Ideal Boilers Buccaneer GT 5 Guide

Buccaneer G.T.
Installation, Assembly and Servicing
Oil or Dual Gas Fired Boilers
CAUTION. To avoid the possibility of injury during the installation, servicing or cleaning of this
appliance care should be taken when handling edges of sheet steel components.
Assembly and Installation Instructions for Ideal Buccaneer GT Oil, Gas or Dual Fired heating boilers should be read
in conjunction with the general technical data tables enclosed and any other technical publication supplied with the
burner.

GENERAL
CONTENTS
Boiler Models/Packing ..................................................4
Installation ......................................................................5
Levelling/Dimensional info ............................................6
Chimney connection ......................................................7
Connection......................................................................8
Control Panel..................................................................9
Commissioning.............................................................12
Boiler Maintenance ......................................................14
Precautions...................................................................15
Characteristics Table ...................................................16
Main Dimensions..........................................................17
Exploded Views ............................................................18
Assembly Instructions .................................................21
2
INTRODUCTION
THE TECHNICAL INSTRUCTIONS FOR THE INSTALLATION
OF THE BOILER MUST BE SCRUPULOUSLY RESPECTED,
OTHERWISE THE WARRANTY MAY BE CANCELLED.
DUTY
The range of boilers is suitable for: combined indirect pumped
domestic hot water and central heating systems; independent
indirect pumped domestic hot water or central heating
systems.
Fully pumped systems may be open vented or sealed.
The range of boilers is NOT suitable for:
1. Gravity DHW systems.
2. Gravity heating systems.
3. Direct domestic hot water supply.
GAS SAFETY (INSTALLATION AND USE)
REGULATIONS, 1994
It is law that all gas appliances are installed and serviced by a
CORGI registered installer in accordance with the above
regulations. Failure to install appliances correctly could lead to
prosecution. It is in your own interest, and that of safety, to
ensure the law is complied with.
The installation of the boiler MUST also be in accordance with
the latest l.E.E Wiring Regulations, local building regulations,
bye-laws of the local water authority, the building regulations
and the Building Standards (Scotland) and any relevant
requirements of the local authority.
Detailed recommendations are contained in the following
British Standard Codes of Practice:
BS. 6891 Low pressure installation pipes.
BS. 6798 Installation of gas fired hot water boilers of rated
input not exceeding 60 kW.
BS. 5449 Forced circulation hot water systems.
BS. 5546 Installation of gas hot water supplies for
domestic purposes (2nd Family Gases)
BS. 6644 Ventilation (for gas appliances of rated input
exceeding 60 kW)
BS. 5440:2 Ventilation (for gas appliances of rated input not
exceeding 60 kW)
Buccaneer GT Range - Installation
FOUNDATION
The boiler must stand on a non-combustible floor
(i.e. concrete or brick) which must be flat, level and of a
suitable load bearing capacity to support the weight of the
boiler (when filled with water) and any ancillary equipment.
If the boiler is mounted on a plinth then the dimensions must
exceed the plan area of the boiler by at least 75mm on each
side

Buccaneer GT Range - Installation 3

GENERAL
4Buccaneer GT Range - Installation
1 BOILERS CONCERNED BY THIS DOCUMENT
The Buccaneer GT range of boilers is a range of automatic
hot water boilers connected to a conventional flue to be
fitted with an independent burner using oil or gas.
UIN ANA No. Item Pack Number Buccaneer
34 5
138495 0 Boiler Body (3 section) IC1 1
138496 7 Boiler Body (4 section) IC2 1
138497 4 Boiler Body (5 section) IC3 1
138498 1 Jacket pack (3 section) IC4 1
138499 8 Jacket pack (4 section) IC5 1
138500 1 Jacket pack (5 section) IC6 1
138501 8 Control panel IC7 1 1 1
Options
138502 5 Hours run meter (optional) IC8 1 1 1
PACKING
Before installing your boiler, you can check with the table
below to see if you do indeed have all of the component
packages. For the optional equipment that may be fitted to
these boilers, see the current price list.
Assembled boiler bodies:

GENERAL
Buccaneer GT Range - Installation 5
2 INSTALLATION OF THE BOILER
The minimum dimensions indicted on the following drawing
must be respected to ensure good access around the boiler.
Remark: To allow the inlet of the combustion air, the boiler
room must be adequately ventilated, the section and the
location of which must comply with local recommendations.
VENTILATION GENERAL
Detailed recommendations for air supply are quoted in BS.
6644. The ventilation requirements in this gas fired boiler
standard are also valid for oil fired boilers or the same heat
input.
Remark: We draw your attention to the risks of corrosion of
the boilers installed in or near to rooms in which the
atmosphere can be polluted by chloride or fluoride
substances. E.G.; industrial buildings (solvents), refrigerating
machines, etc... in these cases we cannot provide a warranty.
LEVELLING
Insert the cylinder into the hole provided in each foot of the
heating body and screw the adjustable foot into it. Level.
* Attention must be paid to the space occupied by the burner when the door is open.
Note: (1) Adjustable feet 35mm - 45mm (2) Thickness of burner door with insulation
Boiler size (no. of sections) 3 4 5
Dimension A 545 672 799
Dimension B 471 598 725
Dimension D 330 457 584
Flow and return tappings 1 1/4”1
1/4”1 1/4”
Flue outlet 125 125 125
All dimensions in millimetres unless otherwise stated

GENERAL
6Buccaneer GT Range - Installation
INSTALLATION RECOMMENDATIONS
The installation of the boiler MUST be in accordance with the
following British Standards and Codes of Practice:
BS. 799 Pts. 4,5,6 & 7 Oil Burning Equipment
BS. 5410 Pts. 2 & 3 Installations for Space Heating and
Hot water Supply
BS. 5449 Pt.1 Hot water Systems
BS. 5854 Flues and Flue Structures in Buildings
BS. 5885 Pt.1 Gas Burners - with outputs of
60kW upwards
BS.6644 Installation of Gas Fired Boilers
BS.6880 Low Temperature Hot Water Heating
Systems
BS.6891 Low Pressure Gas Pipework
British Gas Industrial Gas Fired Boilers and
Publication No. IM.11 Air Heaters
3 ASSEMBLY
For the assembly of the boiler, refer to the relevant paragraph
of the instruction book.
4 HYDRAULIC CONNECTION
Dimensional information required
WATER SYSTEM: General
Recommendations relating to the water system are contained
in BS. 5449 Pt. 1, BS. 5401 Pt. 2, and BS. 6880.
Flow & Return in
Buccaneer GT 3 1.25
Buccaneer GT 4 1.25
Buccaneer GT 5 1.25
The following must be confirmed with:
Current Building Regulations and Clean Air Act
Water Authority Regulations
Local Authority Regulations and Regional bylaws
Gas Safety Regulations
Any special regional requirements of local Electricity and Gas
undertaking.
Fire Service and Insurance requirements.
All electrical wiring MUST comply with the current I.E.E.
regulations for the electrical equipment of buildings. In the
interests of safety, a competent installer should be employed
to effect the installation of the appliance. Manufacturer’s
notes must NOT, in any way, be taken as overriding statutory
obligations.

5 CONNECTION TO THE CHIMNEY
According to the output, the difference between the
temperature of the flue gas and the ambient temperature can
be as much as 160°C. The installer will have to respect all of
the usual precautions (dilution - piping - T for the evacuation
of condensation) in order to prevent deterioration of the
chimney.
CHIMNEY AND FLUE CONNECTIONS
Detailed recommendations, relating to the design of flues for
GAS fired applications are quoted in BS. 6644 abd British
Gas Publication No. IM 11, whilst BS. 5410 Pt. 3 similarly
applies OIL fired burners.
INSTALLATION
Buccaneer GT Range - Installation 7
Power Mass flow of Temperature Chimney
the flue gas of the flue gas
Oil 13% CO2
Natural gas 9% CO2 min. Ø min. H
kW g/s < °C mm m
Buccaneer GT 16-26 10.5 < 180 125 5
Buccaneer GT 26-33 13.5 < 180 125 6.5
Buccaneer GT 33-40 16.5 < 180 125 7

INSTALLATION
8Buccaneer GT Range - Installation
Dimensional information required for the connection
Connection
The boiler must be installed according to the profession with
an airtight pipe in a material that is resistant to hot gases
from the combustion and possible acid condensations. This
pipe will be as short as possible, remove and without any
sudden change in its section.
Flue Outlet mm
Buccaneer GT 3 125
Buccaneer GT 4 125
Buccaneer GT 5 125
6 BURNER CONNECTION
The gas supply MUST be sized in accordance with British
Gas recommendations and be fabricated in compliance with
CP. 331 Pt. 3 and any Local Gas Board installation
standards.
The Local Gas Board should be contacted, at a stage prior to
actual installation, for any advice or information required.
Details and advice, relating to the use of L.P.G. for firing the
BUCCANEER GT range of heating boilers, are available on
request to Caradon Ideal Ltd
GAS SUPPLY
OIL STORAGE TANK
The oil storage tank, oil supply pipe and connections to the
burner unit MUST comply with the requirements of BS. 779
and CP. 5410.
The installation should conform to the recognised standards
of good practice in the trade and comply with the relevant
Codes of Practice, Building Regulations and Local Authority,
Fire and Insurance requirements.
Piercing Øof the burner door

INSTALLATION
Buccaneer GT Range - Installation 9
CAUTION: Must be carried out by a qualified professional
7 ELECTRICAL CONNECTION
As the electrical wiring has been carefully checked in the
factory, the internal connections of the control panel must
not be modified under any circumstances.
The electrical connections of the boiler must conform with
the IEE wiring regulations in force, respecting the indications
which appear on the electrical drawings supplied with the
control panel and the directives given hereafter.
Control panel
All the connections will be made on the connection block
provided for this purpose outside of the panel.
The connection cables may be fed along the inside of the
boiler by the cut-outs which are situated in the upper rear
panel of the boiler, the latter allowing the possible use of
electrical duct which are on general sale.
These cables will be attached to the rear metal sheet of the
panel with the help of cable clamps (7 cable clamps supplied
in a separate bag) fitted to the metal sheet.
Sensor connections
230/240V Connections

INSTALLATION
10 Buccaneer GT Range - Installation
Assembly of the SVR sanitary hot water option
The housing of the SVR option has to be mounted on the
front of the control panel. For this purpose:
- Remove the cover with a screwdriver
- Plug the 2 connections into the panel on the rear face of
the housing, blue to blue and red to red
- Introduce the housing from the front and attach it with two
plastic screws situated on the front of the device ( 1/4 turn in
clockwise direction).
The thermostat limiter supplied with the SVR option must be
fitted on the rear sheet of the panel with the 2 screws for the
sheet which are supplied. The 3 pin male block of this
thermostat is to be connected in the place provided on the
block after having removed the bridge; the bulb of the
thermostat must be placed in the pocket on the boiler body.
12
34

INSTALLATION
Buccaneer GT Range - Installation 11
Fitting an SV-mattic regulator
Possible additional connections
The SV-matic regulator must be fitted in the front part of the
control panel. For this purpose:
- Remove the cover
- Plug the 2 connectors into the panel on the rear face of
the box, blue to blue and red to red
- Insert the box from the front and attach it with two plastic
screws situated on the front of the device
( 1/4 turn in clockwise direction).
- An alarm LED is connected to the pins 15 and 16
- A flue gas thermostat is connected to the pins 13 and 14
after the existing bridge has been removed. The pins are
interchangeable.
- A hour run meter (package IC 8) can be mounted on the
front face of the panel. To do this, remove the cover, take
the two wires from behind the cover and connect them to
the meter (wires are interchangeable). Clip the hour run
meter in the panel.
Connection of the burner
The boiler is equipped with a wire with a 7 pin male
European connection plug which can be connected to the
female socket supplied with the burners
12
12

INSTALLATION
12 Buccaneer GT Range - Installation
8 COMMISSIONING
CONTROL PANEL
Description
1. On/Off switch
2. Burner switch: Used for switching OFF (summer position ) or switching ON (winter position ), by means of action
on the burner and the pump (the operation of the D. H. W. is not stopped). In case of fitting an SV-matic regulator or an
D. H. W. priority (SVR), this switch is put out of service by the regulator.
3. Heating accelerator switch: Used for switching OFF (summer position ) or switching ON (winter position ) the
accelerator.
In case of fitting a regulator or an SVR module, it must be set to the winter position .
4. Boiler thermometer
5. 3 position switch:
Manual position, this position must be used for boilers which are not equipped with SV-matic regulation or
room temperature thermostats.
The temperature of the boiler is regulated by the boiler thermostat 7. This position can be used to test the
burner on an installation equipped with SV-matic regulation or with a room temperature thermostat.
AUTO Automatic position, this position must be used for normal operation for boilers equipped with SV-matic
regulation or room temperature thermostats.
TEST STB: Temporary action to test the safety thermostat
6. Safety thermostat With manual reset (factory setting - 100°C)
7. Boiler thermostat: It can be adjusted from 30 to 85°C. However, a factory fitted stop limits the temperature to 75°C.
This stop can be moved if necessary. The boiler thermostat must compulsorily be set at maximum in case an SV-matic
regulator or a room temperature thermostat is fitted.
8. Fuse 4 AT
9. Place for an SV-matic regulator or the SVR option
10. Place for the possible hour run meter

Commissioning
The first commissioning must be made by a qualified
professional.
Before the boiler is ignited, check that the installation is filled
with water.
Carry out the commissioning tasks in the following
chronological order:
•Set the boiler thermostat 7 to the chosen position (change
the position of the stop if necessary)
IMPORTANT. for the boilers equipped with a room
thermostat or an SV-matic regulator, set the boiler
thermostat to its maximum.
•Place the setting potentiometer of the domestic hot water
11 to the desired temperature (SVR or SV-matic option).
•Check the position of the 3 position switch 5,
which must be:
- either in manual position: boilers not equipped with a
room temperature thermostat or an SV-matic regulator,
- or in automatic position "AUTO": boilers equipped with
a room temperature thermostat or an SV-matic regulator
•Check that the safety thermostat 6 is ON. For this
purpose, unscrew the hexagonal cap and press the reset
button with a screwdriver.
•Turn the ON/OFF switch 1 to the ON position
•Turn the burner switch 2to winter ? . If the boiler is
equipped with SV-matic regulation or with the SVR
domestic hot water option, this switch is taken out of
service by the regulator.
•Turn the heating pump switch 3to winter .
Note: If there is no SV-matic regulation, the boiler thermostat
should never be placed beneath the mark 4(40°C) in order to
avoid condensation of the combustion products on the walls
of the boiler.
Information of the user
The installer must give the operation and maintenance
instructions to the user and give all the information required
on this matter, to allow the installation to operate safely.
INSTALLATION
Buccaneer GT Range - Installation 13
PRINCIPLE OF OPERATION
Regulation of the boiler
The regulation of the boiler is provided either by the boiler
thermostat 7, or by the room temperature thermostat, or the
SV-matic regulator if fitted.
For the boilers equipped with a room temperature thermostat
or an SV-matic regulator, the temperature of the boiler is
modulated by the regulator on the burner according to the
room or the external temperature. The thermostat of the
boiler will then be set at maximum. The safety during the
operation is ensured by the safety thermostat with manual
reset 6.
Regulation of the heating
The regulation of the heating can be provided in a number of
ways (manual mixing valve, thermostatic taps,...), and the
installer will have to explain to the customer the operation of
the regulation of the heating.
For the boilers equipped with an SV-matic regulator that
operates on the valve. the heating temperature is modified by
means of the regulator on a monitored mixing valve
depending on the external temperature.
Regulation of the domestic hot water
(with SVR or SV-matic option ... B)
The presence of a load pump and an anti-thermosyphon
valve on the domestic hot water circuit allows correct
regulation of the domestic hot water temperature. The
domestic hot water temperature is set by a potentiometer 11
situated on the SVR or SV-matic regulator. When the
domestic hot water is reheated, the burner and the load
pump are started up whereas the heating pump is shut off ;
the boiler temperature is then regulated by the thermostat
limiter integrated in the SV-matic regulator or fitted with the
SVR option (this thermostat is factory set at 70°C). Once the
domestic demand is satisfied, the burner is shut off and the
load pump continues to operate for 4 minutes after the
burner has stopped (this time is adjustable from 30 s to 15
min), to allow the residual calories which have accumulated
in the heating body to be used up to complete the reheating
of the tank, especially in summer.

INSTALLATION
14 Buccaneer GT Range - Installation
BOILER
It is not advisable to drain an installation, except in case of
absolute necessity. Check regularly the water level of the
installation and top it up if necessary, avoiding a sudden inlet
of cold water into the hot boiler.
This operation should only be done a few times a year;
otherwise, look for the leakage and remedy it without delay.
The good performance of the boiler depends on its
degree of cleanliness.
Cleaning of the boiler must be carried out as often as
required and at least, as for the chimney, once a year or
more, according to the regulations in force.
The following operations are always carried out with the
boiler and the power supply shut off.
Cleaning of the flue gas circuit:
For this purpose:
- Remove the front cover
- Open the door by unscrewing the four locknuts
(13mm spanner)
9 MAINTENANCE
Data plate
Week
01-52
Year
01=1991
02=1992
XX-XX
Manufacturing year code

INSTALLATION
Buccaneer GT Range - Installation 15
- Remove the convection accelerators
(only for boilers with 3, 4 and 5 sections)
- Sweep carefully the upper flues and the hearth with the
brush provided
- Remove the spot from the hearth with a vacuum cleaner
- Replace the convection accelerators
- Close the door and replace the front cover
PRECAUTIONS TO BE OBSERVED IN CASE
OF PROLONGED STOPPAGE OF THE BOILER
- Have the boiler and the chimney carefully swept. Shut the
boiler doors to avoid any air flow inside.
- If the boiler is going to be stopped for several months, we
also advise removing the pipe which connects the boiler
to the chimney and to close off the nozzle with a cover.
- In case of stoppage of the heating in winter leading to risks
of freezing, we advise the use of a concentrated anti-freeze
agent to prevent the heating water from freezing.
Otherwise, completely drain the installation (in this case,
the slot of the valve screw on the load pump must be
positioned vertically. The tank and the sanitary hot water
piping must also be drained.

INSTALLATION
16 Buccaneer GT Range - Installation
10 PERFORMANCE DATA
CHARACTERISTICS TABLE
Boiler Size 3 4 5
Maximum Heat Output kW 26 33 40
Btu/h x 10388 112 136
Minimum Heat Output kW 16 26 33
Btu/h x 10355 88 112
Combustion Chamber Volume m30.016 0.02 0.025
ft30.56 0.74 0.9
Flue Way Volume m30.03 0.04 0.05
ft31.09 1.45 1.8
Boiler Water Content l 19 24.5 30
gal 4.18 5.4 6.6
Hydraulic Resistance at 15k mbar 1.7 2.8 4.1
in.w.g. 0.68 1.12 1.64
Combustion Chamber Resistance mbar 0.05 0.05 0.05
in.w.g. 0.02 0.02 0.02
Minimum Draught at Smokehood outlet mbar 0.15 0.2 0.2
(for max output) in.w.g. 0.06 0.08 0.08
Boiler DRY weight less burner unit kg 121 149 177
lb 267 328 390
General Data
Boiler Size 3 4 5
Maximum Oil Rate l/h 2.67 3.4 4.12
gal/h 0.59 0.75 0.91
Maximum Flue gas volume l/sec 16.7 21.2 25.7
ft3/min 35.4 45 54.6
Oil Firing Data
Boiler Size 3 4 5
Maximum Gas Rate m3/h 2.7 3.4 4.2
ft3/h 95.3 120 148
Maximum Flue gas volume m3/sec 0.015 0.02 0.023
ft3/min 31.7 42.4 48.7
Gas Firing Data
Data Notes:
Fuel rates and flue gas data relates to maximum outputs
ratings Gas firing data relates to the use of NATURAL GAS
ONLY Details for the use of LPG are available, on request, to
Caradon Ideal Ltd. The gas rate at calorific values differing
from the standard quoted above may be calculated by direct
proportion CALORIFIC VALUE; 38.5 MJ/m3(1035 btu/ft3)

ASSEMBLY
Buccaneer GT Range - Installation 17
Clearances
Main Dimensions
Boiler Size 3 4 5
Dimension A 545 672 799
Dimension B 471 598 725
Dimension D 330 457 584
Flow and Return Tappings 11/4”11/4”11/4”
Flue Outlet 125 125 125
All dimensions in millimetres unless otherwise stated

18 Buccaneer GT Range - Installation
ASSEMBLY
11 EXPLODED VIEWS AND LIST OF SPARE PARTS
Boiler Body
Insulation

Buccaneer GT Range - Installation 19
ASSEMBLY
Jacket
Control Panel

20 Buccaneer GT Range - Installation
ASSEMBLY
BOILER MAIN CASING
Ref Code no. PART
1 8199 8973 Base Unit 3 Elements
1 8199 8974 Base Unit 4 Elements
1 8199 8975 Base Unit 5 Elements
2 9498 2106 Adjustable Foot
3 8199 8980 Main Casing Complete 3 Elements
3 8199 8981 Main Casing Complete 4 Elements
3 8199 8982 Main Casing Complete 5 Elements
4 8199 0012 Duct 125/130
5 8199 0015 Left Baffle
6 8199 0016 Central Baffle
7 8199 0017 Right Baffle
10 8199 0008 Lower Hinge
11 8199 0009 Upper Hinge
12 8199 8905 Firebox Door
13 8199 0007 Firebox Door Axle
14 9425 0222 Door Insulation - Front
15 9425 0223 Door Insulation - Intermediate
16 9425 0224 Door Insulation - Rear
17 9508 6032 Silicon Glass - Fibre Cordon
18 8199 0004 Window Eye Glass
19 9755 0197 Window Gasket
20 9521 6246 Window
21 9425 0225 Window Insulation
22 9754 9447 Out/Return Tube
23 9536 1215 Sheath
24 9758 1286 Sheath Spring
25 9536 5613 Sheath Separator
26 9754 9448 Drain Tube
8199 8983 Pack of Screws
BOILER EXTERIOR PANELS
Ref Code no. PART
8199 8800 Jacket Complete 3 Elements
8199 8801 Jacket Complete 3 Elements
8199 8802 Jacket Complete 4 Elements
40 8199 8805 Jacket Complete 5 Elements
40 8199 8806 Side Panel Complete 3 Elements
40 8199 8807 Side Panel Complete 4 Elements
41 9532 0186 Cable Grip PA 268/RO
42 8199 8833 Rear Panel Complete
43 9649 6160 Push Rivet
44 8199 8803 Front Panel
45 9755 0146 Side Piece
46 8199 8829 Head Complete 3 Elements
46 8199 8830 Head Complete 4 Elements
46 8199 8831 Head Complete 5 Elements
47 9755 0187 Rubber Profile
48 8199 8804 Door Front Panel
8199 8985 Jacket Screw Pack
STANDARD CONTROL PANEL
Ref Code no. PART
8199 8916 Complete Control Panel
50 8199 8917 Complete Support Components
51 9750 9009 Electro - Mechanical Facia
52 9532 5091 Start/Stop Bi-Polar Switch
53 9532 5362 Bi-Polar Test Switch
54 9532 5103 Reverser Switch
55 9654 7000 4 AT Fuse
56 9655 0023 Fuse Carrier
57 9563 3315 Safety Thermostat 100°C
58 9536 5574 Controllable Thermostat 30 - 90°C
59 8218 8973 Control Button + Lugs
60 9536 5157 Flat Thermometer
8199 4906 Electric Circuit T.C.
8199 4907 Electric Circuit Sensors
9650 2815 1430 ohms Resistor
63 8199 4908 Burner Cable
8199 8984 Control Panel Screw Pack
VARIOUS
Ref Code no. PART
9696 0223 Brush
INSULATION
Ref Code no. PART
8199 8986 Complete Insulation Pack 3 Elements
8199 8987 Complete Insulation Pack 4 Elements
8199 8988 Complete Insulation Pack 5 Elements
29 8199 4048 Rear Insulation
30 8199 4041 Left Body Insulation 3 Elements
30 8199 4042 Left Body Insulation 4 Elements
30 8199 4043 Left Body Insulation 5 Elements
31 8199 4044 Right Body Insulation 3 Elements
31 8199 4045 Right Body Insulation 4 Elements
31 8199 4046 Right Body Insulation 5 Elements
32 8199 4040 Support Components Insulation
33 8199 4047 Cross Piece Support Insulation
34 8406 8082 Attachments