DeDietrich GT 430 User manual

GT 430
Fuel oil/gas boilers
300011893-001-B
EN
Installation and
Service Manual

2GT 430 03/12/07 - 300011893-001-B
Contents
1 Declaration of compliance CE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3
2 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4
3 Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5
3.1 The various existing control panels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5
3.2 Technical characteristics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7
3.3 Main dimensions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12
4 Installing the boiler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13
4.1 Boiler location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13
4.2 Ventilation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14
5 Mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14
6 Hydraulic connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15
6.1 Important recommendations on connecting the heating circuit to the boiler and the drinking water system . . . . . . . . . . . . . . . . . .15
6.2 Important recommendations for connecting the boiler to the heating circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17
6.3 Filling the system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .18
6.4 Sludge removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .18
7 Chimney connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .19
7.1 Flue size . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .19
7.2 Chimney connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .19
8 Fuel-oil or gas connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20
9 Electrical connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20
10 Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .21
10.1 Sweeping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .21
10.2 Chemical sweeping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .23
10.3 Cleaning the casing material . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .25
10.4 Precautions required in the case of long boiler stops (one or more years) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .25
10.5 Precautions required if the heating is stopped when there is a risk of freezing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .25
11 Burner maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .26
12 System maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .26
12.1 Water level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .26
12.2 Draining . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .26
12.3 Rating plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .26
Spare parts - GT 430 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .27

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03/12/07 - 300011893-001-B GT 430
1 Declaration of compliance CE
Manufacturer DE DIETRICH THERMIQUE S.A.S.
57 rue de la gare
F-67580 MERTZWILLER
*[phone]
++33 (0)3 88 80 27 99
Issued by See end of notice
We hereby certify that the series of appliances specified hereinafter is in compliance with the standard model described in the EC declaration
of compliance, and that it is manufactured and marketed in compliance with the requirements and standards of the following European
Directives:
Product type GT 430 - Fuel oil/gas boilers
Formats 8, 9, 10, 11, 12, 13, 14, sections
Standard applied - 90/396/EEC Gas Appliance Directive
Reference Standard : EN 303.1 / EN 303.2 / EN 304
- 2006/95/EC Low Voltage Directive
Reference Standard : EN 60.335.1
- 2004/108/EC Electromagnetic Compatibility Directive
Generic standards : EN1000-6-3 ; EN 61000-6-1
- 92/42/EEC Efficiency Directive
Reference Standards : EN 303.2 / EN 304
Inspecting organisation CERTIGAZ:
- 1312AQ951
- 1312AQ952
Date: 22 June 2004 Signature
Technical Director
M. Bertrand Schaff

4GT 430 03/12/07 - 300011893-001-B
2Introduction
Directive 97/23/EC
Gas and oil boilers with a maximum operating temperature of 110°C
and hot water tanks with a maximum operating pressure of 10 bar
pertain to article 3.3 of the directive, and therefore, cannot be CE-
marked to certify compliance with the directive 97/23 EC.
The boilers and hot water tanks are designed and manufactured in
accordance with the sound engineering practice, as requested in
article 3.3 of the directive 97/23/EC; it is certified by compliance with
the directives 90/396/EC, 92/42/EC, 2006/95/EC and 2004/108/EC.
Warning : The boiler shall be assembled and installed by a
qualified professional only.
For a proper operating of the boiler, follow carefully the
instructions.
Symbols used
Caution danger Risk of injury and damage to equipment. Attention must be paid to the warnings on
safety of persons and equipment
Specific information Information must be kept in mind to maintain comfort
ZReference Refer to another manual or other pages in this instruction manual

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03/12/07 - 300011893-001-B GT 430
3 Description
The boilers of the GT 430 range are pressurised hot water boilers
designed for connecting to a flue pipe which require a separate
automatic fuel-oil or gas burner.
3.1 The various existing control panels
3.1.1 - S3 Standard control panel
Standard panel to be fitted
Panel comprising the settings, control and safety devices allowing
the boiler to operate autonomously, without regulation.
The standard panel is used to connect the boiler to the boiler room
control cabinet.
This cabinet can be fitted with control units.
3.1.2 Control panel K3
Separate panel
Panel comprising the settings, control and safety devices allowing
the boiler to operate autonomously.
Panel K3 also allows the boiler to be used as a "slave" boiler for
installations with 2 to 10 boilers in cascade, one of which is fitted with
a "DIEMATIC-m3" control panel.
Side panel
A version of the K3 control panel with lateral attachment is also
available.

6GT 430 03/12/07 - 300011893-001-B
3.1.3 Control panel DIEMATIC-m3
Separate panel
Top of the range electronic control panel with digital display,
comprising the settings, control and safety devices allowing the boiler
to operate autonomously.
The DIEMATIC-m3 panel is fitted as standard with a control unit
which operates according to the outside temperature.
The DIEMATIC-m3 panel also allows the boiler to be used as a
"master" boiler for installations with 2 to 10 boilers in cascade.
The other boilers (1 to 9) must be fitted with a "K3" control panel.
Side panel
A version of the DIEMATIC-m3 control panel with lateral
attachment is also available.
3.1.4 Control panel B3
Separate panel
Top of the range electronic control panel with digital display,
comprising the settings, control and safety devices allowing the boiler
to operate autonomously.
This panel makes it possible to give priority to DHW.
Side panel
A version of the B3 control panel with lateral attachment is also
available.

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3.2 Technical characteristics
3.2.1 Boilers for following countries: France - Belgium - Spain - Luxemburg - Czech Republic - Portugal -
Estonia
Maximum operating pressure: 6 bar
Boiler thermostat setting: 30 to 90°C
Maximum operating temperature: 100°C
Safety thermostat: 110°C
((1) Nominal operation (top boiler power)
In order for the boiler to operate correctly, it is imperative
to respect the draught at the nozzle.
(2)CO2= 13% on fuel oil and 9.5% on natural gas.
(3) Boiler temperature : 80 °C
Ambient temperature : 20 °C
(4) Stand-by losses in accordance with prevailing standard (EN 303/
304)
1 mbar = 10 mmCE = 10 daPa
Boiler GT 430-8 GT 430-9 GT 430-10 GT 430-11 GT 430-12 GT 430-13 GT 430-14
Useful output kW 250-310 310-370 370-430 430-495 495-570 570-645 645-700
Power input kW 271-339 336-404 402-470 465-538 563-620 618-701 699-760
Number of sections 8 9 10 11 12 13 14
Water content l 366 409 452 495 538 581 624
Water resistance
∆T = 10K
mbar
19 32 50 68 93 125 150
∆T = 15K 11 18 26 31 41 55 70
∆T = 20K 5 8 13 18 24 31 37
Pressure in the
furnace for nozzle
pressure = 0
mbar 0.57 0.73 0.96 1.2 1.57 2.0 2.5
Smoke temperature (1) (3) °C 200 200 200 200 200 200 200
Mass flue gas flow
rate (1) (2)
Fuel oil Kg/h 516 615 716 823 947 1071 1163
Gas 568 677 789 906 1043 1180 1280
Combustion chamber
Diameter,
combustion chamber mm 530 530 530 530 530 530 530
Width, combustion
chamber mm 638 638 638 638 638 638 638
Depth, combustion
chamber mm 1183 1343 1503 1663 1823 1983 2143
Volume m30.310 0.354 0.396 0.439 0.481 0.523 0.565
Stand-by losses (4) ∆T = 50K W 580 600 640 740 780 870 870
Net weight kg 1802 2072 2238 2454 2638 2880 3057

8GT 430 03/12/07 - 300011893-001-B
3.2.2 Boilers for following countries: Germany - Austria - Poland - Slovenia - Serbia
Maximum operating pressure: 6 bar
Boiler thermostat setting: 30 to 90°C
Maximum operating temperature: 120°C
Safety thermostat: 110°C (1)
*Maintenance consumption : total heat emission when the burner is
off as a percentage of the nominal input power when the difference
between the mean boiler temperature and the room temperature is
50K.
(1) Nominal operation (top boiler power)
In order for the boiler to operate correctly, it is imperative
to respect the draught at the nozzle.
(2)CO2= 13% on fuel oil and 9.5% on natural gas
(3) Ambient temperature : 20 °C
1 mbar = 10 mmCE = 10 daPa
Boiler GT 430-8 GT 430-9 GT 410-10 GT 430-11 GT 430-12 GT 430-13 GT 430-14
Useful output kW 220-265 265-315 315-365 365-425 425-485 485-550 550-615
Power input kW 236-288 285-342 339-396 392-460 457-525 522-594 592-665
Number of sections 8 9 10 11 12 13 14
Water content l 366 409 452 495 538 581 624
Water resistance ∆T = 10K mbar 11 20 31 47 66 88 111
∆T=20K 4 6 8 14172328
Pressure in the
furnace for nozzle
pressure = 0
mbar 0.4 0.55 0.68 0.9 1.1 1.5 1.8
Smoke temperature (1) (3) °C 180 180 180 180 180 180 180
Mass flue gas flow
rate (1) (2)
Fuel oil Kg/h 450 530 610 710 810 910 1020
Gas 470 555 640 745 850 955 1070
Combustion chamber
Diameter,
combustion chamber mm 530 530 530 530 530 530 530
Width, combustion
chamber mm 638 638 638 638 638 638 638
Depth, combustion
chamber mm 1183 1343 1503 1663 1823 1983 2143
Volume m30.310 0.354 0.396 0.439 0.481 0.523 0.565
Maintenance
consumption* (3) ∆T = 50K % 0.17 0.15 0.14 0.12 0.11 0.11 0.10
Net weight kg 1802 2072 2238 2454 2638 2880 3057

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03/12/07 - 300011893-001-B GT 430
3.2.3 Boilers for following countries: Switzerland
Maximum operating pressure: 6 bar
Boiler thermostat setting: 30 to 90°C
Maximum operating temperature: 120°C
Safety thermostat: 110°C
*Maintenance consumption: total heat emission when the burner is
off as a percentage of the nominal input power when the difference
between the mean boiler temperature and the room temperature is
50K.
(1) Nominal operation (top boiler power)
In order for the boiler to operate correctly, it is imperative
to respect the draught at the nozzle.
(2)CO2= 13% on fuel oil and 9% on natural gas
(3) Ambient temperature : 20 °C
(4) in accordance with DIN 4705 Teil 1
1 mbar = 10 mmCE = 10 daPa
Boiler GT 430-8 GT 430-9 GT 410-10 GT 430-11 GT 430-12 GT 430-13 GT 430-14
Useful output kW 180-224 212-264 252-312 305-400 365-470 425-530 475-580
Power input kW 196-244 231-287 274-340 332-435 397-511 462-576 517-631
Number of sections 8 9 10 11 12 13 14
Water content l 366 409 452 495 538 581 624
Water resistance (1)
∆T = 10K
mbar
10 16 26 44 63 84 103
∆T = 15K 6 9 14 20 28 37 48
∆T=20K 3 4 7 12162125
Pressure in the
furnace for nozzle
pressure = 0 (1)
mbar 0.3 0.45 0.6 0.8 1.1 1.3 1.5
Smoke temperature (1) (3) °C 160 160 160 170 170 170 170
Mass flue gas flow
rate (1) (2) (4)
Fuel oil Kg/h 373 439 520 665 781 880 963
Gas 410 483 572 732 860 969 1061
Combustion chamber
Diameter,
combustion chamber mm 530 530 530 530 530 530 530
Width, combustion
chamber mm 638 638 638 638 638 638 638
Depth, combustion
chamber mm 1183 1343 1503 1663 1823 1983 2143
Volume m30.310 0.354 0.396 0.439 0.481 0.523 0.565
Maintenance
consumption* ∆T = 50K % 0.2 0.17 0.16 0.12 0.11 0.11 0.10
Net weight kg 1802 2072 2238 2454 2638 2880 3057

10 GT 430 03/12/07 - 300011893-001-B
3.2.4 Boilers for following countries: Russia
Maximum operating pressure: 6 bar
Boiler thermostat setting: 40 to 85°C
Maximum operating temperature: 100°C
Safety thermostat: 110°C
(1) Nominal operation (top boiler power)
In order for the boiler to operate correctly, it is imperative
to respect the draught at the nozzle.
(2)CO2= 13% on fuel oil and 9.5% on natural gas.
(3) Ambient temperature : 20 °C
1 mbar = 10 mmCE = 10 daPa
Boiler GT 430-8 GT 430-9 GT 410-10 GT 430-11 GT 430-12 GT 430-13 GT 430-14
Useful output kW 300-357 357-419 419-481 481-543 543-605 605-667 667-729
Power input kW 329-394 392-462 461-532 526-597 595-667 659-731 727-798
Number of sections 8 9 10 11 12 13 14
Water content l 366 409 452 495 538 581 624
Water resistance (1) ∆T = 10K mbar
Water resistance (1) ∆T = 15K 14.7 20.8 28.2 36.9 47.0 60.0 75.2
∆T = 20K
Pressure in the furnace for nozzle pressure
= 0 (1) mbar 0.92 1.30 1.59 2.05 2.04 2.15 3.06
Smoke temperature - Ambient
temperature(1) (3) K <190 <190 <190 <190 <190 <190 <190
Mass flue gas flow
rate (1) (2)
Fuel oil Kg/h 600 710 810 910 1020 1120 1220
Gas 630 740 850 960 1070 1170 1280
Combustion chamber
Diameter,
combustion chamber mm 530 530 530 530 530 530 530
Width, combustion
chamber mm 638 638 638 638 638 638 638
Depth, combustion
chamber mm 1183 1343 1503 1663 1823 1983 2143
Volume m30.310 0.354 0.396 0.439 0.481 0.523 0.565
Stand-by losses (3) ∆T = 50K W 315 358 413 451 494 505 555
Net weight kg 1802 2072 2238 2454 2638 2880 3057

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03/12/07 - 300011893-001-B GT 430
3.2.5 Boilers for following countries: Bulgaria - China - Greece - Romania - Tunisia - Cyprus - Denmark -
Sweden - Norway - Finland
Maximum operating pressure: 6 bar
Boiler thermostat setting: 40 to 85°C
Maximum operating temperature: 100°C
Safety thermostat: 110°C
(1) Nominal operation (top boiler power)
In order for the boiler to operate correctly, it is imperative
to respect the draught at the nozzle.
(2)CO2= 13% on fuel oil and 9.5% on natural gas.
(3) Ambient temperature : 20 °C
1 mbar = 10 mmCE = 10 daPa
Boiler GT 430-8 GT 430-9 GT 410-10 GT 430-11 GT 430-12 GT 430-13 GT 430-14
Useful output kW 300-390 390-450 450-540 540-600 600-670 670-720 720-780
Power input kW 337-438 438-505 505-606 606-674 674-752 752-808 808-876
Number of sections 8 9 10 11 12 13 14
Water content l 366 409 452 495 538 581 624
Water resistance (1)
∆T = 10K
mbar
37 55 86 105 136 161 204
∆T = 15K 20 27 37 47 62.5 78.5 110
∆T = 20K 9.5 13.5 22.5 27 33.5 40 54
Pressure in the
furnace for nozzle
pressure = 0 (1)
mbar 1.1 1.5 2.0 2.5 2.5 2.5 3.5
Smoke temperature (2) (4) °C 220 220 220 220 220 220 220
Mass flue gas flow
rate (1) (2)
Fuel oil Kg/h 650 750 900 1000 1116 1200 1450
Gas 700 810 972 1080 1207 1297 1405
Combustion chamber
Diameter,
combustion chamber mm 530 530 530 530 530 530 530
Width, combustion
chamber mm 638 638 638 638 638 638 638
Depth, combustion
chamber mm 1183 1343 1503 1663 1823 1983 2143
Volume m30.310 0.354 0.396 0.439 0.481 0.523 0.565
Stand-by losses (3) ∆T = 50K W 315 358 413 451 494 505 555
Net weight kg 1802 2072 2238 2454 2638 2880 3057

12 GT 430 03/12/07 - 300011893-001-B
3.3 Main dimensions
(1) The lateral control panel can be mounted to the right or left of the
boiler. Exact height positioning defined by the fitter during assembly.
(2) Inscribed diameter (in mm):
- Front section : 455
- Intermediate section : 530
Equivalent diameter (in mm) : 573
Mk : Tapped connection
Heating outlet - weld
Heating return - weld
Rp 2 draining outlet
Sludge removal hole Ø Rp 2 1/2 - plugged
Boiler type GT 430-8 GT 430-9 GT 410-10 GT 430-11 GT 430-12 GT 430-13 GT 430-14
ø A (exterior) 250 250 250 300 300 300 300
ø B 2" 1/2 2" 1/2 2" 1/2 3" 3" 3" 3"
ø C plate intact or pre-drilled to the diameter specified on order
D 235 235 235 254 254 254 254
E 1427 1427 1427 1447 1447 1447 1447
J 1800 1950 2120 2305 2465 2625 2785
L 1505 1665 1825 1985 2145 2305 2465
S 1183 1343 1503 1663 1823 1983 2143
Control panels B3, K3
and DIEMATIC-m3
F 113.5 113.5 113.5 113.5 113.5 113.5 113.5
G 355 355 355 355 355 355 355
H 190 190 190 190 190 190 190
K 1690 1690 1690 1690 1690 1690 1690
M 755 755 755 755 755 755 755
Standard panel - S3
F 127.5 127.5 127.5 127.5 127.5 127.5 127.5
G 130 130 130 130 130 130 130
H 105 105 105 105 105 105 105
K 1605 1605 1605 1605 1605 1605 1605
M 738 738 738 738 738 738 738

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03/12/07 - 300011893-001-B GT 430
4 Installing the boiler
4.1 Boiler location
For the assembly and because of their design, GT 430 boilers require
no special base. 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.
(1) Top view
(2) Burner door
* Caution: adapt the dimensions on the basis of the
dimensions of the burner when the door is open.
GT 430-8 GT 430-9 GT 410-10 GT 430-11 GT 430-12 GT 430-13 GT 430-14
Amm 1505 1665 1825 1985 2145 2305 2465
Bmm 130 -40 120 -40 120 -40 120
Cmm 1500 2000 2000 2000 2500 2500 2500
Cross section "S"cm2840 960 1090 1240 1390 1550 1710

14 GT 430 03/12/07 - 300011893-001-B
4.2 Ventilation
The location of air inlets in relation to the high ventilation openings
shall ensure that the air is renewed in the entire volume of the boiler
room.
It is in any case imperative to conform to the local regulations in force.
Caution:
In order to avoid damage to the boiler, it is necessary to prevent the
contamination of combustion air by chlorine and/or fluoride
compounds, which are particularly corrosive.
These compounds are present, for example, in aerosol sprays,
paints, solvents, cleaning products, washing products, detergents,
glues, snow clearing salts, etc.
Therefore:
• Do not suck in air evacuated from premises using such
products: hairdressing salons, dry cleaners, industrial premises
(solvents), premises containing refrigeration systems (risk of
refrigerant leakage), etc.
• Do not stock such products close to the boilers.
If the boiler and/or peripheral equipment are corroded by such
chloride or fluoride compounds, the contractual guarantee
cannot be applied.
5 Mounting
ZFor mounting instructions, see installation instructions.

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6 Hydraulic connections
6.1 Important recommendations on connecting the heating circuit to the boiler and the
drinking water system
Installation must be carried out in accordance with the prevailing
regulations, the codes of practice and the recommendations in these
instructions.
France
Heating installations must be designed and constructed in such a
way as to prevent the return of water from the heating circuit and
products put into it into the drinking water network located upstream;
the installation must not be in direct relation with the drinking water
network (Article 16-7 of the departmental health Directive). When
these installations are fitted with a filling system connected to the
drinking water network, they comprise a CB disconnector
(disconnector for zones with non-controllable pressure differences)
which satisfy the functional requirements of the NF P 43-011
standard.
- Before connecting the heating circuit hydraulic connections, it is
essential to rinse the heating circuits to remove any particles which
might damage certain components (safety valve, pumps,
valves...).
- Take care to ensure the hydraulic isolation of the primary and
secondary circuits using stop valves in order to facilitate
maintenance operations on the calorifier. These are used to carry
out maintenance on the tank and its systems without draining the
entire installation.
These valves are also used to isolate the tank unit when conducting
a pressurised check on the leak tightness of the installation if the test
pressure is greater than the admissible operating pressure.
Safety valve
There must be no total or partial closing mechanism between the
boiler and the safety valves (France: DTU - 65.11, § 4.22 - NF P 52-
203).
The expansion vessel must be connected directly to the boiler
without valves or stop valves.
Likewise, the safety valve must be connected directly to the boiler
without valves or stop valves.

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Example of an installation: boiler with domestic hot water
production using an independent tank
The example of an installation shown below does not cover every
possible configuration.
1. Heating outlet
2. Heating return
3. 3-bar safety valve + Pressure gauge
5. Flow switch
6. Air separator
7. Automatic air vent
9. Isolating valve
10. 3-way mixing valve
11. Boiler pump
12. Sludge decanting pot (particularly recommended on older
installations)
13. Flush valve
14. Water low safety pressure-sensitive switch
15. Shunt pump
16. Expansion vessel
17. Drain cock
18. Heating circuit filling (with disconnector depending on prevailing
regulations)
19. Water treatment if TH > 25°
20. Water meter
26. DHW load pump
27. one-way valve
28. Domestic cold water inlet
29. Pressure reducer (if mains pressure 5.5 bar)
30. Sealed safety unit calibrated to 7 bar with indicator type discharge
31. Independent domestic hot water tanks
32. Domestic hot water loop pump (optional)
56. Domestic hot water circulation loop return
57. Domestic hot water outlet
8219N008C
92
14
12
17
11
27
9
56
32
9
10
1
9
57
9
27
26
15
9
17
18
919 20 9
17
16
13
3
79
7
30
28
9
29
27
9
31
56
9
9
9

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6.2 Important recommendations for connecting the boiler to the heating circuit
Installation must be carried out in accordance with the prevailing regulations, the codes of practice and the recommendations in these
instructions.
`Minimum safety valve flowrate as a function of maximum boiler nominal output :
Minimum relieving capacity
Maximum gross boiler output
(a) = kW, (b) = Kg/h, (c) = MBtu/h, (d) = lb/h
Example
Maximum boiler nominal output is 500 kW.
Minimum safety valve flowrate must be 4000 Kg/h
`Water flow in the boiler :
The water flow in the boiler when the burner is operating must correspond with the following formulae:
- Nominal water flow Qn = 0.86 Pn/20
- Minimum flow Qmin = 0.86 Pn/45 (this flow also corresponds with the minimum recycle flow in the boiler)
- Maximum water flow Qmax = 0.86 Pn/5
Qn = flow in m3/h
Pn = Nominal output (full boiler output) in kW.
`Operation in cascade
After stopping the burner:
- Timeout required before the order to close a butterfly valve: 3 min
- Switch a possible shunt pump (located between the boiler and a butterfly valve) off via the end of run contact of the butterfly valve
`Operation with 2-stage burner
- The water temperature in the boiler is maintained at 50°C or more ; the first stage must be set to a minimum of 30% of the nominal stage.
- Operation at modulated low temperature (minimum outlet temperature: 40°C) ; the first stage must be set to a minimum of 50% of the nominal
stage.

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`Operation with modulating burner
- The water temperature in the boiler is maintained at 50°C or more: the burner can modulate down to 30% of the nominal stage
- Operation at modulated low temperature (minimum outlet temperature: 40°C) ; the burner can modulate down to 50% of the nominal stage
6.3 Filling the system
Filling shall be performed with a low flow rate from a low point in the
boiler room in order to ensure that all the air in the boiler is bled from
the high point of the system.
All the pumps must be stopped before filling (included shunt
pump(s)).
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.
Do not add cold water suddenly into the boiler when it is
hot.
6.4 Sludge removal
A tapped ø 2’’ 1/2 hole with a plug has been provided on the
bottom of the front of the boiler..
Fit a 1/4 turn valve (not supplied) 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.
Comments :
never replace a boiler in an existing system without carefully rinsing
the system first. Install a sludge decanting pot on the return pipe, very
close to the boiler.

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7 Chimney connection
The high-performance features of modern boilers and their use in
specific conditions as a result of the advance in burner technology
(e.g. first-stage or low modulation range operation) lead to very low
flue gas temperatures (<160°C).
For this reason :
- Use flue gas pipes designed to enable the flow of condensates
which may result from such operating modes in order to prevent
damage to the chimney.
- Install a draining tee at the bottom of the chimney.
The use of a draught moderator is recommended as well.
7.1 Flue size
Refer to applicable regulations while determining the size of the flue.
Please note that GT 430 boilers have pressurised and tight furnaces
and that the pressure at the nozzle must not exceed 0 mbar, unless
special sealing precautions have been taken, for instance in order to
connect a static condenser/regenerator.
In order for the boiler to operate correctly, it is imperative
to respect the draught at the nozzle (= 0).
7.2 Chimney connection
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.:
A : ø 250 mm: for 8 to 10 sections,
A : ø 300 mm: for 11 to 14 sections.

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8 Fuel-oil or gas connections
The burner head deflector must be flush with the insulation
of the burner door.
C : Furnace door insulation
(1) Max attachment diameter:
- Max øB = 290 mm
- Max øB = 330 mm with 4 fastenings at 15° or 45°
ZRefer to the instructions supplied with the burner.
9 Electrical connections
ZRefer to the connection instructions supplied with the control
panel..
øA 135 175 190 240 250 290
øB 170 200 220 270 325 330
øM 8 8 10 10 14 12