DeDietrich GT 400 A Instruction manual

82N529 09
2
1
GT 400 A
Fuel oil/gas hot water boiler English
11/03/09
94863449
Assembly and installation 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.

2GT 400 A 21/09/06 - 94863449- 82294154E
Guideline of Notices
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.
ZReference 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.
- Aboilercleaningandmaintenanceshouldbeperformed annually.
Verify complete system operation at the same time.
- Correct the problem immediately to prevent damage to the
system!
! Caution:
Refer to User’s Manual regarding the carcinogenic hazard of
crystalline silica that may be found during installation, servicing
and removal of this boiler.
Safety Considerations
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.
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.
Installation and service must be performed by a qualified
installer, service agency or the gas supplier.
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 beundertakenonlyby 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.

3
21/09/06 - 94863449 - 82294154E GT 400 A
Contents
Contents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3
Regulations and guidelines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4
1 Boilers covered by this document . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4
2 Uncrating . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4
3 Packing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5
4 Technical specifications of boilers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7
Main Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8
Boiler Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9
1 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9
2 Ventilation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10
Piping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .27
1 Dimensional information required. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .27
2 Recommendations . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .27
3 Filling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .28
4 Ancillaries. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .28
Combustion and ventilation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .30
1 Clearances. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .30
2 Replacement procedures. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .31
3 Dimensional information required for connection of the boiler. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .31
Oil or gas connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .32
1 Specific technical information supplied with the burner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .32
Electrical. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .33
1 Wiring. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .33
2 Wiring procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .33
3 Wiring boiler panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .34
Start up procedures. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .35
1 Shut-down procedures. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .36
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .37
1 Boiler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .37
2 Shut down procedure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .38
Service and maintenance schedule . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .39
Isometric views and list of spare parts - GT 400 A. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .40

4GT 400 A 21/09/06 - 94863449- 82294154E
Regulations and guidelines
Theinstallationandoperatinginstructionsshownherearegiven 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
QUALIFIEDPROFESSIONAL ONLY. STRICT COMPLIANCEWITH
THESE INSTALLATION AND OPERATING INSTRUCTIONS IS A
PRECONDITION FOR THE CORRECTANDGUARANTEEOFTHE
BOILER.
• THE INSTALLATION MUST CONFORM TO THE
REQUIREMENTS OF THE AUTHORITY HAVING JURISTRICTION
OR,INTHEABSENCE 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 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
The boilers of the GT400 A range are automatic independent hot-
water boilers designed for connecting to a flue which require a
separate fuel oil or gas burner.
1 Boilers covered by this document
The GT 400 A boilers are pressurized hot water heating boilers,
connectedtoaflue, fittedwithanindependentburnerusing domestic
fuel oil or gas.
The boiler is equipped with standard control panel.
2 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.

5
21/09/06 - 94863449 - 82294154E GT 400 A
3 Packing
Beforeinstallingtheboiler,checkthe chart below toensureyouhave
all the components.
ITEM Box nr. GT 408A GT 409A GT 410A GT 411A GT 412A GT 413A GT 414A
Underframe (dimensionsaccordingtomodel) 1111111
Front section 1111111
Normal intermediate section 567891011
Special intermediate section 1111111
Rear section 1111111
Common accessories CS 20 1111111
Accessories (compositionaccordingtomodel) 1111111
Baffles
CS 30 1
CS 31 11
CS 34 1
CS 35 11
CS 36 1
Inner body insulation
CS 51 1
CS 53 11
CS 55 11
CS 57 11
Casing : common parts
CS 428 1
CS 429 1
CS 430 1
CS 431 1
CS 432 1
CS 433 1
CS 434 1
Casing : varying parts
CS 11 11
CS 12 111
CS 13 111222
CS 14 11
Wiring ducts
CS 41 1
CS 42 1
CS 43 1
CS 44 1
CS 45 1
CS 46 1
CS 47 1
Standard control panel FA 122 1111111

6GT 400 A 21/09/06 - 94863449- 82294154E
Technical documents
CS 418 1
CS 419 1
CS 420 1
CS 421 1
CS 422 1
CS 423 1
CS 424 1
ITEM Box nr. GT 408A GT 409A GT 410A GT 411A GT 412A GT 413A GT 414A

7
21/09/06 - 94863449 - 82294154E GT 400 A
4 Technical specifications of boilers
- CSA-MBHOutputbasedonThermalEfficiencyTestAccordingto
ANSI Z21.13a/CSA 4.9a-2005
- [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 [CO2 content, Vent
Pressure & Net-Flue Gas Temp]
- 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
- AllModelsareDesignCertified&EligibletoBearApprovalMarking
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.
Item Unit GT 408 A GT 409 A GT 410 A GT 411 A GT 412 A GT 413 A GT 414 A
Firing Sequence Consult Burner Technical Data
[CSA] - Gas Input MBH 1730 1947 2278 2567 2826 3100 3389
kW 507.0 570.5 667.6 752.3 828.3 908.6 993.3
[CSA] - # 2 Fuel Oil Input US GPH 12.00 13.50 15.80 17.80 19.60 21.50 23.50
[CSA] - Output [Gas-Oil] MBH 1471 1655 1937 2182 2402 2635 2880
kW 431.1 485.0 567.6 639.4 704.1 772.3 844.2
[NET] - Output [Gas-Oil] MBH 1279 1439 1684 1897 2089 2292 2505
Cast Iron sections # 8 9 10 11 12 13 14
Flue-waybaffles # 16161624202020
Water capacity US Gal 96.72 108.08 119.45 130.81 142.17 153.54 164.90
Liter 366 409 452 495 538 581 624
Water resistance
[∆t = °F]
18° F Ft. H2O1.24 1.84 2.88 3.51 4.55 5.39 6.82
27° F Ft. H2O0.669 0.903 1.24 1.57 2.09 2.63 3.68
36° F Ft. H2O0.318 0.452 0.753 0.903 1.12 1.34 1.81
Combustion chamber
Dimensions
Diameter
[equivalent] Inch 20.87
mm 530
Depth Inch 46.57 52.87 59.17 65.47 71.77 78.07 84.87
mm 1183 1343 1503 1663 1823 1983 2143
Volume ft310.95 12.50 13.98 15.50 16.99 18.47 19.95
m30.31 0.354 0.396 0.439 0.481 0.523 0.565
MAWP [Water] PSI ASME IV Rating Class 30 - (90 PSI) [See Canadian Provincial CRN approvals]
Min. Safety Relief Capacity MBH 1471 1655 1937 2182 2402 2635 2880
FA 122 Panel
Electrical connection V/P/H 120/1/60
Max. Water Temp. Safety
Limit [MR] °F 248
°C 120
Operating Water
Temperature Range °F 86 - 185
°C 30 - 85
Chamber resistance Inch w.c. 0.44 0.60 0.80 1.00 1.00 1.00 1.00
mbar 1.1 1.5 2 2.5 2.5 2.5 2.5
Gas-Vent Category # I, II - III or IV
Boiler Vent Connection Inch 10 10 10 12 12 12 12
Weight [Dry] lb 3241 3638 4034 4431 4828 5225 5622
kg 1470 1650 1830 2010 2190 2370 2550

8GT 400 A 21/09/06 - 94863449- 82294154E
Main Dimensions
GT 400 A
(1) 3” 150# weld neck flange
(2) 1/2” NPT tapping for temp sensing well, etc…
(3) 2” NPT tapping for safety relief valve
(4) 3/4” NPT tapping for low water cutoff probe type
(5) 1/2” NPT tapping for combination pres/temp gauge
Notes:
-Dimension are for gas burners only
-Oil and combination oil/gas burner, refer to burner manufacturer
specifications
2
251/8
L
==
S
¯
A
==
==
6207/8
51/2
53/4
415/16
403/8
255/8
31/4
¿3
61
51/8
161/8 51/8 5
¿3 1/2
291/8
251/8
451/4
71/4
211/2
451/4
591/16
41/8
8229N071
2
2
1/2
0
I
6A
(4)(5)
(1)
(3) (2)
Type of boiler GT 408 A GT 409 A GT 410 A GT 411 A GT 412 A GT 413 A GT 414 A
L591/4" 651/2" 717/8 781/8" 841/2" 903/4" 97"
S469/16 527/8" 591/8 651/2" 713/4" 781/16" 843/8"
Ø A out. 97/8 97/8 97/8 1113/16" 1113/16" 1113/16" 1113/16"
Dimension "X" Maximum Burner Length (inches)
Boiler Model Riello Weishaupt Power flame Fuel Master Gordon Piatt
GT408A 2213/16 23 26
321/2
26
GT409A 32
GT410A
331/16
313/16
251/8
GT411A
301/8
GT412A
GT413A 377/16 35
GT414A 381/2
G50_0001
X

9
21/09/06 - 94863449 - 82294154E GT 400 A
Boiler Installation
1Installation
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
necessaryto placeit ona fireprooffloor, butthe floor must be able to
bear the weight.
Additional
the space required when the burner door is open.
Top view
Burner door open
Combustion air
per local codes
21 1/2"
59 1/16"
41/8"
40 1/8"
71/8"
20 3/8"40 3/8"20 3/8"
B
L
X
S
Dimension
L
Dimension
B
Dimension
C
GT 408 A 591/4" 53/8" 24"
GT 409 A 651/2" 15/8" 71"
GT 410 A 717/8" 41/8" 71"
GT 411 A 781/8" 15/8" 71"
GT 412 A 841/2" 41/8" 76"
GT 413 A 903/4" 15/8" 76"
GT 414 A 97" 41/8" 76"
25 1/8"
R = 17"
R = 30 5/8"
5/8"
10 1/8"

10 GT 400 A 21/09/06 - 94863449- 82294154E
2Combustion Air Supply
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
voidthewarrantyandanyotherresponsibilityorliabilityofDeDietrich
Thermique/FES Ltd.
Note: Ensure boiler room is adequately ventilated and clear
and free from combustible materials, gasoline and other
flammable vapours and liquids.
Assembly
To fit the sections, proceed in the following order :
- fit the rear section
- fit the special intermediate section
-fitall of the normal intermediate sections
- fit the front section .
1: rear
2: front
8229 025AN
12
8229-0043 8229-0045 8229-0041 8229-0042
Boiler model
Rear section
n° 8229-0043
Special intermediate
section
8229-0045
Normal intermediate
section
8229-0041
Front section
8229-0042
GT 408 A 1 1 5 1
GT 409 A 1 1 6 1
GT 410 A 1 1 7 1
GT 411 A 1 1 8 1
GT 412 A 1 1 9 1
GT413A1 1101
GT414A1 1111

11
21/09/06 - 94863449 - 82294154E GT 400 A
Step one
Front - Rear
GT 408 - GT 410 - GT 412 - GT 414
GT 409 - GT 411 - GT 413
- Fitthe2rearattachmentbrackets(inthebody accessories pack)
and attach them onto the framework using 2 bolts HM 12X25/25 +
4 washers L12 and 2 nuts HM 12.
Use the corresponding holes following the indication on
the frame.
- Put the lower insulation in place (fabricto the top) packs CS 51 to
CS 57. Adapt length if necessary or fold the lower insulation after
the casing has been completely assembled.
Step two
Mounting of framework and thermocord
• Locate the framework depending on the direction in which the
burner door will be opened and the length of the burner.
• Put the rear section in position on the framework and support it.
Attach it at the brackets using 2 bolts HM 12x40/40 + 4 washers
L 12 + 2 nuts HM 12.
• Using a silicone gun, put silicone mastic points (1 cartridge
supplied with the accessory pack CS 20) into the sealing
groove of the section (approx. every 5 to 10 cm) then carefully
put the thermocord in place in the sealing groove.
do not pull on the cord when it is being put in, to avoid
stretching to preserve its thickness. Avoid to locate the
junction point at the bottom of the section.
HM 12
40x40
HM 12
L 12
2/5"
8"

12 GT 400 A 21/09/06 - 94863449- 82294154E
Step three
Handle the nipples with gloves, there might be sharp
edges. Clean the bores and nipples with a solvent.
Coat them with the lubricant supplied with the sections.
Step four
- Drive in the 2 nipples gently.

13
21/09/06 - 94863449 - 82294154E GT 400 A
Step five
Assembling the sections
A: thermocord
Special intermediate section before rear section.
Place the special intermediate section, note front back
relationship with the sealing groove against the thermocord.
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.

14 GT 400 A 21/09/06 - 94863449- 82294154E
Step six
- Put the special assembly tool in place. - Tighten progressively so the upper and lower connections come
together equally at the same time.
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.

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21/09/06 - 94863449 - 82294154E GT 400 A
Step eight
Installing the assembly rods and upper casing supports
(1) Front - (2) Rear - (3) Top view
- Install the upper assembly rods (body accessories pack) in the
order given in the figure above. Placetheexpansionspring and its
washer on each rod towards the rear. Stop tightening the nuts
when the free space between the threads is about 1/16" to 1/
8".
- Installtheuppercasingsupports(packCS13)andtheuppercross-
pieces (packs CS428 to CS434 and CS11 to CS14) with the
assemblyrods (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.

16 GT 400 A 21/09/06 - 94863449- 82294154E
Step nine
Hydraulic test
After assembling the boiler body, the installer must carry
out a water tightness test at a pressure equal to 1.5 times
the operating pressure (that is 137 PSI minimum - 113 PSI
in Alberta) for 30 minutes at least. The test must be done at
room temperature.
Any drop in pressure indicates a leakage in the boiler body.
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.
8229N081
7
PSI
88.5
0
7
5
8
11
9
10
6
6

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21/09/06 - 94863449 - 82294154E GT 400 A
Step ten
`Install the flue nozzle (body accessories pack) using the 4
boltsHM12x40+4nutsH12and4washersontheflueoutlet
(pack CS20).
Step eleven
• Using a pipe wrench, install the 2 threaded rods (body
accessory pack) M12 x 175 for the flue outlet.
• Install the flow flange and the gasket (body accessories pack)
using 4 nuts H 19 (24 mm spanner).
• Install the return flange with the water balancing tube (only GT
411 A to GT 414 A) and the gaskets using 4 nuts H19 (24 mm
spanner).
• Install the flue outlet onto the boiler body (6 nuts H 12 + 6 flat
washers L 12 - 19 mm spanner).
• Install 2 bolts HM 12 x 60 + 2 nuts on the flue outlet for the
cleaning traps (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

18 GT 400 A 21/09/06 - 94863449- 82294154E
Step twelve
Install the lower (solid) and upper plugs with the thermo-wells
(body accessory pack). Do not forget the hemp.
- Using a pipe wrench, put the 8 M 12 x 50 studs in place
for the cleaning doors and the burner door and the 2 M 12 x 85
studs for the hinges of the sweeping doors.
Fit the hinges for the clean-out doors (pack CS20) using 2
bolts HM 12 x 25 + 2 nuts M 12+ 2 washers DE 12.
Fitthecombustion chamber door hinge (body accessories
pack) on the left or the right according to the direction the door
will be opened, using 3 bolts HM 12 x 30 + washers CL 14.
Attach the guide flap (body accessories pack) using 2 bolts HM 12
x 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
5).
Install the hinge mounted on its pin.

19
27/03/07 GT 400 A
Step fourteen
Attach the hinge (body accessories pack) on the burner door
using the3 boltsHM12x30+ 3washers L 12(previously removed).
Leave the 3 bolts HM12x30 and the 3 washers L12 on the
burner door in place on the opposite side to the hinge.
Install the left and right hand clean-out doors in place with their
pin (pack CS 20).
Step fifteen (Flue-way baffles installation)
The part number of the baffles is marked on the casting.
Install the upper (1), middle (2) and lower (3) + (4) baffles, noting
the sequence given in the chart.
interlock the baffles one into another before placing
them completely in the flue way.
`Close the sweeping doors and secure using 3 nuts HM12 + 3
thick washers L12 x 32 x 5.
Baffles GT 408 A
pack CS 30
GT 409 A - GT 410 A
pack CS 31
GT 411 A
pack CS 36
GT 412 A
pack CS 34
GT 413 A - GT 414 A
pack CS 35
Upper 
8229-0010
8229-0022 2 x 8229-0010 2 x 8229-0010 1 x 8229-0022 2 x 8229-0010 1 x 8229-0022 3 x 8229-0010
Middle 
8229-0011
8229-0023 2 x 8229-0011 2 x 8229-0011 1 x 8229-0023 2 x 8229-0011 1 x 8229-0023 3 x 8229-0011
Lower




8229-0012
8229-0024 2 x 8229-0012 2 x 8229-0012
1 x 8229-0024 2 x 8229-0012 2 x 8229-0012

20 GT 400 A 21/09/06 - 94863449- 82294154E
Step sixteen
Install thelowercasingsupports(packCS 428toCS 434)onthe
framework using 1 bolt HM 8 x 25 + lock washer for each support. Install the body insulation panels. Bear up the insulation by tying
each strap to the lower casing support at each side of the boiler.
Boiler
Body insulation width
203/8"203/8"341/2"325/8"363/4"
Front Rear
GT 408 A 1 - - - 1
GT 409 A 1 1 1 - -
GT 410 A 1 1 - 1 -
GT 411 A 1 1 - - 1
GT 412 A 1 2 1 - -
GT 413 A 1 2 - 1 -
GT 414 A 1 2 - - 1
pack CS 10 CS 13 CS 14 CS 11 CS 12