler off" thermostat output onnect only if the burner is of the modulating type T8 Stage "boiler on" thermostat output Insert in the control circuit of burner stage Ideal Viscount GTE - Installation, Assembly & Servicing

44 VA S T8 T7 T6 T T L N 0V 50Hz L N I AL ONTROL PANEL If the electrical characteristics of the burner exceed the following values: - start current> 6 A or - P > 50 W (or / cont. hp. motor), or - I > A cos ϕ = 0, 7 The burner controls must be relayed. 7-pin plugs for connecting to the control panel and burner connectors VIS59 onnecting a safety thermostat alarm transfer system The isolated pin standing by on the safety thermostat is used to connect an alarm transfer system (thermostat with reversing contact). If the safety thermostat trips, a 0 V signal is active at that terminal. Proceed as follows to connect the alarm transfer system : - Open the control panel ( screws on the rear) to access the rear of the safety thermostat. - onnect the alarm transfer system to the thermostat pin using a 6.5 mm Faston clip. The other end of the cable is connected to an indicator or sound alarm. VIS550 Ideal Viscount GTE - Installation, Assembly & Servicing

45 ONTROL PANEL 7.. Schematic iagram L A Z j6a TS q TH q ZT q TH *TS q A 5 A 6 A 7 A 8 A 9 A 0 A A () L T T T6 T7 T8 S N A VA N A Z VIS55 urner A onnection strip j 6 A 6 A ircuit-breaker L Phase N Neutral TH Stage boiler thermostat TH Stage boiler thermostat TS Safety thermostat TS ondenser safety thermostat (for versions GTG 00) VA Alarm indicator Z urner switch ZT ST-Test switch onnecting strip * Optional onnector Wiring iagram Viscount GTE Standard Z A A ZT a TH TH j6a A TS L 6 NO MA L 5 RO 7 RO 7A A 5 A 0 NO VI 9 RO 7 OR 8 MA V/J OR 8 A NO MA A A NO A 0 VI 9 RO 7A A A 5 A L 6 MA L 5 V/J TS* L N A VA S T8 T7 T6 T T L N 0V ALI 50Hz VIS55 GR Grey NO lack MA rown RO Red OR Orange L lue VI Violet A White V Green/Yellow ALI Main Supply urner A onnecting oard j6a ircuit reaker 6A L Phase N Neutral TH oiler Thermostat st Stage TH oiler Thermostat nd Stage TS Safety Thermostat TS ondenser Thermostat VA Alarm Indicator Z urner Switch ZT Test Switch ST * Optional elivered Earth A 5 A V/J A NO A 0 VI 9 OR 8 RO 7A RO 7 L 6 L 5 A MA NO MA Wire A 6 TW A A A 0 A 9 A 8 TH ZT A TH Z A TS j6a Z A eginning ZT A 6 A TH TH TH TW A 7 ZT A A Z A A 5 TS j6a Z A End Ideal Viscount GTE - Installation, Assembly & Servicing 5

46 8 5 8 ONTROL PANEL 7..5 Starting Up and Operation IMPORTANT Initial starting up shall be performed by a qualified professional A I VIS55 efore turning the boiler on, make sure that the installation is filled with water. Perform the start-up operations in the order given below : oiler temperature regulation by means of the thermostats. Set boiler thermostats to the selected position. If the burner has two stages, the stage thermostat must always be set to value which is approximately 5 less than that of the stage thermostat. If required, move the maximum temperature stop as instructed below. IMPORTANT If there is no control unit, we advise you never to set the boiler thermostat below mark (approx. 0º) in order to avoid the risk of combustion products condensing on the walls of the boiler. ontrol unit in heating cabinet Refer to the instructions supplied with the control unit. Make sure that safety thermostat 7 is set by unscrewing the hexagonal cap and pressing the reset button with a screwdriver. Set main On/Off switch to the On. Moving the thermostat stop : The stop is factory-set to limit the maximum temperature to 75. To move the stop, proceed as follows : - Pull the thermostat button out carefully (use pliers and a cloth). - Remove the stop with the pliers. - Put the stop in the hole of the desired higher temperature (maximum 85 ) VIS55 6 Ideal Viscount GTE - Installation, Assembly & Servicing

47 0 6A ONTROL PANEL 7. e Luxe ontrol Panel 7.. escription l 7 5 VIS555. Three-position switch Auto /Manual / / TEST ST The switch may be left on either position manual or automatic AUTO. Test ST: temporary action to test the safety thermostat: Press the TEST ST switch and set pump shut-off switch. to the "summer" position.. ouble Switch urner / Heating pump: This double button is used to control the burner and the heating pump. oth buttons are in "Winter" position: heating and hot water production systems operate (if a hot water tank is included). oth buttons are in "Summer" position: only the domestic hot water production system operates (if a hot water tank is included).. Main ON/OFF switch. Location for hour run meter for the first and second stage (optional). 5. oiler thermostats (with 0º to 85º adjustment range): A factory-set stop limits the maximum temperature to 75º. The stop may be moved if necessary (see section 5.). 6. Stage or stage indicators: These only go on if the relevant thermostat or control unit require heating and if the safety contact is closed. 7. oiler thermometer 8. Location for flue gas thermometer (optional) 9. Safety thermostat with manual reset (set to 0º) A ircuit-breaker with delayed action and manual reset.. Switch for selecting the number of burner stages. urner alarm indicator Ideal Viscount GTE - Installation, Assembly & Servicing 7

48 ALI ALI N VA L N VA L L N L ALI N VA L N 9 0 L S ONTROL PANEL 7.. Electrical onnections IMPORTANT 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 shall be made in compliance with the instructions given in the electrical diagrams supplied with the device and the guidelines provided in the manual. are shall be taken to comply with applicable standards and regulations. The unit shall be powered by a circuit with an omnipole switch with an opening distance of over mm. The earth connection shall comply with standards in force. Installation All the connections shall be made to the terminal block provided for that purpose in the boiler control panel. Proceed as follows to open the control panel: ALIMENTATION STROMZUFÜHR SUPPLY MAIN ALIMENTATION STROMZUFÜHR SUPPLY MAIN ALARME TS VOYANT ALARMLEUHTE TS ALARM INIATOR TS 0V 50Hz VA-TS E REYLAGE POMPE KESSELKREISPUMPE SHUNT ALARME TS VOYANT ALARMLEUHTE TS ALARM INIATOR TS E SEURITE ONTAT SIHERHEITSKONTAT ONTAT SAFETY L L N L N N 5 Loosen the two screws located on either side of the front of the panel by two turns. Tilt back the control panel. Unscrew the component guard cover (two screws and serrated washers). ring the connecting cables to the control panel through the openings located on the rear panel of the boiler and one or two cable channels, depending upon the type of boiler. Fasten the cables to the base of the control panel with cable clamps (6 cable clamps supplied in the bag) assembled as shown opposite. 0V 50Hz VA-TS L L N L N N 0V 50Hz VA-TS S L N L N L N N VIS556 Make the connections as shown opposite L N ALI L N L N L N L N 0V 50Hz VA - TS VA S x 0.75 mm min. 0 V main supply x 0.75 mm min. Heating pump x 0.75 mm min. Flow switch Remove white wire bridge VIS557 8 Ideal Viscount GTE - Installation, Assembly & Servicing

49 ONTROL PANEL onnecting one or two hour run meters (package I8) One or two optional hour run meters (stage and ) may be fitted on the front of the control panel. Proceed as follows : - ut the cover off with a cutter along the edges of the coloured rectangle. - Pull out the two wires standing by in the control panel. - onnect the wires to the hour run meter (the wires are interchangeable). - lip the hour 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 hour run meters display the operating time of each stage. 6A VIS558 onnecting the flue gas thermometer (package I 8) An optional flue gas thermometer may be fitted on the front of the control panel. Proceed as follows : - ut the cover off with a cutter along the edges of the coloured rectangle. - lip the thermometer into the opening. - ring the sensor to the back of the boiler via the cable channel and insert it in the flue gas pipe A 9 VIS559 Ideal Viscount GTE - Installation, Assembly & Servicing 9

50 ONTROL PANEL onnecting the burner The control panel is supplied with the burner power cable. One end of the cable has two 7 and -pin European plugs which are connected to the burner connectors. The other end of the cable is connected to the control panel. 7-pin plug for one-stage burners or stage of two-stage burners. -pin plug for stage of the burner. VIS56 urner without plug-in connectors In this case, the connectors supplied with the burner cable must be rewired. The diagram opposite shows the wire numbers and the terminals of the burner connectors. The table below specifies the way in which the cables are to be connected on the burner control box. V/J 6 5 S T T N L 5 T6 T7 T8 VIS56 onnector Wire From onnection to the burner ontrol ox Terminal No No L ontinuous phase from the safety thermostat urner main supply V/J Earth connection Earth connection N Neutral taken after On/Off Neutral terminal T/T / ry contact of the stage boiler thermostat Insert in the control circuit of boiler stage S 5 urner alarm indicator Alarm output (phase) 6 Stage On indicator (or hour run meter) Stage operation monitoring output (phase) 5 Stage On indicator (or hour run meter) Stage operation monitoring output (phase) T6 Stage boiler thermostat input Insert in the control circuit of burner stage T7 Stage "boiler off" thermostat output onnect only if the burner is of the modulating type T8 Stage "boiler on" thermostat output Insert in the control circuit of burner stage If the electrical characteristics of the burner exceed the following values: - start current> 6 A or - P > 50 W (or / cont. hp. motor), or - I > A cos ϕ = 0, 7 The burner controls must be relayed. 7-pin plugs for connecting to the control panel and burner connectors VIS59 50 Ideal Viscount GTE - Installation, Assembly & Servicing

51 ONTROL PANEL 7.. Schematic iagrams A ZG a J6A 6 ES 7 9 A 6 b a ZT A b ZEH TH a A ES RG 6 A 0 7 b a 8 9 ZT 5 RG TS 9 RG A S 5 A TH 8 b a ZEH 7 Z b a 8 A A A A A P VA-TS V N L T T S T6 T7 T8 5 V VA VA A ZG a 9 A A 5 A H h 6 A A 5 0 A h H 7 A A HEATING PUMP URNER A ONNETING OAR A ASAE ONNETION H SAFTEY ONTAT H IRUIT REAKER S OMESTI HOT WATER j6a SHUNT PUMP ES REGULATOR P OILER THERMOSTAT st STAGE RG OILER THERMOSTAT nd STAGE THSAFETY THERMOSTAT THALARM INIATOR TS SAFETY THERMOSTAT ALARM INIATOR VA ON/OFF INIATOR st STAGE VA-TSON/OFF INIATOR nd STAGE V EARTH V URNER SWITH nd STAGE ZEH SUMMER-WINTER SWITH ZG MAIN SWITH ZT TEST SWITH VIS56 Ideal Viscount GTE - Installation, Assembly & Servicing 5

52 5 Ideal Viscount GTE - Installation, Assembly & Servicing MA A A5 A5 A0 A A0 A9 A A9 N0 ES A9 A a ZG MA L0A RG OR A L0 VI5 A a L MA0 MA5 V/J OR9A OR9 L L A7 NO5 L L OR9 OR9 RO8 VI5 MA5 MA5A A MA 5 5 OR9 A 6 6 OR6 A6 7 7 OR9A OR9 RO8 A0 8 8 RO7 TS LA MA5 9 9 A8 V/JA 0 0 V/J A7 A0 NO9 N06 WIRE START EN A A ZEH RG A 5 ZG ZG RG RG 5 ES 6 ES ZEH TS TS RG RG A A A A RG A A A RG RG A A A 7 ES 9 A A ZT A A A 8 6 RG A A A A MA L A A A NO RO A A A L L L OR NO RO A RO NO A OR A VI8 a A MA7 ZEH b a b RO8 A A A H H S J6A ES P RG TH LA L 5 5 MA MA9A a MA9 b ZT MA5 HEATING PUMP URNER ONNETING OAR ASAE ONNETION HOUR RUN METER ST STAGE HOUR RUN METER ST STAGE SAFETY ONTAT IRUIT REAKER OMESTI HOT WATER SHUNT PUMP REGULATOR OILER THERMOSTAT ST STAGE A a b MA OR9 WIRE START EN A 8 8A 9 9A 0 A RG A A A A A ZEH ZT A A A A A A A RG A H H ZT A ES A A ES ES 7 RG RG E F H A A X 0 H H A A ES 5 ES RG 5A 5 6 RG A 7 ZT A MA A VI A MA MA VI VI MA MA MA L L L L L L L VJ VJ VJ MA MA MA A OR L NO9 TH TS VA VA-TS V V X - Y Z ZEH ZG ZT V/J V/J L N ALI 0V-50Hz J6A OR9 NO b L0 VA a OR8 WIRE START EN A A OR 7 7A 8 Z A 9 A 6 Z V VA A A A 9 A TH L L L 0 0A 0 A ZG V 5 ZG V V L 0 V VA VJ VJ A A X TS VJ A TS TH VJ TH TH VJ TH NO ZG J6A RO A 5 V MA 5 A 0 TH MA 5A TH 8 MA 5 8 Z OR 6 A 7 TH VI RO OR TH TH J6A Z ZEH TS OR 9A TS ES 6 OR 9 ES 6 RG OR OR 9 RG 9 ZT ZT A 6 VI7 OILER THERMOSTAT N STAGE SAFETY THERMOSTAT ALARM INIATOR SAFETY THERMOSTAT ALARM INIATOR ON/OFF INIATOR ST STAGE ON/OFF INIATOR N STAGE EARTH UNER SWITH N STAGE SUMMER - WINTER SWITH MAIN SWITH TEST SWITH RO7 L L L0 N VA-TS OR OR8 L L NO6 L GR NO MA RO OR L VI A V A7A a A7 L L V/J V/J OR Z b a b MA5 Grey lack rown Red Orange lue Violet White Green/Yellow N L N L N VA L L V/J V/J MA9A MA0 RO6 RO S A6 L0 L0A NO V V/J N X RO V/J NO L Y A8 A9 NO NO T TH L LE NO MA5A MA5 NO RO8 V/J RO6 NO V/JA OR NO L0 L0 5 5 V 6 6 A7A MA7 MA7A NO5 NO NO 7 7 OR6 8 8 MA5A MA5A MA5 A7 NO TH MA5 NO NO T NO 5 S NO 7 NO 8 NO 9 NO 0 NO 6 V/J NO NO NO NO 9 9 VI7 V/J V/J VI8 VI8A NO 0 0 V/J V/J NO T6 T7 H MA7A LE LF H VI8A LF NO NO NO T8 5 VIS56 ONTROL PANEL

53 0 6A 8 8 ONTROL PANEL 7.. Starting Up and Operation IMPORTANT Initial starting up shall be performed by a qualified professional. 9 0 l 5 VIS56 IMPORTANT If there is no control unit, we advise you never to set the boiler thermostat below mark (approx. 0º) in order to avoid the risk of combustion products condensing on the walls of the boiler. efore turning the boiler on, make sure that the installation is filled with water. Perform the start-up operations in the order given below: oiler temperature regulation by means of the thermostats. Set boiler thermostats 5 to the selected position. If the burner has two stages, the stage thermostat must always be set to value which is approximately 5º less than that of the stage thermostat. If required, move the maximum temperature stop as instructed below. Set switch to the manual position. ontrol unit in heating cabinet Make sure that safety thermostat 9 is set by unscrewing the hexagonal cap and pressing the reset button with a screwdriver Set the burner and heating pump buttons to the Winter. position. Set main On/Off switch to the On. Moving the thermostat stop: The stop is factory-set to limit the maximum temperature to 75º. To move the stop, proceed as follows: - Pull the thermostat button out carefully (use pliers and a cloth). - Remove the stop with the pliers. - Put the stop in the hole of the desired higher temperature (maximum 85º) VIS565 Ideal Viscount GTE - Installation, Assembly & Servicing 5

54 SERVIING 8. FUEL-OIL OR GAS ONNETIONS Refer to the instructions supplied with the burner IMPORTANT The operations described below shall only be performed with the boiler and power supply off. 9. MAINTENANE 9. leaning The boiler will only operate efficiently if the exchange surfaces are kept clean. The boiler should be swept as an when required, at least along with the chimney, once a year or more, depending upon applicable regulations and specific needs. VIS566 VIS567 - Turn off the power to the boiler. - Remove the upper front panel. - Remove the retaining upper front crosspiece and then the lower left and right-hand front panels. - Remove the lower front panel. - Unfasten the wing nuts and remove the four sweeping doors. 5 Ideal Viscount GTE - Installation, Assembly & Servicing

55 SERVIING VIS57 VIS568 - Remove the baffle plates from the upper flue ways. - arefully sweep the four flue ways with the brush supplied for that purpose. - rush the baffle plates as well. - If possible, use a vacuum cleaner. - Remove the left and right-hand casing covers. - Remove the top insulating material vis569 VIS570 - Unfasten the nuts up to the stop. - Push in the handles of the sweeping covers. - Remove the sweeping covers. - rush the vertical plates. - Put back the sweeping covers, insulating material and casing covers by reversing the procedure above. Note: chemical sweeping is recommended for such boilers. - Put the baffle plates back in place. Interlock them with each other while fitting them into the flue ways. - lose the upper sweeping doors. Ideal Viscount GTE - Installation, Assembly & Servicing 55

56 SERVIING 7 8 VIS575 - Unscrew the eight closing nuts and open the furnace door These screws must not be unfastened in any event. - rush out the inside of the furnace. - lean the soot accumulated in the furnace and lower flue ways with a vacuum cleaner. - lose the lower sweeping doors. - Put back the front casing panels by reversing the removal procedure. 9 0 VIS576 VIS575 - Remove the lower rear panels. - Remove the lower rear crosspiece. - Remove the lower insulating material on the rear. - Unfasten the wing nuts and remove the lower left and righthand sweeping doors. - Remove any soot deposit with a scraper or a vacuum cleaner. - Open the lower sweeping cover of the flue gas box (two H 0 nuts + Ø 0 washers). - Remove the soot. - Put back the sweeping cover and doors. - Put back the lower insulating material, the crosspiece and panels by reversing the removal procedure. 56 Ideal Viscount GTE - Installation, Assembly & Servicing