DeDietrich GT 430 User manual

GT 430 A
Oil-Gas Fired Hot Water boiler English
11/20/09
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. For assistance or
additional information consult a qualified installer, service agency
or the gas supplier.
82294154
11-20-09

2
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 t hat will or ca n 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 a ssembly of gas and vent connections, the initial
start-up, the electrical connections, the mainte nance and service
can only be perfor med by a licensed se rvice contra ctor 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 l ocal and state codes as well as common i ndustry
practices during the install ation 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 prob lem immediately to prevent damage to the
system!
! Caution:
Refer to User’s Manual regar ding 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 in stallation 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 be undertaken only by trained and
skilled personnel.
Keep bo iler area cle ar 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.
82294154
11-20-09
"Installation of this equipment must be in accordance to National and
local codes having jurisdiction"
[Canadian Installations] CSA B139 for Oil & CSA B149 for Gas
[USA Installations] NFPA 31 for Oil & NFPA 54/ANSI Z223.1 for Gas.
The boiler must be connected to a venting system that will safely exhaust
all flue gases in an effective manner.
The boiler is certified to use only these fuels listed below, do not burn
garbage or paper, never leave combustible material near it. Do not burn
gasoline, crankcase draining or any other fuel containing gasoline.
Natural Gas, Propane Gas & # 2 Fuel Oil

3
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
82294154
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4
Regulations and guidelines
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 responsibility 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 OPER ATING INSTRUCTIONS IS A
PRECONDITION FOR THE CORRECT AND GUARANTEE OF THE
BOILER.
• THE INSTALLATION MUST CONFORM TO THE
REQUIREMENTS OF THE AUTHORITY HAVING JURISDICTION
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
JURISDICTION, THE INSTALLATION MUST CONFORM TO THE
STANDARD FOR CONTROLS AND SAFETY DEVICES FOR
AUTOMATICALLY FIRED BOILERS ANSI/ASME CSD-1.
• THE INSTALLATIO 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 JURISDICTION OR, IN THE
ABSENCE O F SUCH REQUIREMENTS , WI TH 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 GT430 A range are automatic independent hot-
water boilers designed for con necting to a flue which require a
separate fuel oil or gas burner.
1 Boilers covered by this document
The GT 430 A boilers are pressurized hot water heating boilers,
connected to a flue, fitted with an independent burner using 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.
82294154
11-20-09
Only a qualified and licensed 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.

Unit GT 430-8A GT 430-9A GT 430-10A GT 430-11A GT 430-12A GT 430-13A GT 430-14A
MBH 1,730 1,947 2,278 2,567 2,826 3,100 3,389
kW 507.2 570.5 667.7 752.3 828.3 908.6 993.2
US GPH 12.00 13.50 15.80 17.80 19.60 21.50 23.50
MBH 1,474 1,659 1,941 2,187 2,408 2,641 2,887
kW 432.1 486.1 568.9 640.9 705.8 774.2 846.2
MBH 1,282 1,442 1,688 1,902 2,094 2,297 2,511
# 8 9 1011121314
# 16161624202020
US Gal 96.70 108.06 119.42 130.78 142.14 153.50 164.86
Liter 366 409 452 495 538 581 624
18° F Ft. H
2
O [mbar]
1.360 [40.656] 2.040 [60.984] 3.232 [96.595] 4.095 [122.390] 5.241 [156.667] 6.630 [198.181] 8.312 [248.467]
27° F Ft. H
2
O [mbar]
0.605 [18.069] 0.907 [27.104] 1.437 [42.947] 1.824 [54.527] 2.331 [69.681] 2.977 [88.990] 3.694 [110.430]
36° F Ft. H
2
O [mbar]
0.340 [10.164] 0.510 [15.246] 0.808 [24.147] 1.025 [30.647] 1.310 [39.167] 1.658 [49.545] 2.079 [62.155]
Inch
mm
Inch 46.57 52.87 59.17 65.47 71.77 78.07 84.37
mm 1,183 1,343 1,503 1,663 1,823 1,983 2,143
Ft
3
10.95 12.50 13.98 15.50 16.98 18.47 19.95
Depth
Volume
GT 430A Series - Cast Iron Sectional Boiler Technical
Specification Data Table
Water Capacity
NET I=B=R Water Rating
Combustion
Chamber
Dimensions
Diameter
[equivalent]
20.87
530
Water
Resistance
[∆T = °F]
Model
Item
Firing Sequence Consult Burner Technical Data
[CSA] - Gas Input
[CSA] - # 2 Fuel Oil Input
[CSA] - Output [Gas-Oil]
Cast Iron Sections
Flue-way baffles
m
3
0.31 0.354 0.396 0.439 0.481 0.523 0.565
Ft
3
19.88 22.53 25.14 27.79 30.37 32.98 35.59
m
3
0.563 0.638 0.712 0.787 0.860
0.934 1.008
PSI
MBH 1,618 1,820 2,130 2,400 2,643 2,899 3,168
V/P/H
° F
° C
° F
° C
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
#
Inch 10 10 10 12 12 12 12
lb 3,241 3,638 4,034 4,431 4,828 5,225 5,622
kg 1,470 1,650 1,830 2,010 2,190 2,370 2,550
• CSA - MBH Output based on Thermal Efficiency Test According to ANSI Z21.13a/CSA 4.9a-2005
• All Models Certified for 0 - 4,500 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
• Conversion Btu/Hr to kW = 3,412 Btu/Hr 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
•
Due to ongoing and continuous product improvements, DDR Americas Inc. reserves all rights to amend and delete information provided on this
product specification table.
90
Adjustable 40 - 100 [factory preset stop at 85] Optional Hi-Temperature kit available
Chamber Resistance
Gas-Vent Category I-II-III-IV & Sidewall
Boiler Vent Connection
Weight [Dry]
MAWP [Water]
Min. Safety Relief Capacity
Volume
Combustion chamber
and flue way volume
Volume
Note:
S3NA Panel
Electrical Connection 120/1/60 < 10A
Max. Water Temp.
Safety Limit [MR]
Fixed non adjustable 248
Fixed non adjustable 120
Water Operating
Temperature Range
Adjustable 104 - 212 [factory preset stop at 185] Optional Hi-Temperature kit available
82294154
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8
Main Dimensions
GT 430 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 430-8A GT 430-9A GT 430-10A GT 430-14 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
GT430-8A
2213/16 23 26
321/2
26
GT430-9A 32
GT430-10A
331/16
313/16
251/8
GT430-11A
301/8
GT430-12A
GT430-13A
377/16 35
GT430-14A 381/2
G50_0001
X
GT 430-11A GT 430-12A GT 430-13A
82294154
11-20-09

9
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. It s 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.
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"
82294154
11-20-09
Do not install boiler on combustible
flooring, pad or carpet.
Dimension 'X' - consult burner information,
an additional 24 inches in front of the burner
is needed for servicing.

10
2Combustion Air Supply
Boilers operating in atmospheres t hat contain fluorides or chlorides
such as beauty shops and automotive repair garage s whe re 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. Bo iler damage by contaminants will
void the warranty and any other responsibility or liability of De Dietrich
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
-fit all 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 430-8 A 1 1 5 1
GT 430-9 A1 1 6 1
GT 430-10 A 1 1 7 1
GT 430-11 A 1 1 8 1
GT 430-12 A 1 1 9 1
GT 413 A1 1101
GT 414 A
1 1111
82294154
11-20-09
Combustion air supply must be sized according to national and local codes
CSA B149.1 & .2 CSA B139
ANSI Z223.1 & NFPA 31

11
Step one
Front - Rear
GT 430-8A - GT 430-10A - GT 430-12A - GT 430-14A
GT 430-9A - GT 430-11A - GT 430-13A
- Fit the 2 rear attachment brackets (in the body 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 (fabric to 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"
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12
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.
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Step five
Assembling the sections
A : thermocord
Special intermediate section before rear section.
Place the special intermed iate section, note fro nt back
relationship with the sealing groove against the thermocord.
For safety, insert an up per assembly rod ( body accessories
pack) into the holes in the 2 sections.
Gently and at the same time driv e in the 2 nipples of the rear
section using a hammer and a piece of wood.
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Step six
- Put the special assembly tool in place. - Tighten progressively so the upper and lower connectio ns 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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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. Place the expansion spring 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".
- Install the upper casing supports (packCS13) and the upper cross-
pieces (packs CS428 to CS434 and CS11 to CS14) with the
assembly rods (body accessories pack) as shown in details A-B-
C-D.
- Install the lower assembly rods in the order given in the figure.
- Remove the assembly tool.
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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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Step ten
`Install the flue nozzle ( body accessories pack) using the 4
bolts HM 12 x 40 + 4 nuts H 12 and 4 washers on the flue outlet
(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
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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 t he clean-out doors (pack CS20) using 2
bolts HM 12 x 25 + 2 nuts M 12+ 2 washers DE 12.
Fit the combustion 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.
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Step fourteen
Attach the hinge ( body accessories pack) on the burner door
using the 3 bolts HM 12 x 30 + 3 washers 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
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Insert baffles as shown in table below
for each flue way shown above.

20
Step sixteen
Install the lower casing supports (pack CS 428 to CS 434) on the
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
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Step seventeen
- Install the rear insulation (pack CS10).
Step eighteen
Pack CS 41 to CS 47 :
Put the left and right cable ways in place, respecting the
assembly sequence.
Secure the cable ways (3 screws HM5x25 + serrated washers).
Secure the front top panel (package CS10) with 4 screws
HM5x25 + serrated washers.
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Step nineteen : Control panel
(1) Front - (2) Rear
Position the control panel on the front bushes.
Open the control panel (3 screws at the back).
Step twenty : Standard control panel
 Attach the control panel at the rear, on the top panel using 2 self
tapping screws dia. 3.94 x 25 + lock washers.
 Carefully unwind and remove the various sensor and pass them
through the opening in the front top cover. Insert them into the wells
and secure them using a spring.
 The extra well is for auxilliary high temperature limit with manual
reset.
Step twenty one : Electrical connections
• Make the electrical connections on the two terminal blocks
provided for this purpose inside the control panel - see § 7.
• Close the control panel (3 self tapping screws + lock washers on
the rear).
8229N085A

!
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