DeDietrich GT 300 A, GT 300 II, GT 304 A/II, GT 305 A/II, GT 306 A/II Operating Instructions Manual

...

GT 300 A/II

Please Read & Save these instructions for Future Reference

Oil-Gas Fired Hot Water boiler

English

03/14/08

Installation and operating instructions

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.

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.

94863873

Guideline of Notices

"All installations of this appliance must be be in accordance to all national and local codes and authorities having jurisdiction"

[Canadian Installation] CSA B139 for Oil & CSA B149 for Gas [USA Installations] NFPA 54/ANSI Z223.1 for Gas & NFPA 31 for Oil

This boiler must be connected to a venting that will safely and effectively discharge all flue gases to the outside in an effective manner.

Never burner garbage or paper in the unit, and never leave combustible materials around it.

Do not use gasoline, crankcase draining, or any other oil containing gasoline

Safety Considerations

Warning:



indicates presence of hazards that can cause, if not avoided, severe personal injury, death or substantial property damage.

! Caution:

indicates presence of hazards that will or can cause, if not avoided, minor personal injury or property damage.

Notice:



Application comment for optimum use of equipment and adjustment as well as useful information.

Reference to an other instruction book.

Observe the following symbols

DANGER



due to explosion of gas.

- Work only on gas components when you have a license to do so.

- Note that the assembly of gas and vent connections, the initial start-up, the electrical connections, the maintenance and service can only be performed by a licensed service contractor or technician.

DANGER



due to electricity.

- Prior to doing any work on the heating system, disconnect all electrical power to the boiler at the emergency switch.

- It is NOT sufficient to shut off only the boiler control!

! CAUTION!

SYSTEM DAMAGE due to improper installation.

- Observe local and state codes as well as common industry practices during the installation and operation of the heating appliance.

! CAUTION!

SYSTEM DAMAGE due to inadequate cleaning and maintenance.

- A boiler cleaning and maintenance should be performed annually. Verify complete system operation at the same time.

- Correct the problem immediately to prevent damage to the system!

Please observe the following safety instructions. Read this manual carefully. Correct installation and adjustment of the burner and the control

panel is a precondition for safe, efficient operation of the gas boiler. Read this manual and the specifications on the safety label carefully

before attempting to put the burner into operation.

Do not store or use gasoline or other flammable liquids in



the vicinity of this or any other appliance. Installation and service must be peformed by a qualified installer, service agency or the gas supplier.

WHAT TO DO IF YOU SMELL GAS:

- Do not try to light any appliance.

- Do not touch any electric switch, do not use any phone in your building.

- Immediately call your gas supplier from a neighbor’s phone. Follow the gas supplier’s instructions.

- If you cannot reach your gas supplier, call the Fire Department.

Warning:



Improper installation, adjustment, and/or operation could cause carbon monoxide poisoning resulting in injury or death. This product must be installed and serviced by a professional service technician who is experienced and qualified in hot water boiler installation and gas combustion.

! Caution: Strict compliance with these instructions is a

precondition for the correct operation of the boiler.

! IMPORTANT

Service on this boiler should be undertaken only by trained and skilled personnel. Keep boiler area clear and free from combustible materials, gasoline and other flammable vapors and liquids. Do not place any obstruction in the boiler room that will hinder the flow of combustion and ventilating air. Read these instructions carefully before proceeding with the installation of boiler. Post instructions near boiler for reference by owner and serviceman. Maintain instructions in legible condition.

GT 300 A/II 06/10/06 - 94863873 - 85534150E

Contents

Contents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3

Regulations and guidelines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4

Installation codes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4

General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4

1 Uncrating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4

2 Packing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4

3 Technical specifications of boilers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5

4 Main Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6

Boiler Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7

1 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7

2 Ventilation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7

3 Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7

Piping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8

1 Dimensional information required. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8

2 Recommendations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8

3 Filling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8

4 Ancillaries. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9

Combustion and ventilation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10

1 Clearances. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10

2 Replacement procedures. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11

3 Dimensional information required for connection of the boiler. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12

Oil or gas connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12

1 Specific technical information supplied with the burner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12

Electrical. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13

1 Wiring. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13

2 Wiring procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13

3 Wiring boiler panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14

Start up procedures. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15

1 Start up procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16

2 Shut-down procedures. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16

Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17

1 Boiler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17

Service and maintenance schedule . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .19

Spare parts - GT 300 A/II . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20

06/10/06 - 94863873 - 85534150E GT 300 A/II

Regulations and guidelines

Only a qualified and licenced heating professional is to carry out the removal, installation, startup and maintenance of this boiler. The boiler must be installed according to all national and local codes having jurisdiction. The operation of the boiler must be verified and all safety controls checked. Any defect or abnormal operations must be corrected immediately. The entire system requires annual service and cleaning at least once a year.

The installation and operating instructions shown here are given as a guide for installation and operation and are not meant to replace any State or Local Codes that may apply to the individual installation. Good engineering practice should be used. Any deviation from laws or regulations or industry Code or these instructions will void the boiler warranty and any other responsability or liability of the De Dietrich Thermiques S.A.

Installation codes

• THE BOILER SHALL BE ASSEMBLED AND INSTALLED BY A QUALIFIED PROFESSIONAL ONLY. STRICT COMPLIANCE WITH THESE INSTALLATION AND OPERATING INSTRUCTIONS IS A PRECONDITION FOR THE CORRECT AND GUARANTEE OF THE BOILER.

• THE INSTALLATION MUST CONFORM TO THE REQUIREMENTS OF THE AUTHORITY HAVING JURISTRICTION OR, IN THE ABSENCE OF SUCH REQUIREMENTS, TO THE CAN/ CGA B-149 FUEL GAS INSTALLATION CODES AND CSA B-139 OIL INSTALLATION CODES.

• WHERE REQUIRED BY THE AUTHORITY HAVING JURISTRICTION, THE INSTALLATION MUST CONFORM TO THE STANDARD FOR CONTROLS AND SAFETY DEVICES FOR AUTOMATICALLY FIRED BOILERS ANSI/ASME CSD-1.

The GT300 A/II are series of oil or gas fired, cast iron, automatic boilers.

1 Uncrating

Upon arrival, check shipment to ensure all parts have been shipped. Inspect all items for delivery damage. Report all damage and shortages to the delivery carrier. Report any damage and shortages to the Distributor.

• THE INSTALLATION OF THE RELIEF VALVE SHALL BE CONSISTENT WITH ANSI/ASME BOILER PRESSURE VESSEL CODE, SECTION IV CSA B51.

• THE BOILER MUST NOT BE INSTALLED ON CARPETING.

• IF AN EXTERNAL ELECTRICAL SOURCE IS UTILIZED, THE BOILER WHEN INSTALLED, MUST BE ELECTRICALLY BONDED TO GROUND IN ACCORDANCE WITH THE REQUIREMENTS OF THE AUTHORITY HAVING JURISTRICTION OR, IN THE ABSENCE OF SUCH REQUIREMENTS, WITH THE CANADIAN ELECTRICAL CODE PART 1, CSA C22.1, ELECTRICAL CODE.

LABEL ALL WIRES PRIOR TO DISCONNECTION WHEN



SERVICING CONTROLS. WIRING CAN CAUSE IMPROPER OPERATION AFTER SERVICINGS. “VERIFY PROPER OPERATION AFTER SERVICE”.

General

2 Packing

See the separate assembly instruction book. For the optional equipment you may use with this boiler, see the

current price list.

GT 300 A/II 06/10/06 - 94863873 - 85534150E

Item

GT 300 A/II Technical Specification Table

Firing Sequence

[CSA] - Gas Input

[CSA] - # 2 Fuel Oil Input

[CSA] - Output [Gas-Oil]

[NET] - Output [Gas-Oil]

Cast Iron Sections

Flue-way baffles

Water Capacity

18° F

Water

Resistance

27° F

[∆T = °F]

36° F

Diameter

[equivalent]

Combustion

Chamber

Depth

Dimensions

Volume

MAWP [Water]

Min. Safety Relief Capacity

Electrical Connection

Max. Water Temp.

Safety Limit [MR]

Water Operating

FA 122 Panel

Temperature Range

Chamber Resistance

Gas-Vent Category

Boiler Vent Connection

Weight [Dry]

Model

Unit

GT 304 A/II

GT 305 A/II

GT 306 A/II

GT 307 A/II

GT 308 A/II

GT 309 A/II

Consult Burner Technical Data

MBH 404 598 808 1,024

1,226

1,442

kW 118 175 237 300 359 423

US GPH

MBH 343 509 686 870 1,042

kW 100.6

2.80 4.15 5.60 7.10 8.50 10.00 1,226

149.1

201.2

255.1

305.3

359.2

MBH 298 442 597 757 906 1,066

#456789 # 6 10 10 10 12 12

US Gal

25.37

30.65

35.94

41.22

46.51

51.80

Liter 96 116 136 156 176 196

Ft. H Ft. H Ft. H

Inch

0.368 0.60221 1.0371 1.539 2.275 3.5129

0.1539 0.24758 0.47508 0.6524 1.007 1.539

0.0869 0.1405 0.26765 0.36802 0.56876 0.86986

14.84 377

Inch 24.45 30.75 37.05 43.35 49.65 54.96

mm 621 781 941 1,101 1,261 1,396

Ft m

PSI

3.39 4.31 5.23 6.14 7.06 7.98

0.096 0.122 0.148 0.174 0.2 0.226 ASME IV Rating Class 30 - (81 PSI) [See Canadian Provincial CRN approvals]

MBH 343 509 686 870 1,042 1,226

V/P/H

° F

° C

° F

° C

120/1/60

248 120

104 - 185

40 - 85

Inch w.c. 0.80 0.16 0.28 0.48 0.72 0.88

mbar 0.2 0.4 0.7 1.2 1.8 2.2

I, II - III or IV

Inch 777888

lb 1,124 1,340 1,530 1,744 1,953 2,154

kg 510 608 694 791 886 977

Note:

• CSA - MBH Output based on Thermal Efficiency Test According to ANSI Z21.13a/CSA 4.9a-2005

• All Models Certified for 0 - 2,000 feet ASL installation altitude, consult factory for higher altitudes

• [NET] MBH Output Factor 1.15, Allowance for Piping and Pickup Losses

• Chamber Resistance Based on Neutral Chimney-Vent Pressure Gas Vent Category Based on Several Factors [CO

•

• Approved for Direct-Vent, Use Only Approved Venting as Listed

• Natural Draft Applications, Approved for Type L vent [Gas-Oil] or Type B Vent [Gas Only]

• Conversion Btu to kW = 3,412 Btu per kW

• All Models are Design Certified & Eligible to Bear Approval Marking as Shown.

• 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

• To Obtain Current IBR Ratings, consult their publications and website.

Due to ongoing and continuous product improvements, Flexible Eutectic Sales Ltd. Reserves all rights to amend and delete information provided on this product specification table.

06/10/06 - 94863873 - 85534150E GT 300 A/II

content, Vent Pressure & Net-Flue Gas Temp]

4 Main Dimensions

GT 300 A/II

A Water flow tapping 2 1/2" NPSC B Water return 2 1/2" NPSC

C Drain 1 1/2" FPT D Rp 2 1/2 diameter sludge removal hole

Type of boiler GT 304 A/II GT 305 A/II GT 306 A/II GT 307 A/II GT 308 A/II GT 309 A/II

Ø R

5/8"

9/32

7" 7" 7" 8" 8" 8"

44 25

G50_0001

59/64" 19/32"

7/32

7/8

33/64"

3/16"

63 44

Dimension "X" Max. Burner Length (inches)

Boiler Model Riello Weishaupt Power Flame Fuel Master Gordon Piatt

GT304 A/II GT305 A/II GT306 A/II GT307 A/II GT308 A/II GT309 A/II

15/32

1/4

1/8

Notes:

13/16" 31/64"

7/64"

25/32"

- Dimension are for gas burner only

- Oil and combination oil/gas, refer to burner manufacturer specifications

GT 300 A/II 06/10/06 - 94863873 - 85534150E

Boiler Installation

Combustion air supply must be provided according to national and local codes: CSA B149.1 -.2 & CSA B139 ANSI Z223.1 & NFPA 31

Illustration above showing minimum distances to combustible materials and servicing.

Boiler must not be installed on combustible material or on carpet.

1Installation

The GT 300 A/II boiler has a base frame, 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.

1/8

46"

59/64

8553N138

Boiler type L GT 304 A/II 33"

GT 305 A/II

GT 306 A/II

GT 307 A/II

GT 308 A/II

GT 309 A/II

40"

5/16"

9/16"

7/8"

3/16"

1/2"

2 Combustion Air Supply

20"

11/32

31"

20"

Dimension 'X', consult burner info. additional 24 inches for servicing Caution : note addtional space required when the burner door is open. Multiple installation of several boilers side by side, these dimensions

need to be modified.

Boilers operating in atmospheres that contain fluorides or chlorides such as beauty shops and automotive repair garages where air conditioning services are performed or industrial applications that may have corrosive elements in the air must have a clean source of combustion and ventilation air. Boiler damage by contaminants will void the warranty and any other responsibility or liability of De Dietrich Thermique/FES Ltd.

Warning: Ensure boiler room is adequately ventilated and



clear and free from combustible materials, gasoline and other flammable vapours and liquids.

4 Main Dimensions

GT 300 A/II

A Water flow tapping 2 1/2" NPSC B Water return 2 1/2" NPSC

C Drain 1 1/2" FPT D Rp 2 1/2 diameter sludge removal hole

Type of boiler GT 304 A/II GT 305 A/II GT 306 A/II GT 307 A/II GT 308 A/II GT 309 A/II

Ø R

5/8"

9/32

7" 7" 7" 8" 8" 8"

44 25

G50_0001

59/64" 19/32"

7/32

7/8

33/64"

3/16"

63 44

Dimension "X" Max. Burner Length (inches)

Boiler Model Riello Weishaupt Power Flame Fuel Master Gordon Piatt

GT304 A/II GT305 A/II GT306 A/II GT307 A/II GT308 A/II GT309 A/II

15/32

1/4

1/8

Notes:

13/16" 31/64"

7/64"

25/32"

- Dimension are for gas burner only

- Oil and combination oil/gas, refer to burner manufacturer specifications

GT 300 A/II 06/10/06 - 94863873 - 85534150E

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 conj unction with vent manufacturer instructions and appliance manufacturer instructions.

All De Dietrich GT series oil-gas fired cast iron boilers are high performance boilers that could operate under all 4 vent categories as established by ANSI Z21.13/CSA 4.9 Standard. To assist with application where the vent category is unknown a graph below has been provided to assist you in determining the vent category and what venting materials would be acceptable. Although the gas vent categories were developed specifically for gas fired appliances, using this information is helpful for oil fired boilers. It is very important the venting be selected according to the conditions that the boiler will operate under, minimum and maximum firing conditions of the boiler must be respected. The venting installed must comply and be certified to all applicable codes and standards for each jurisdiction.

Gas-Vent Category [4] Definitions:

Cat. I

A Boiler, which operates with a non-positive vent (breech) pressure and flue gas temperatures which avoids excessive condensation production in the chamber and venting.

Cat. II

A Boiler, which operates with a non-positive vent (breech) pressure and flue gas temperatures produce condensation production in the chamber and venting.

Chart created by Craig Holdforth

Cat. III

A Boiler, which operates with a positive vent (breech) pressure and flue gas temperatures which avoids excessive condensation production in the chamber and venting.

Cat. IV

A Boiler, which operates with a positive vent (breech) pressure and flue gas temperatures produces condensation production in the chamber and venting.

Chart A

Gas-Fired Appliance Vent Categorization

[According to ANSI Z21.13/CSA 4.9 Gas Boiler Standard]

Carbon Dioxide [CO2] Content %

6 7 8 9 10 11 12 11 10 9 8 7 6

(Net, Minus Room Temperature)

Chimney-Vent Flue Gas Temperature °F

500

456

412

368

324

280

236

192

148

104

Typical Vent Types [A,B,C & L]

[BH, AL294C®, 304-316L SS]

Category I

Category II

Typical Vent Types

Negative

Chimney-Vent Pressure

[Inches w.c.]

Category III

Typical Vent Types

[BH, AL294C®, 304-316L SS]

Category IV

Typical Vent Types

[BH, AL294C®, 304-316L SS]

Positive

260

236

211

187

162

138

113

(Net, Minus Room Temperature)

Chimney-Vent Flue Gas Temperature °C

5.1 Boiler Venting – Category I & II 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 negative vent pressure condition that is stable.

Warning & Cautions for Co-Venting:

Co-venting with other appliances shall conform latest ANSI Z223.1 & CAN/CGA 149 installation codes, any improper operation shall be corrected, the common venting shall be sized according to the appropriate tables in Part II of the above mentioned codes.

Category I Vent Systems Requirements:

1. Flue gas temperatures above the green line shown in chart A.

2. Approved type of venting for category I appliances.

3. A barometric draft control maybe employed as required, but is not necessary for correct boiler operation. Consult a chimney-vent specialist for correct application and usage.

4. Breeching and chimney vent sized in accordance to local and national codes or by good engineering methods.

5. Vent safety device equipped on the venting or as equipped on burner.

6. Condensate TEE fitting supplied on the boiler breeching as close as possible and be orientated to avoid accumulation of flue gas condensation in the boiler or venting is also used to determine flue gas emissions.

Category II Vent Systems Requirements:

1. Flue gas temperatures below the green line shown in chart A.

2. Approved type of venting for category II appliances.

3. A barometric draft control maybe employed as required, but is not necessary for correct boiler operation. Consult a chimney-vent specialist for correct application and usage.

4. Breeching and chimney vent sized in accordance to local and national codes or by good engineering methods.

5. Vent safety device equipped on the venting or as equipped on burner.

Lined Masonry Chimney

Caution-Warning:

Flue gas condensation is very aggressive and corrosive which could lead to failure of the venting system or drains, consult local and national codes regarding flue gas condensation disposal. 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.

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5.2 Boiler Venting – Category III & IV Vent Systems Typical Layouts and Requirements.

Caution & Warning:

Warning & Cautions for Co-Venting:

Category III Vent Systems Requirements:

1. Flue gas temperatures above the green line shown in chart A.

2. Approved type of venting for category III appliances

3. Breeching and chimney diameter sized in accordance to national & local codes or by good engineering methods.

4. Vent safety device equipped on burner [MR]

5. Condensate TEE fitting supplied on the boiler breeching as close as possible and be orientated to avoid accumulation of flue gas condensation in the boiler or venting.

Category IV Vent Systems Requirements:

1. Flue gas temperatures below the green line shown in chart A.

2. Approved type of venting for category IV appliances

3. Breeching and chimney diameter sized in accordance to national & local codes or by good engineering methods.

4. Vent safety device equipped on burner [MR]

5. Condensate TEE fitting supplied on the boiler breeching as close as possible and be orientated to avoid accumulation of flue gas condensation in the boiler or venting.

Caution-Warning:

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5.3 Boiler Venting – Side-Wall or Direct Vent Systems Typical Layouts and Requirements.

Caution & Warning:

Side-wall & Direct Vent Systems:

These systems do not fall under any of the gas vent categories, these systems are pre-engineere d. These applications of this venting system must be followed exactly, for safe, efficient and trouble free operation.

System Requirements:

1. Venting sized accordance to direct vent table

2. Type “BH” [AL294C®] vent material

3. Condensate TEE fitting supplied on the boiler breeching as close as possible and be orientated to avoid accumulation of flue gas condensation in the boiler or venting is also used for determining flue gas emission s.

4. Vent termination TEE

5. Vent safety device equipped on burner [MR]

Vent Termination Locations & Warning – See Section 5.5

Caution-Warning:

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5.4 Boiler Venting – Side-wall or Direct Vent Systems Sizing Tables & Vent Safety Device

• All venting lengths must be calculated to equivalent lengths, all application must include at least one 90° elbow

• Venting must be a type ‘BH” [AL294C® material]

• Maximum vent length [equivalent] = 30 ft. [9m]

• Minimum vent length [equivalent] 5 ft. [1.5m]

• Maximum number of 90° elbows = 2 or 3 45° elbows, each

90° elbow is equivalent to 10 ft. or straight pipe, the 45° elbow is equivalent = 5 ft.

• Condensate TEE must be provided [equivalent length = 7 ft.]

• Appliance reducing adapter [equivalent length 3 ft.]

• Sealed combustion, combustion air intake sizing, must be

sized according to the burner manufacturers instructions

• Vent [breeching] pressure shall not exceed 0.20 inches w.c. [0.50 mbar]

Determining vent length [equivalent] Example:

Appliance reducing adapter [x1] = 3 ft. Condensate TEE [x1] = 7 ft. 12” vent straight vent pipe [x3] = 3 ft.

Elbow 90° [x1] = 10 ft.

Termination TEE [x1] = 0 ft.

Length [equivalent] = 23 ft.

• Vent termination must be a TEE type, follow warning regarding termination locations. Do not include the termination TEE length in the vent length calculation.

• Venting shall be sloped, so any condensation developed will drain through the condensate TEE fitting

• Vent safety device, differential air pressure switch [manual reset] NC switch opens on rise of pressure.

• Optional function of power burners which can employ an post purge function to exhaust flue gases for a fixed time [1 minute to 4 minutes maximum]

• Burner employing a standby air damper closed position, the closed position should be slightly opened to allow hot flue gases to escape upward through venting and not be entrapped in the combustion head. Important note, that in negative building pressures, the observation and odor of flue gases may enter the boiler room.

GT 300 A/II Series

Model

GT 304 A/II 7 inch 5 inch GT 305 A/II 7 inch 5 inch GT 306 A/II 7 inch 5 inch GT 307 A/II 8 inch 6 inch GT 308 A/II 8 inch 6 inch GT 309 A/II 8 inch 6 inch

Boiler

Connection ø

Oil-Gas

Vent ø

[∆p] Pressure switch Setting [inches w.c.]

Set vent safety

pressure switch

150% above burner

gas manifold or

head pressure

setting

Model

GT 408 A 10 inch 8 inch GT 409 A 10 inch 8 inch GT 410 A 10 inch 8 inch GT 411 A 12 inch 10 inch GT 412 A 12 inch 10 inch GT 413 A 12 inch 10 inch GT 414 A 12 inch 10 inch

GT 400 A Series

Boiler

Connection

Oil-Gas

Vent ø

GTE 500 A Series

Model

GTE 515 A 16 inch 12 inch GTE 521 A 16 inch 12 inch GTE 516 A 16 inch 12 inch GTE 522 A 18 inch 14 inch GTE 517 A 16 inch 12 inch GTE 523 A 18 inch 14 inch GTE 518 A 16 inch 12 inch GTE 524 A 18 inch 14 inch GTE 519 A 16 inch 12 inch GTE 525 A 18 inch 14 inch GTE 520 A 16 inch 12 inch

Boiler

Connection ø

Oil-Gas

Vent ø

[∆p] Pressure switch Setting

[inches w.c.]

Set vent safety

pressure switch

150% above

burner gas

manifold or

head pressure

setting

Model

Boiler

Connection ø

Oil-Gas

Vent ø

[∆p] Pressure

switch Setting

[inches w.c.]

Set vent safety

pressure switch

150% above

burner gas manifold or

head pressure

setting

[∆p] Pressure

switch Setting

[inches w.c.]

Set vent safety

pressure switch

150% above

burner gas manifold or

head pressure

setting

5.5 All Side-wall and direct Vent termination locations installation precautions: Warning/Caution:

In all cases avoid potential vent termination locations where excess debris or snow could accumulate and bock the vent termination to any degree.

Minimum clearance of 4 ft. [1.22m] horizontally from, and in no case above or below, unless a 4 foot [1.22m] horizontal distance is maintained, from electric meters, gas meters, regulators & relief equipment.

Do Not Co-Vent Any Direct Vent or Sidewall Venting System

A VENT SHALL NOT TERMINATE…..

Directly above a paved sidewalk or driveway which serves 2 buildings. Less than 7 ft. any paved sidewalk or drive way Less than 6 ft. of a combustion air inlet to any building Less than 4 ft. above a meter/regulator assembly [horizontally] of the vertical center-line of the regulator vent outlet to a maximum vertical distance of 15 ft. Less than 4 ft. of any gas service regul a t or vent outlet Less than 1 ft. above grade or normal anticipated snow level for the area Less than 3 ft. from windows, doors [that can be opened], combustion air supply or any appliance or building. Underneath a veranda, porch or deck unless:

1. The veranda, porch or deck is fully open on a minimum of 2 sides beneath the floor &

2. The distance between the top of the vent termination and the underside of the veranda, porch or deck is greater than 1 ft.

(GAS INSTALLATIONS CANADA)

B149.1

(OIL INSTALLATIONS CANADA)

A VENT SHALL NOT TERMINATE…..

B139-00

Directly above a paved sidewalk or driveway which serves 2 buildings. Less than 7 ft. any paved sidewalk or drive way Less than 6 ft. from an open-able window, door or mechanical combustion air supply Less than 6 ft. of any combustion air inlet Less than 3 ft. of the vertical centerline of the meter/regulator assembly on a horizontal plane perpendicular to the regulator Less than 6 ft. of gas service regulator vent outlet Less than 4 ft. of oil tank vent or oil tank fill inlet Less than 1 ft. above grade or normal anticipated snow level for the area. Within 6 ft. of a property line Underneath a veranda, porch or deck Flue gases are within 6 ft. of combustible material or any openings of surrounding buildings. Less than 3 ft. from an inside corner or L-shaped structure Where flue gases may be directed towards brickwork, siding or other construction that may cause damaged from heat or condensate from the flue gases.

A VENT SHALL NOT TERMINATE…..

ٛ Less than 3 ft. of any combustion air inlet source located within 10 ft. ٛ Less than 1 ft. from any obstructions ٛ Less than 1 ft. above grade or normal anticipated snow level for the area . ٛ Over public walkways, driveways or other areas where condensate or

vapor could create nuisance or hazard or could be detrimental to the operation of regulators, relief's, valves or other equipment

A VENT SHALL NOT TERMINATE…..

ٛ Less than 5 ft. from vent outlet of the supply tank ٛ Less than 7 ft. above walkways ٛ Less than 1 ft. from any door, window or air inlet source ٛ Less than 1 ft. from grade or snow level. ٛ Less than 3 ft. from a air intake that is within 10 ft ٛ Less than 1 ft. from soffit of the roof ٛ Less than 3 ft. from any building corner or L shape structure

NFPA 54 / ANSI Z223

(GAS INSTALLATIONS USA )

NFPA 31

(OIL INSTALLATIONS USA)

WARNING-CAUTION

Consult Local Codes & Authorities for other Requirements not mentioned

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6 Dimensional information required for connection of the boiler

The boiler must be connected to venting system that will safely and effectively discharge all flue gases to the outside in an effective manner.

Consult local and national codes regarding the boiler breeching and chimney sizing.

Follow the information and documentation as supplied with the burner, regarding:

The specific installation requirements, wiring, fuel supply and piping and all adjustments of the air and fuel and start-up procedure as be followed as supplied with the burner documentation

Consult the burner manufacturer regarding the required maintenance of the burner and the service intervals.

The entire heating system must be check once each heating season.

Do not start the burner/boiler unless all access cover and panels are in place.

53N14 A 85 0

1/611

15"

/165

A : chimney connection : GT 304 A/II to GT 306 A/II : 7" GT 307 A/II to GT 309 A/II : 8"

1 Specific technical information supplied with the burner

• The boiler and its individual shutoff valve must be disconnected from the gas supply piping system during any pressure testing of that system at test pressures in excess of 1/2 psi (3.5kPa),

• The boiler must be isolated from the gas supply piping system by closing its individual manual shutoff valve during any pressure testing of the gas supply piping system at test pressures equal to or less than 1/2 psi (3.5 kPa),

• The boiler shall be installed such that the gas ignition system components are protected from water (dripping, spraying, rain, etc.) during appliance operation and service (circulator replacement, condensate trap, control replacement, etc.),

• The boiler and its gas connection must be leak tested before placing the boiler in operation,

• After placing the boiler in operation, the ignition system safety shutoff device must be tested,

• Provision for vent, bleed and gas relief lines (when applicable),

• A sediment trap must be provided upstream of the gas controls,

• Location of manual main shutoff valve outside the jacket when codes require.

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9/16

32"

Oil or gas connections

1 Wiring

Warning/Caution: Label all wiring prior to disconnection for servicing controls. Wiring errors can cause improper and dangerous operation.

"Verify Proper Operation After Serving"

Wiring in accordance with the requirements of the authority having jurisdiction or, in the absence of such requirements, with the Canadian Electrical Code Part 1, CSA C22.1, Electrical Codes.

2 Wiring procedure

De Dietrich boiler suggested field wiring procedure.

Electrical

1 : Top view

2 : Boiler panel

3 : Front

A : Race ways located under top panel of boiler

B : Wiring to be run in electrical race way to boiler control panel from

ancillaries 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

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Flexible Eutectic Sales Ltd. [De Dietrich North America] FA 122 Panel – Boiler Controller

Boiler Control Wiring

Wiring Legend

L – Main Line 120v N – Main Neutral N – Burner Neutral

TCH2

10 5

TCH1

Internal

278912 411

L1 – Burner Line 120v T1 – Boiler Limit T2 – Burner Limit T6 – Boiler Operating Limit T7 – Burner Low Fire – As Required T8 – Burner Hi Fire S3 – Optional Burner Alarm VA – Optional Hi Temp Alarm A1-A2 – Optional Alarm Device [Supplied by Others] J1-J2 – Field Supplied jumpers

12 11

VA S3

10 9 8 7 6

T8 T7 T6 T2 T1

J1J2

T6 T7 T8

T1T2

Limit CircuitFiring Rate Circuit

Burner Connections

WARNING – CAUTION:

ALL ELECTRICAL CONNECTIONS

MAYBE FROM MULTIPLE SOURCES

Application Note for BMS or BAS systems:

The Local-Remote switch or enable/disable forced relay,

must interrupt the TCH2 control . TheTS & TCH1 limits

must remain in the limit circuit.

Panel Wiring Options:

On-Off Control [Single stage burners] use jumper as shown

2 Stage Control [2 Stage burners] Remove jumper 2 install firing rate control from burner T6 – T8

Progressive Modulating Control [Multi-Stage burners] Remove jumpers 1 Installed burner limit circuit between T1 & T2 Remove jumper 2 Install burner firing rate control between T6 [common] T7 [min rate] & T8 [max rate]

L15N

120v 60Hz.

L N

Burner Power

Vent Safety

Device

Auxiliary Hi-

Limit [Optional]

LWCO

Service Switch

Consult burner manufacturer:

All burner wiring Modulating Signal and required Controls Burner Motor May require additional power source BMS Local-Remote Control Wiring.

Wiring Symbols

Fused

Disconnect

Main fuse

disconnect

6A 120V max

Service Switch

[Others]

LWCO Device

[As required]

Vent Safety Device [NC]

Burner Safety

Interlock –

Optional [Others]

Auxiliary limit –

Optional [Others]

120V Alarm

indicator [Others]

Factory Wiring

Field Wiring

[Others]

Alarm Wiring

[Others]

Jumper Wiring

[Others]

Strain Relief

[Others]

N L

06/10/06 - 94863873 - 85534150E GT 300 A/II

1 Wiring

Wiring in accordance with the requirements of the authority having jurisdiction or, in the absence of such requirements, with the Canadian Electrical Code Part 1, CSA C22.1, Electrical Codes.

2 Wiring procedure

De Dietrich boiler suggested field wiring procedure.

Electrical

1 : Top view

2 : Boiler panel

3 : Front

A : Race ways located under top panel of boiler

B : Wiring to be run in electrical race way to boiler control panel from

ancillaries 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

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FOR YOUR SAFETY READ BEFORE OPERATING

WARNING: If you do not follow these instructions exactly,



a fire or explosion may result causing properly damage, personal injury or loss of life.

A. This appliance does not have a pilot. It is equipped with an ignition

device wich automatically lights the burner. Do not burner by hand.

B. BEFORE OPERATING smell all around the appliance area for gas. Be sure to smell next to the floor because some gas is heavier than air and will settle on the floor.

1 Start up procedures

• Inspect for proper baffling insertion into flue passes. All cleanout doors properly sealed. Burner door closed and properly latched.

• Gas and oil systems ready. Proper vent connections. Required combustion and ventilation air provided.

• Waterside of system properly filled and vented of air.

• Lighting instruction followed.

try to light the

WHAT TO DO IF YOU SMELL GAS

• Do not try to light any appliance.

• Do not touch any electric switch; do not use any phone in your building.

• Immediately call your gas supplier from a neighbor’s phone. Follow the gas supplier’s instructions.

• If you cannot reach your gas supplier, call the fire department.

C. Use only your hand to push in or turn the gas control knob. Never use tools. If the knob will not push in or turn by hand, don’t try to repair it: call a qualified service technician. Force or attempted repair may result in a fire or explosion.

D. Do not use this appliance if any part has been under water. Immediately call a qualified technician to inspect the appliance and to replace any part of the control system and any gas control which has been under water.

• To be performed by a licensed tradesperson in accordance with the guidelines shown in this manual. 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.

2 Shut-down procedures

• Disengage all electrical power switches to heating system burners, pumps. Isolate all boiler valves and fuel valves.

• For off-season shutdown, open boiler combustion flue ways and clean. Ensure venting, chimney, combustion and ventilation air openings free from blockage. Do not drain waterside of system.

- Shutoff fuel supply lines

1 Boiler

Ensure all access cover and doors are in place prior to starting the boiler-burner.

Maintenance

It is not advisable to drain an installation, except in case of absolute necessity. Check the water level of the installation and top it off if necessary, avoiding a sudden inlet of cold water in the hot boiler.

Check for system leaks.

• Cleaning of the flue gas circuit :

- switch off the electricity supply to the boiler

- unhook the front cover

Professional water treatment is recommended.

The good performance of the boiler depends on cleanliness.

Cleaning the boiler must be carried out as often as required and at least, as for the flue once a year. The following operations are always carried out with the boiler and the power supply shut off.

GT 300 A/II 06/10/06 - 94863873 - 85534150E

- open the sweeping door (upper door) by unscrewing the 4 lock nuts.

- remove the convection baffles,

- using the brush supplied, carefully sweep the 6 flue sections,

- also brush the convection baffles and the front face,

- if possible use a vacuum cleaner,

- put the convection accelerators back in place (pay attention to their direction),

- shut the door.

• Maintenance of the combustion chamber

- open the combustion chamber door (lower door) by unscrewing the

4 lock nuts

- brush the inside of the combustion chamber

- using a vacuum cleaner, vacuum up the soot deposits which have accumulated in the combustion chamber

- close the door and replace the front cover

1 : stop pins 2 : brush

Baffle Position Baffle Fraction mm GT 304 A/II GT 305 A/II GT 306 A/II GT 307 A/II GT 308 A/II GT 309 A/II

Upper [3rd Pass]

Middle [2nd Pass]

Lower

[1st Pass]

8219-0017 16 1/4 410 8219-0018 22 7/16 570

8219-0019 16 1/4 412 222242 8219-0020 22 1/2 572 000002

3 : vacuum cleaner brush 4 : vacuum cleaner

088400 400488

• Cleaning the smoke box (Flue Hood)

For this purpose :

-remove the sweeping left and right hand covers of the smoke box (2

wing nuts) and remove the soot which has accumulated using a vacuum cleaner

-replace the sweeping covers.

• Burner maintenance :

In accordance with the directions supplied with the burner.

8553N136

+ 47 hidden pages

DeDietrich GT 300 A, GT 300 II, GT 304 A/II, GT 305 A/II, GT 306 A/II Operating Instructions Manual

Specifications and Main Features

Frequently Asked Questions

User Manual