DeDietrich GT 400 A Assembly And Installation Instructions Manual
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DeDietrich GT 400 A Assembly And Installation Instructions Manual

DeDietrich GT 400 A Assembly And Installation Instructions Manual

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GT 400 A
Fuel oil/gas hot water boiler
Assembly and installation instructions
Please Read & Save This Instruction Manual for Future Reference
Warning:
Before putting the boiler into operation read this manual
carefully.
Warning:
The operating manual is part of the documentation that is
delivered to the installation's operator. Go through the
information in this manual with the owner/operator and
make sure that he or she is familiar with all the necessary
operating instructions.
94863449
Notice:
This manual must be retained for future reference. Improper
installation, adjustment, alteration, service or maintenance can
cause injury, loss of life or property damage. Refer to this
manual. For assistance or additional information consult a
qualified installer, service agency or the gas supplier.
English
11/03/09

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Summary of Contents for DeDietrich GT 400 A

  • Page 1 GT 400 A English Fuel oil/gas hot water boiler 11/03/09 Assembly and installation instructions Please Read & Save This Instruction Manual for Future Reference Warning: Before putting the boiler into operation read this manual Notice: carefully. This manual must be retained for future reference. Improper...
  • Page 2 The boiler is certified to use only these fuels listed below, do not burn garbage or paper, never leave combustible material near it. Do not burn gasoline, crankcase draining or any other fuel containing gasoline. Natural Gas, Propane Gas & # 2 Fuel Oil GT 400 A 21/09/06 - 94863449 - 82294154E...

  • Page 3: Table Of Contents

    Isometric views and list of spare parts - GT 400 A ......

  • Page 4: Regulations And Guidelines

    1 Boilers covered by this document The GT 400 A boilers are pressurized hot water heating boilers, The boiler is equipped with standard control panel. connected to a flue, fitted with an independent burner using domestic fuel oil or gas.

  • Page 5: Packing

    CS 11 CS 12 Casing : varying parts CS 13 CS 14 CS 41 CS 42 CS 43 Wiring ducts CS 44 CS 45 CS 46 CS 47 Standard control panel FA 122 21/09/06 - 94863449 - 82294154E GT 400 A...
  • Page 6 Box nr. GT 408A GT 409A GT 410A GT 411A GT 412A GT 413A GT 414A CS 418 CS 419 CS 420 Technical documents CS 421 CS 422 CS 423 CS 424 GT 400 A 21/09/06 - 94863449 - 82294154E...

  • Page 7: Technical Specifications Of Boilers

    - All Models Certified to Fire; # 2 oil, Natural & Propane Gases. Consult factory for Available Burners. - All Models Comply and Certified in Accordance to the latest Canadian & US standards 21/09/06 - 94863449 - 82294154E GT 400 A...

  • Page 8: Main Dimensions

    Main Dimensions GT 400 A ¿3 15/16 (1) 3” 150# weld neck flange (4) 3/4” NPT tapping for low water cutoff probe type (2) 1/2” NPT tapping for temp sensing well, etc… (5) 1/2” NPT tapping for combination pres/temp gauge (3) 2”...

  • Page 9: Boiler Installation

    Boiler Installation 1 Installation The GT 400 A boiler has a sturdy underframe, it does not need any special base although a housekeeping pad is recommended to keep steel parts out of casual water. Its furnace is closed, so it is not necessary to place it on a fireproof floor, but the floor must be able to bear the weight.

  • Page 10: Assembly

    Front section Boiler model section section n° 8229-0043 8229-0045 8229-0041 8229-0042 GT 408 A GT 409 A GT 410 A GT 411 A GT 412 A GT 413 A GT 414 A GT 400 A 21/09/06 - 94863449 - 82294154E...
  • Page 11 Avoid to locate the junction point at the bottom of the section. 21/09/06 - 94863449 - 82294154E GT 400 A...
  • Page 12 Clean the bores and nipples with a solvent. Handle the nipples with gloves, there might be sharp edges. Coat them with the lubricant supplied with the sections. Step four - Drive in the 2 nipples gently. GT 400 A 21/09/06 - 94863449 - 82294154E...
  • Page 13 For safety, insert an upper assembly rod (body accessories pack) into the holes in the 2 sections. Gently and at the same time drive in the 2 nipples of the rear section using a hammer and a piece of wood. 21/09/06 - 94863449 - 82294154E GT 400 A...
  • Page 14 Step seven - Fit the remaining sections one by one in the order given, proceeding as per steps 3-4-5-6. - Leave the assembly tool in place. GT 400 A 21/09/06 - 94863449 - 82294154E...
  • Page 15 (packs CS428 to CS434 and CS11 to CS14) with the assembly rods (body accessories pack) as shown in details A-B- C-D. - Install the lower assembly rods in the order given in the figure. - Remove the assembly tool. 21/09/06 - 94863449 - 82294154E GT 400 A...
  • Page 16 Ensure that all the air in the boiler is vented to avoid any bursting of the body. After the tightness test, drain the boiler and remove all the parts used for the test. GT 400 A 21/09/06 - 94863449 - 82294154E...
  • Page 17 (see detail). • Attach the cleaning traps (pack CS 20) Using 4 bolts H 12 + 2 washers L 12 and 2 washers M 12. GT 411 A to GT 414 A 21/09/06 - 94863449 - 82294154E GT 400 A...
  • Page 18 25 + 2 washers CL 14. Step thirteen Body accessories pack Install the burner door ( 4 M 12 nuts+ 4 thick washers L12 x 32 x Install the hinge mounted on its pin. GT 400 A 21/09/06 - 94863449 - 82294154E...
  • Page 19 Install the upper (1), middle (2) and lower (3) + (4) baffles, noting the sequence given in the chart. Close the sweeping doors and secure using 3 nuts HM12 + 3 thick washers L12 x 32 x 5. 27/03/07 GT 400 A...
  • Page 20 GT 408 A GT 409 A GT 410 A GT 411 A GT 412 A GT 413 A GT 414 A pack CS 10 CS 13 CS 14 CS 11 CS 12 GT 400 A 21/09/06 - 94863449 - 82294154E...
  • Page 21 Put the left and right cable ways in place, respecting the assembly sequence. Secure the cable ways (3 screws HM5x25 + serrated washers). Secure the front top panel (package CS10) with 4 screws HM5x25 + serrated washers. 21/09/06 - 94863449 - 82294154E GT 400 A...
  • Page 22 Make the electrical connections on the two terminal blocks provided for this purpose inside the control panel - see § 7. • Close the control panel (3 self tapping screws + lock washers on the rear). GT 400 A 21/09/06 - 94863449 - 82294154E...
  • Page 23 (CS13) 19 (CS13) (CS434) • Install the remaining side panels in the order given in the table : position each panel in the lower casing supports then attach it in the wiring trough. 21/09/06 - 94863449 - 82294154E GT 400 A...
  • Page 24 CS12+CS13 (CS10) 5/8" 5/8" 5/8" 5/8" GT 412 A 7" CS14+CS13 (CS10) GT 413 A 5/8" 5/8" 5/8" 5/8" 1/2" CS11+CS13 (CS10) GT 414 A 5/8" 5/8" 5/8" 5/8" 20" CS12+CS13 (CS10) GT 400 A 21/09/06 - 94863449 - 82294154E...
  • Page 25 2 self-tapping screws ø 3.94 x 12.7 + lock washers. Attach the burner’s upper front panel onto the burner door and fix it using 2 bolts HM 12 x 25 + flat washers. 21/09/06 - 94863449 - 82294154E GT 400 A...
  • Page 26 Stick the data plates and the warning label on the casing of the boiler on a visible location. A : Stick data plate B : Stick English warning label C : Stick French warning label GT 400 A 21/09/06 - 94863449 - 82294154E...

  • Page 27: Piping

    21/09/06 - 94863449 - 82294154E GT 400 A...

  • Page 28: Filling

    26. Water treatment if TH > 25° 13. Non return valve 27. Heating circuitfilling (with disconnector if required 14. Heating pump under applicable regulations). 15. Low-water cutoff safety device [as required by code] GT 400 A 21/09/06 - 94863449 - 82294154E...
  • Page 29 5 Boiler Venting 5. Boiler Venting & Chimney General Caution & Warning: It is advised and recommended that the heating contractor-professional apply vent materials that are approved and agency listed. Installation of any venting must follow all local codes in conjunction with vent manufacturer instructions and appliance manufacturer instructions.
  • Page 30 The P-trap assembly must be properly filled with water to avoid escape of flue gas emissions. The flue gas condensation may require neutralization prior to entering the drain. GT 400 A 21/09/06 - 94863449 - 82294154E...
  • Page 31 5 Boiler Venting 5.2 Boiler Venting – Category III & IV Vent Systems Typical Layouts and Requirements. Caution & Warning: Improperly sealed venting system could result in carbon monoxide [CO] poisoning; ensure adequate support and fastening of the system. Ensure venting can safely exhaust all flue gases outside in an effective manner. These systems must operate under a positive vent pressure condition that is stable.
  • Page 32 The P-trap assembly must be properly filled with water to avoid escape of flue gas emissions. The flue gas condensation may require neutralization prior to entering the drain. GT 400 A 21/09/06 - 94863449 - 82294154E...
  • Page 33 [x3] = 3 ft. Elbow 90° [x1] = 10 ft. Termination TEE [x1] = 0 ft. Length [equivalent] = 23 ft. GT 300 A/II Series GT 400 A Series Boiler [∆p] Pressure Boiler Oil-Gas [∆p] Pressure switch Oil-Gas Model Model...
  • Page 34 Less than 1 ft. from soffit of the roof the flue gases. Less than 3 ft. from any building corner or L shape structure WARNING-CAUTION Consult Local Codes & Authorities for other Requirements not mentioned GT 400 A 21/09/06 - 94863449 - 82294154E...

  • Page 35: Dimensional Information Required For Connection Of The Boiler

    The sizing of the boiler breeching and chimney venting must follow local and national code " requirements. GT 408 A to GT 410 A GT 411 A to GT 414 A 10" 12" Ø A 21/09/06 - 94863449 - 82294154E GT 400 A...

  • Page 36: Oil Or Gas Connection

    A sediment trap must be provided upstream of the gas controls, Do not start the burner/boiler unless all access cover and • Location of manual main shutoff valve outside the jacket when codes require. panels are in place. GT 400 A 21/09/06 - 94863449 - 82294154E...

  • Page 37: Electrical

    Main power to 4x4 junction box or enter rear of boiler through race way. C : 4x4 junction box location D : Run BX cable between insulation and casing from boiler panel E : Allow extra cable to swing burner open 21/09/06 - 94863449 - 82294154E GT 400 A...
  • Page 38 Boiler Control Panel Wiring GT 400 A 21/09/06 - 94863449 - 82294154E...

  • Page 39: Start Up Procedures

    Follow burner manufactures instructions. • Mandatory factory start-up report to be completed and returned to comply with the warranty process. • Proper operating instructions of equipment to be related to operating personnel. 21/09/06 - 94863449 - 82294154E GT 400 A...

  • Page 40: Shut-Down Procedures

    NO.1. Control dial temperature settings Dial # Temp F Important : (in the absence of bas) Do not set controls below the number 5 (122f) setting. GT 400 A 21/09/06 - 94863449 - 82294154E...

  • Page 41: Maintenance

    Middle 1 x 8229-0023 1 x 8229-0023 1 x 8229-0023 1 x 8229-0012 1 x 8229-0012 2 x 8229-0012 2 x 8229-0012 2 x 8229-0012 Lower 1 x 8229-0024 1 x 8229-0024 21/09/06 - 94863449 - 82294154E GT 400 A...

  • Page 42: Shut Down Procedure

    - Shut the boiler doors to avoid any air flow inside. - If the boiler has been stopped for several months, we also advise removing the flue connection and cap it. - Shut off the fuel shut off valves GT 400 A 21/09/06 - 94863449 - 82294154E...

  • Page 43: Service And Maintenance Schedule

    2. Cap off venting of boiler at the boiler collars 3. Shut off supply & Return Valves 4. Shut off the fuel supply valves 5. Disconnect power at the panel 6. Clean boiler and venting 21/09/06 - 94863449 - 82294154E GT 400 A...

  • Page 44: Isometric Views And List Of Spare Parts - Gt 400 A

    Isometric views and list of spare parts - GT 400 A 82274096E when ordering spare parts, do not forget to state the code number given opposite the description of the required part in the liste. BOILER BODY AND ACCESSORIES 35 34...
  • Page 45 INSULATION & CASING 21/09/06 - 94863449 - 82294154E GT 400 A...
  • Page 46 CONTROL PANEL GT 400 A 21/09/06 - 94863449 - 82294154E...
  • Page 47 Seal for flame supervision window 8229-8841 Complete casing 8 sections 8229-8905 Complete right hand cleaning door 8229-8842 Complete casing 9 sections 8229-8906 Complete left hand cleaning door 8229-8843 Complete casing 10 sections 21/09/06 - 94863449 - 82294154E GT 400 A...
  • Page 48 Complete right hand wiring duct 8 sections 8229-8828 Complete right hand wiring duct 9sections 8229-8829 Complete right hand wiring duct 10 sections 8229-8830 Complete right hand wiring duct 11 sections 8229-8831 Complete right hand wiring duct 12 sections GT 400 A 21/09/06 - 94863449 - 82294154E...
  • Page 49 21/09/06 - 94863449 - 82294154E GT 400 A...
  • Page 50 GT 400 A 21/09/06 - 94863449 - 82294154E...
  • Page 51 21/09/06 - 94863449 - 82294154E GT 400 A...
  • Page 52 Bp 30 – 57, RUE DE LA Gare F – 67580 MERTZWILLER Tel: +33/3/88/80/27/00 – Fax: +33/3 88 80 27 99 Ni IRC : 347 555 559 RCS STRASBOURG www.dedietrich-thermique.com DDR AMERICAS INC In Canada: In USA or South America: 1090 Fountain St., Unit #10...

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